HYBRID THREADING TOOL WITH CUTTING SECTION AND ROLLING SECTION

Abstract

Hybrid threading tool (110) defining a longitudinal axis, comprising: a cutting section (122) with a plurality of cutting teeth (152), wherein the plurality of cutting teeth (152) is configured for cutting a first thread into a workpiece (100); and a forming section (124) attached to the cutting section (122) and arranged with it along the longitudinal axis, wherein the forming section (124) has a plurality of forming teeth (155) configured to plastically deform the first thread into a second thread for the workpiece (100); wherein the plurality of cutting teeth (152) is arranged in a first web (118a) and a second web (118b) and further comprises a chip opening (120) defined in the circumferential direction between the first web (118a) and the second web (118b), wherein the chip opening (120) extends along the longitudinal axis through the cutting section (122) and is configured to receive chips from the cutting of the first thread, wherein the chip opening (120) extends along the longitudinal axis into the forming section (124).

Description

INTRODUCTION

[0001] The technical field relates generally to a threading tool and more particularly to a hybrid threading tool having a cutting section and a rolling section.

[0002] Some parts contain threaded holes for attachment to another component. For example, vehicle engine blocks often contain a threaded hole for receiving, supporting, and threaded connection to a bearing component. More specifically, the engine block may contain a threaded main bearing pin hole. These and other types of threaded holes preferably have high fatigue strength, high load-holding capacity, and other advantageous performance characteristics.

[0003] However, conventional methods for threading holes are deficient in certain respects. Currently available threading tools, machines, systems, etc., are also inadequate. These limitations can be exacerbated in high-volume manufacturing processes. Accordingly, the performance of the produced threaded hole and the associated threaded fastener is limited. Furthermore, such manufacturing processes and systems can be inefficient or suffer from other problems.

[0004] DE 10 2006 010 651 A1 describes a tool for producing a thread, in particular an internal thread. The tool comprises at least one cutting area with at least one cutting edge and at least one thread-forming area. It is therefore a combination tool. In this tool, the cutting area(s) and the thread-forming area(s) are coupled or connected to one another in such a way that they can be rotated or rotated together about a tool axis. At least one cutting area is formed at least partially on a frontal tool end and / or adjacent to a frontal tool end, and a frontal recess intended for receiving chips is formed on the frontal tool end.

[0005] Therefore, it is desirable to provide improved methods and systems for manufacturing parts with high-quality threaded holes. It is also desirable to provide improved methods and systems for manufacturing parts with threaded holes that exhibit high fatigue strength and high load-holding strength. Furthermore, it is desirable to make these systems and methods more efficient. Other desirable features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims, when considered in conjunction with the accompanying drawings and the foregoing technical field and background. DESCRIPTION

[0006] According to the invention, a hybrid threading tool is provided for threading a hole in a workpiece. The hybrid threading tool defines a longitudinal axis and includes a cutting portion having a plurality of cutting teeth. The plurality of cutting teeth are configured to cut a first thread into a workpiece. The hybrid threading tool also includes a forming portion attached to the cutting portion and arranged therewith along the longitudinal axis. The forming portion includes a plurality of forming teeth configured to plastically deform the first thread into a second thread for the workpiece.

[0007] In some embodiments, the cutting portion includes a first end and a second end spaced apart along the longitudinal axis. The forming portion includes a third end and a fourth end spaced apart along the longitudinal axis. The second end of the cutting portion is knot-connected to the third end of the forming portion.

[0008] In some embodiments, the cutting portion is tapered along the longitudinal axis.

[0009] In some embodiments, the cutting portion is fully tapered from the first end to the second end with a single taper angle.

[0010] Additionally, in some embodiments, the cutting portion has a first major diameter and the forming portion has a second major diameter. The first major diameter is at most between eighty percent (80%) and ninety-five percent (95%) of the second major diameter.

[0011] In some embodiments, the cutting section and the forming section are integrally connected and have common material properties.

