Finite element simulation of stresses in cutting tools during tapping

Tapping is inherently more complex than other machining processes. The main reason for this complexity is that the chip removal process takes place in a closed environment. For this reason, in order to use the tap tools more efficiently, it is necessary to know the cutting conditions and the stresses that occur in the tool during cutting. In this study, holes of different diameters were drilled in the AISI 1050 material and threaded with M10 taps with three different geometries. Uncoated HSS and TiN coated HSS taps were used in the study. The tapping operations were carried out in dry conditions. The simulation conditions were chosen exactly the same as the experimental conditions. Stresses during tapping were analyzed using the Third Wave AdvantEdge program based on the finite element method (FEM). The tapping tools were modeled by reverse engineering method and then imported in the program. In general, the coating applied to the tools positively affected the stresses on the cutting tool.