Performance evaluation of tapping processes using a 7075 aluminium alloy with different cooling systems and threading heads

摘要

Modern industry faces a great challenge: the production of consumer goods based on a triangle comprising low costs, low production time and high quality. The optimisation of modern manufacturing processes should seek not only the reduction of manufacturing time but also the reduction of mineral resources and electric energy consumption. In the context of metalworking, considering tapping processes, studies on the use of minimum quantity of lubricant are minimal and scarce. Hence, this study deals with the application of minimum quantity of lubricant and emulsion to the processes of form and machine tapping. To this end, 7075-T651 aluminium alloy workpieces were threaded using both tapping processes at three cutting/forming speeds. M10 threads with a pitch of 1.5 mm were considered the standard profile. Torque and thrust force were monitored, and three threading heads were employed in the experimental tapping tests. According to the results, it can be concluded that the best option was to use minimum quantity of lubricant in order to reduce environmental impact, given its efficient disposal of fluids and compatibility with Softsynchro threading heads, which kept both torque and axial force close to the mean values. Furthermore, this threading head model was also the best for reducing the manufacturing time of the threads.