[0012] In some embodiments, the cutting section and the forming section have different material properties.

[0013] In some embodiments, the cutting section and the forming section are made of different materials.

[0014] Additionally, in some embodiments, the cutting section and the forming section have different heat treatments that provide the different material properties.

[0015] Furthermore, in some embodiments, the cutting section has a higher hardness than the forming section. Furthermore, the forming section has a higher material toughness than the cutting section.

[0016] According to the invention, the plurality of cutting teeth are arranged in a first land and a second land. Furthermore, the tool comprises a chip opening defined circumferentially between the first land and the second land. The chip opening extends along the longitudinal axis through the cutting section and is configured to receive chips from cutting the first thread. The chip opening extends along the longitudinal axis into the forming section.

[0017] In some embodiments, the tool further comprises a shank. The plurality of cutting teeth and the plurality of forming teeth are mounted on the shank and extend radially outwardly therefrom and away from the longitudinal axis to define a hybrid external tap.

[0018] In some embodiments, the tool further comprises a support body. The plurality of cutting teeth and the plurality of forming teeth are attached to the support body and extend radially inwardly therefrom and toward the longitudinal axis to define an internal thread forming tool.

[0019] According to the invention, a method for manufacturing a hybrid threading tool for threading a workpiece is also provided. In one embodiment, the method comprises manufacturing a plurality of cutting teeth to define a cutting portion of the hybrid threading tool. The method also comprises manufacturing a plurality of forming teeth to define a forming portion of the hybrid threading tool. The forming portion is arranged with the cutting portion along the longitudinal axis. The plurality of cutting teeth are configured to cut a first thread into a workpiece, and the plurality of forming teeth are configured to plastically deform the first thread into a second thread for the workpiece. The plurality of cutting teeth are arranged in a first land and a second land.The tool also includes a chip opening defined circumferentially between the first land and the second land. The chip opening extends along the longitudinal axis through the cutting section and is configured to receive chips from cutting the first thread. The chip opening extends along the longitudinal axis into the forming section.

[0020] In some embodiments, the method further comprises attaching a first body to a second body, which are arranged together along the longitudinal axis. The first body and the second body have different material properties. Furthermore, forming the plurality of cutting teeth comprises forming the plurality of cutting teeth on the first body and forming the plurality of forming teeth on the second body.

[0021] In some embodiments, manufacturing the plurality of cutting teeth and manufacturing the plurality of forming teeth comprises additively manufacturing at least one of the cutting portion and the forming portion.

[0022] Furthermore, in some embodiments, the method comprises at least one of: heat treating at least one of the cutting portion and the forming portion to provide one with a different material property than the other; and coating at least one of the cutting portion and the forming portion to provide one with a different material property than the other.

[0023] Additionally, in some embodiments, forming the plurality of cutting teeth and forming the plurality of forming teeth includes forming the plurality of cutting teeth and the plurality of forming teeth from the outside to form a hybrid external tap.

[0024] In some embodiments, forming the plurality of cutting teeth and forming the plurality of forming teeth comprises forming the plurality of cutting teeth and the plurality of forming teeth from the inside to form a hybrid internal thread forming tool.

