Analysis of form threads using fluteless taps in cast magnesium alloy (AM60)

Threads are used in the most assemblies of industrial products. Commonly, mechanical components need to have threaded parts allowing fast and accurate assemblies and disassemblies. Internal tapping is one of the most demanded machining operations, and threads obtained by forming have been a good alternative. This work investigates the effect of the factors the hole diameter, the forming speed and types of tool on the responses: torque, hardness, fill rate, and thrust force of the form tapping process. The experiments were carried out with three diameters, three forming speeds, and two coatings. The material used was the AM60 alloy due to its high ductility and wide application as head engine. The results revealed torque is more affected by the hole diameter than thrust force, and little hardening occurred using high forming speed with a small diameter. The fill rate of the thread profile was not significantly affected by the intermediate and large diameters. Finally, it can be stated that the recommended hole diameter provided by the tool's supplier can be modified to achieve more accurate thread profiles.