Taps and tapping operations are amongst the most complex and least understood cutting tools and processes. In this paper, the geometry and specification of straight flute taps are studied and discussed. This is followed by an outline of the development of computer-aided predictive models for side force, thrust force and torque in machine tapping operations, based on Armarego's 'Unified-Generalised Mechanics of Cutting Approach'. The models are verified through simulation studies and comprehensive experimental testing. Good qualitative and quantitative correlations are found for the average thrust and torque. These models allow tool designers and process planners to optimise the generation and use of taps. The results confirm the validity and generic nature of the unified-mechanics of cutting approach.
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