[0025] Additionally, a hybrid threading tool for threading a main bearing pin hole of an engine block is disclosed. The threading tool defines a longitudinal axis. In one embodiment, the hybrid threading tool includes a cutting portion having a plurality of cutting teeth. The cutting portion is tapered. The plurality of cutting teeth are configured to cut a first thread into the main bearing pin hole having a first major diameter. The hybrid threading tool also includes a forming portion attached to and disposed with the cutting portion along the longitudinal axis. The forming portion includes a plurality of forming teeth configured to plastically deform the first thread into a second thread for the main bearing pin hole. The second thread has a second major diameter. The first major diameter is at most ninety-five percent (95%) of the second major diameter. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The exemplary embodiments are described below in conjunction with the following drawing figures, wherein like numerals indicate like elements, and wherein: Fig. 1 is a side view of a hybrid threading tool, according to embodiments of the present disclosure; Fig. 2 a side view of the hybrid threading tool from Fig. 1 is a diagram illustrating the cutting of threads into a workpiece according to embodiments of the present disclosure; Fig. 3 a side view of the hybrid threading tool from Fig. 1 is a view illustrating rolling and forming threads in the workpiece according to embodiments of the present disclosure; Fig. 4 is a perspective view of the hybrid threading tool, according to further embodiments of the present disclosure; Fig. 5 is a sectional view of the hybrid threading tool along line 5-5 of Fig. 4 is; Fig. 6 a schematic representation of processes for manufacturing the hybrid threading tool of Fig. 1 is, according to embodiments of the present disclosure; Fig. 7 a schematic representation of processes for producing the hybrid thread tool from Fig. 1, according to additional embodiments of the present disclosure; and Fig. 8 a schematic representation of processes for manufacturing the hybrid threading tool of Fig. 1, according to additional embodiments of the present disclosure. DETAILED DESCRIPTION

[0027] The following detailed description is merely exemplary and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any express or implied theory presented in the preceding introduction, the brief description, or the following detailed description.

[0028] In general, the present disclosure relates to manufacturing systems and methods for threading a hole in a workpiece, part, component, etc. The threaded hole produced by these systems and methods may have high fatigue strength, high load-holding strength, and / or other improved properties.

[0029] In various embodiments, a hybrid threading tool is provided that includes both a thread-cutting portion and a thread-forming portion mounted and arranged along a longitudinal axis of rotation. The thread-cutting portion is configured to cut a first thread in a hole. The thread-forming portion is configured to form, roll, and reshape the first thread and plastically deform it into a second thread for the hole of the workpiece. Methods of making and using the hybrid tool are also disclosed according to various embodiments.

[0030] The hybrid tool can be a hybrid tap for internal threading of a through hole or a blind hole. The hybrid tool can be a hybrid tool for external threading of a shaft or other component.

[0031] The hybrid tool can have a variety of configurations. The thread-cutting and thread-forming sections of the tool can have different shapes, diameters, and / or dimensions. The thread-cutting and thread-forming sections of the tools can also have different material properties. For example, the different sections can be made of different materials, have different heat treatments, different coatings, etc.

[0032] The hybrid tools and associated methods of the present disclosure increase the convenience and efficiency of threaded hole production. The tools and associated methods provide threaded holes with increased fatigue strength, higher load-holding capacity, and other advantages.

[0033] The systems and methods of the present disclosure can be used for threading a variety of parts. In some embodiments, the tool can be used to create one or more threaded holes in a vehicle engine block. More specifically, the threaded hole can be provided in a main bearing bolt hole of an engine block. The manufacturing systems and methods can be useful for creating threaded holes in a cast engine block (e.g., an aluminum alloy engine block), and the tools and methods of the present disclosure can be used in parts manufactured using advanced casting processes. However, it should be understood that the threading tools, systems, and methods of the present disclosure can be used for any suitable part without departing from the scope of the present disclosure.

[0034] In Fig. 1, a workpiece 100 is initially shown with a hole 102. The hole 102 may have a hole axis 104. The hole 102 may be a through hole extending through the entire wall thickness of the workpiece 100, as shown, or the hole 102 may be a blind hole, recessed through a portion of the thickness of the workpiece 100 in further embodiments. The workpiece 100 may be a part of any suitable type. For example, in some embodiments, the workpiece 100 may be an engine block. In some embodiments, the workpiece 100 may be an engine block made of a cast aluminum alloy. The hole 102 may ultimately be used as a main bearing pin hole for the engine block.

[0035] Also illustrated is a hybrid threading tool 110 according to embodiments of the present disclosure. As will be explained, the hybrid threading tool 110 may be configured to cut threads and then form (plastically deform) threads. As shown in the illustrated embodiments, the tool 110 may be an external tap for producing internal threads within the hole 102. However, as discussed with respect to the Fig. 4 and Fig. 5, the hybrid threading tool of the present disclosure may be configured as an internal tap for producing an external thread on a bolt or other workpiece.

[0036] As in Fig. 1, the hybrid threading tool 110 may include an elongated shank 112 that is cylindrical and centered on the axis 104. The shank 112 may have an outer surface that may be at least partially smooth. In some embodiments, portions of the shank 112 may also be tapered. In some embodiments, the shank 112 may include a handle for grasping and manually rotating the tool 110 about the axis 104. In other embodiments, the shank 112 may include a chuck for attachment to a machine for automatically rotating the shank 112 about the axis 104.

[0037] The tool 110 may also include a working end 116. In some embodiments, the working end 116 may include a plurality of threaded lands (e.g., a first land 118a and a second land 118b) circumferentially separated by chip openings 120 (e.g., chip flutes). The chip openings 120 may be recessed slots extending longitudinally along the working end 116. Although only two lands 118a, 118b and one chip opening 120 are illustrated, there may of course be more. For example, there may be at least three lands equally spaced about the axis 104, with corresponding chip openings defined between adjacent pairs of lands.

[0038] The working end 116 may be defined by a first portion and a second portion aligned along the axis. The first portion may be referred to as a cutting portion 122, and the second portion may be referred to as a forming portion 124 or a rolling portion. The cutting portion 122 may have a first longitudinal length 161, and the forming portion 124 may have a second longitudinal length 162. The cutting portion 122 may be configured to cut threads into the hole 102. The forming portion 124 may be configured to plastically deform the threads cut by the cutting portion 122, thereby further threading the hole 102 and forming rolled threads.

[0039] The cutting portion 122 may include a first end 131 and a second end 132, and the forming portion 124 may include a third end 133 and a fourth end 134. The first end 131 may be located at and / or define a terminal end of the hybrid tool 110. The second end 132 and the third end 133 may be connected to each other. The fourth end 134 may be located further along the axis 104 and spaced from the intersection of the second and third ends 132, 133.

[0040] Accordingly, the cutting portion 122 and the forming portion 124 can be coupled and secured to define a unitary, one-piece hybrid tool 110 (e.g., a hybrid tap) that provides the benefits of both cutting and rolling threads. The tool 110 can be used in a single threading operation, such that the cutting portion 122 first cuts threads and the forming portion 124 further rolls and plastically deforms these threads. The threads can have high fatigue resistance and high load-holding strength. Thus, the threads produced by the tool 110 can hold a bolt and maintain the bolt load over a long service life.

[0041] The webs 118a, 118b and the chip openings 120 may extend along both the cutting section 122 and the forming section 124. As shown, the webs 118a, 118b and the chip opening 120 (as well as others described in Fig. 1) extend continuously longitudinally between the cutting and forming sections 122, 124. More specifically, a majority of the chip opening 120 may be axially straight and extend continuously along the axis 104 between the cutting and forming sections 122, 124. Additionally, the lands 118a, 118b within the cutting section 122 may include a plurality of cutting teeth 152 that project radially outward from the axis 104 and extend along a helical path with respect to the axis 104. Within the forming section 124, the lands 118a, 118b may include a plurality of forming teeth 155 that project radially outward from the axis 104 and extend along a helical path with respect to the axis 104. The cutting teeth 152 and the forming teeth 155 may extend helically along the same spiral path around the axis 104.The teeth 152, 155 (including their respective peaks and valleys) may be arranged so that cutting and plastic deformation can occur sequentially during a single actuation of the tool 110. In other words, the cutting teeth 152 at the second end 132 may be continuously connected to the forming teeth 155 at the third end 133. Thus, the material cut by the cutting teeth 152 can be prepared for plastic deformation by the forming teeth 155 during use. The cutting portion 122 can create cut threads 180 in the workpiece 100 during use of the tool 110 (. Fig. 2), and the forming section can plastically deform and roll the threads 180 to produce formed threads 182 in the hole 102 ( Fig. 3).

[0042] With reference to Fig. 1, the cutting portion 122 may be tapered along the longitudinal axis 104. In some embodiments, the cutting portion 122 may be tapered entirely from the first end 131 to the second end 132 of the cutting portion 122 with a single taper angle 138. In contrast, the forming portion 124 may have a substantially constant diameter along its longitudinal length between the third end 133 and the fourth end 134. In some embodiments, the diameter of the cutting portion 122 may gradually change according to the taper angle 138, and the largest diameter of the cutting portion 122 may be defined by the cutting teeth 152 disposed at the second end 132. The taper angle 138 may range from ten to forty-five degrees (10°-45°) in various embodiments. In addition, the taper angle 138 can be between thirty and forty-five degrees (30°-45°).

[0043] The dimensions of the cutting section 122 relative to those of the forming section 124 can be predetermined and selected to achieve the desired results. In general, the forming teeth 155 can have a larger diameter than the cutting teeth 152. For example, the major diameter of the cutting teeth 152 can be at most ninety-five percent (95%) of the major diameter of the forming teeth 155. Thus, the major diameter 140 of the cut thread 180 can be at most ninety-five percent (95%) of the major diameter 197 of the rolled thread 182. More specifically, in some embodiments, the major diameter of the cutting teeth 152 can be between eighty percent (80%) and ninety-five percent (95%) of the major diameter of the forming teeth 155.Thus, the major diameter 140 of the cut thread 180 may be between eighty percent (80%) and ninety-five percent (95%) of the major diameter 197 of the rolled thread 182. Furthermore, in some embodiments, the major diameter of the cutting teeth 152 may be between ninety percent (90%) and ninety-five percent (95%) of the major diameter of the forming teeth 155. As such, the major diameter 140 of the cut thread 180 may be between ninety percent (90%) and ninety-five percent (95%) of the major diameter 197 of the rolled thread 182. Furthermore, the profile of the cutting teeth 152 may be configured to cut and remove material from the workpiece 100, while the profile of the forming teeth 155 may be configured to plastically deform and form threads on the workpiece 100.

[0044] In some embodiments, the cutting portion 122 and the forming portion 124 may have common material properties. For example, the cutting portion 122 may be made of the same material as the forming portion 124 (e.g., tool steel). The portions 122 may also have a common coating, heat treatment, material hardness, etc. In these embodiments, the tool 110 may be constructed such that the cutting portion 122 and the forming portion 124 are formed on a single, common shank 112, and the portions 122, 124 may be subjected to the same heat treatment, coating, etc. As such, the cutting portion 122 and the forming portion 124 may be integrally connected and have common material properties.

[0045] In alternative embodiments, the cutting portion 122 and the forming portion 124 may have different material properties. For example, in some embodiments, the cutting portion 122 may have a higher material hardness than the forming portion 124 to improve the cutting action of the cutting portion 122. The cutting portion 122 may have a hardness of at least RC50, and the forming portion 124 may have a lower hardness in some embodiments. In some embodiments, the forming portion 124 may also have a higher material toughness than the cutting portion 122 to improve the thread rolling performance of the forming portion 124. To provide the portions 122, 124 with different material properties, the portions 122, 124 may be formed separately from different materials and then firmly joined (e.g., by welding).In further embodiments, the tool 110 may be formed using additive manufacturing techniques, and these techniques may be used to form the tool 110 with the attached sections 122, 124 and with different material properties. In further embodiments, one of the sections 122, 124 may be subjected to a different heat treatment than the other to provide the different material properties (e.g., one may receive a first heat treatment and the other a different second heat treatment, or one may be heat treated but the other is not). In further embodiments, one of the sections 122, 124 may be coated differently than the other to provide the different material properties (e.g., one may have a first coating and the other a different second coating, or one may be coated but the other is not).Coatings for portions 122, 124 may be selected from a group consisting of titanium nitride (TiN), titanium carbonitride or carbonitride (TiCN), chrome plate, nitride, aluminum chromium nitride (AlCrN), and aluminum chromium titanium nitride (AlCrTiN) in some embodiments. For example, TiN may be selected to increase chip flow when threading softer materials. TiCn may be selected for its high hardness and wear resistance. Additionally, chrome plate may be selected for its friction-reducing properties. Nitride may be selected for its high hardness. AlCrN may be selected for its thermal properties. AlCrTiN may be selected for its thermal and / or wear-resistant properties. TiCN and / or TiN may also be selected for their thermal properties and high hardness.

[0046] With reference to the Fig. 1-3, methods for threading the hole 102 using the hybrid threading tool 110 according to embodiments will now be discussed. As in Fig. 1, the workpiece 100 can be provided with the hole 102 having a first diameter 184 ( Fig. 1). The hole 102 may be provided with a smooth, annular inner diameter surface 181. In some embodiments, the first diameter 184 may be selected to be approximately equal to a minor diameter 196 of the resulting rolled threads 182. Thus, the amount of cutting by the cutting portion 122 may be relatively small to increase manufacturing efficiency.

[0047] As mentioned above, the hole 102 can be a through hole or a blind hole. A series of hybrid tools 110 with different sizes and / or other characteristics can be provided, and the tool 110 can be selected from the series according to the diameter 184, the material properties of the workpiece 100, and / or other factors. For example, the tool 110 with a larger taper angle 138 can be provided for a workpiece 100 that has higher ductility. Conversely, the tool 110 with a smaller taper angle 138 can be provided for a workpiece 100 that has higher hardness. Likewise, if the hole 102 is a blind hole, the tool 110 with a cutting portion 122 having a shorter length 161 can be selected.Likewise, the tool 110 with a higher taper angle 138 may be selected in cases where the hole 102 is a blind hole, while the tool 110 with a lower taper angle 138 may be selected in cases where the hole 102 is a through hole.

[0048] Then, as in Fig. 2, the tool 110 can be rotated about the axis 104, and the cutting portion 122 of the tool 110 can be advanced into the hole 102. Accordingly, the cutting teeth 152 can remove material to form the cut threads 180. The chips can be received in the openings 120 and move longitudinally along the tool 110 to be removed from the workpiece 100. The cut threads 180 can be cut to dimensions that are inversely proportional to those of the cutting teeth 152. Thus, the cut threads 180 can be cut to a small diameter 139 and a large diameter 140 that gradually taper according to the taper angle 138. As shown, the crown tips 170 of the cut threads 180 can be relatively sharp and pointed.

[0049] Next, the tool 110 can, as shown in Fig. 3, continue to rotate and be advanced further along the axis 104 so that the forming section 124 is provided in the hole 102. As the forming section 124 advances into the hole 102, the forming teeth 155 of the forming section 124 can plastically deform the threads 180 to form rolled threads 182. For example, the forming teeth 155 can plastically deform the crests 170 of the cut threads 180 to form the rolled threads 182. The forming teeth 155 can also plastically deform the thread roots between the crests 170 during this rolling process. These threads 182 can be cut with a minor diameter 196 and a major diameter 197. The minor diameter 196 can approximately correspond to the original diameter 184 of the hole 102 ( Fig. 1). As in Fig. 3, the crown tips 172 of the rolled threads 182 may be sawtooth-shaped, but have a more rounded profile than the crown tips 170 of the cut threads 180.

[0050] Accordingly, the cutting section 122 can efficiently cut the threads 180, and the forming section 124 can subsequently roll the threads 182. The cutting action of the cutting section 122 can improve the load-holding force, and the rolling action of the forming section 124 can improve the fatigue strength of the resulting threads 182. The plastic deformation by the forming section 124 can reduce porosity in the area without generating a high degree of microcracking, since the majority of the thread was previously created by the cutting section 122. The plastic deformation at the thread roots can reduce porosity and compressive residual stress to improve fatigue behavior. The thread body can have minimal microdamage to maintain creep strength and load-holding force.Advantageously, the resulting rolled threads 182 may have high fatigue strength, high load-holding capacity, etc.

[0051] In the Fig. 4 and Fig. 5 illustrates further embodiments of the hybrid threading tool 210 according to embodiments of the present disclosure. The tool 210 may have the same features as the tool described above and shown in the Fig. 1-3. Therefore, the description of these features is not repeated. Components similar to those shown in the Fig. 1-3 are marked with corresponding reference numbers increased by 100.

[0052] As illustrated, the hybrid threading tool 210 may be configured as an internal thread forming tool for producing an external thread on a shaft (e.g., for threading a bolt, etc.). The tool 210 may include a generally annular support body 215. The support body 215 may include a central opening 217 provided with internal threads to define the cutting portion 222 along the first length 261 and the forming portion 224 along the second length 262. As illustrated, the cutting portion 222 may taper in diametrical width along the first length 261, and the forming portion 224 may have a constant diameter, similar to the embodiments described above. The tool 210 may also include a plurality of chip openings 220 between the respective lands 218a, 218b, 218c, 218d.

[0053] As with the embodiments described above, the tool 210 can be used to first cut a thread and then form a thread. In particular, a workpiece (e.g., a shaft, shank, rod, etc.) can be received in the cutting section 222, and the tool 210 can be rotated about the axis 204. By rotating the tool 210 and advancing the tool 210 along the workpiece, the cutting section 222 can first cut a thread, and the forming section 224 can plastically deform the cut thread and form it into a rolled thread.

[0054] Methods for manufacturing the hybrid threading tool 110, 210 will now be discussed using exemplary embodiments. These methods are specifically described with reference to the tool 110 (the external tap) of Fig. 1-3. However, it is understood that these methods can also be used to manufacture the tool 210 (the forming tool) of the Fig. 4 and Fig. 5 can be used.

[0055] In some embodiments, the shank 112 may be a single piece and provided with a smooth outer surface. The shank 112 may then be machined (i.e., material is removed) to form the cutting teeth 152, the forming teeth 155, the chip openings 120, and / or other features of the tool 110. In some embodiments, the tool 110 may then be polished, heat-treated, coated, and / or otherwise finished. In some embodiments, these processes may result in the cutting portion 122 and the forming portion 124 having common material properties.

[0056] In further embodiments described in Fig. 6, the cutting portion 122 and the forming portion 124 may be formed separately (shown in phantom). The cutting teeth 152 of the cutting portion 122 may be formed on one body 310, and the forming teeth 155 of the forming portion 124 may be formed on another body 312. Then, the cutting portion 122 and the forming portion 124 may be joined end-to-end. In some embodiments, the cutting portion 122 and the forming portion 124 may be permanently joined by welding. Furthermore, in some embodiments, the cutting portion 122 may be formed from one material and the forming portion 124 may be formed from a different material. For example, the cutting portion 122 may be formed from a material that has a higher material hardness than that of the forming portion 124.In some embodiments, the forming portion 124 may also be formed from a material having a higher material toughness than that of the cutting portion 122.

[0057] In further embodiments described in Fig. 7, the tool 110 may be additively manufactured. For example, an additive manufacturing device 320 may be used. An emitter 322 may emit energy toward a bed 300 of powder material to form the tool 110 layer by layer. The tool 110 (including the cutting teeth 152 and forming teeth 155) may be additively built and grow progressively. In the illustrated embodiment, the tool 110 may be progressively formed along the axis 104; however, in other embodiments, the tool 110 may also be progressively formed in a different direction (e.g., perpendicular to the axis 104). This process can be convenient and highly efficient. Furthermore, this additive manufacturing method can provide the cutting and forming portions 122, 124 with common material properties.In other embodiments, the additive manufacturing process can provide the cutting and forming sections 122, 124 with different material properties. In further embodiments, the additive manufacturing process can be used to form the cutting and forming sections 122, 124 separately, and after forming, the sections 122, 124 can be joined end-to-end (e.g., by welding).

[0058] In addition, in the Fig. 8, the manufacture of the tool 110 may include the use of a heat treatment apparatus 302. In some embodiments, the heat treatment apparatus 302 may be used to perform at least one heat treatment of the tool 110. In some embodiments, the cutting portion 122 and the forming portion 124 may both be heat treated in the same manner to obtain common material properties. In other embodiments, the cutting and forming portions 122, 124 may be heat treated differently to obtain different material properties. In some embodiments, one of the cutting and forming portions 122, 124 may also be heat treated instead of the other to obtain different material properties.Furthermore, the heat treatment apparatus 302 may be used to achieve different material properties to heat treat at least one section 122, 124 in the separated state, and the sections 122, 124 may then be joined end-to-end (e.g., by welding).

[0059] Likewise, the manufacture of the tool 110, as in Fig.8, may include the use of a coating device 301. In some embodiments, the coating device 301 may be used to provide the tool 110 with at least one coating. In some embodiments, the cutting section 122 and the forming section 124 may be provided with a common coating. In other embodiments, the cutting and forming sections 122, 124 may be provided with different coatings to impart different material properties. In some embodiments, one of the cutting and forming sections 122, 124 may also be coated instead of the other to impart different material properties.

Claims

[1] A hybrid threading tool (110) defining a longitudinal axis, comprising: a cutting portion (122) having a plurality of cutting teeth (152), the plurality of cutting teeth (152) being configured to cut a first thread into a workpiece (100); and a forming section (124) attached to and disposed along the longitudinal axis of the cutting section (122), the forming section (124) having a plurality of forming teeth (155) configured to plastically deform the first thread into a second thread for the workpiece (100); wherein the plurality of cutting teeth (152) are arranged in a first land (118a) and a second land (118b) and further comprising a chip opening (120) defined circumferentially between the first land (118a) and the second land (118b), the chip opening (120) extending along the longitudinal axis through the cutting section (122) and being configured to receive chips from cutting the first thread, the chip opening (120) extending along the longitudinal axis into the forming section (124). [2] The hybrid threading tool (110) of claim 1, wherein the cutting portion (122) has a first end (131) and a second end (132) spaced apart along the longitudinal axis, the forming portion (124) has a third end (133) and a fourth end (134) spaced apart along the longitudinal axis; and the second end (132) of the cutting portion (122) is continuously connected to the third end (133) of the forming portion (124). [3] Hybrid threading tool (110) according to claim 2, wherein the cutting portion (122) is tapered along the longitudinal axis. [4] A hybrid threading tool (110) according to claim 1, wherein the cutting portion (122) has a first major diameter and the forming portion (124) has a second major diameter; and wherein the first major diameter is between eighty percent (80%) and ninety-five percent (95%) of the second major diameter. [5] Hybrid threading tool (110) according to claim 1, wherein the cutting portion (122) and the forming portion (124) are integrally connected and have common material properties. [6] The hybrid threading tool (110) of claim 1, wherein the cutting portion (122) and the forming portion (124) have different material properties; and at least one of: wherein the cutting section and the forming section (124) are made of different materials; wherein the cutting section (122) and the forming section (124) have different heat treatments that provide the different material properties; and wherein the cutting portion (122) has a higher hardness than the forming portion (124), and wherein the forming portion (124) has a higher material toughness than the cutting portion (122). [7] The hybrid threading tool (110) of claim 1, further comprising a shank (112); and wherein the plurality of cutting teeth (152) and the plurality of forming teeth (155) are mounted on the shank (112) and extend radially outwardly therefrom and away from the longitudinal axis to define a hybrid external tap. [8] The hybrid threading tool (110) of claim 1, further comprising a support body (215); and wherein the plurality of cutting teeth (152) and the plurality of forming teeth (155) are mounted on the support body (215) and extend radially inwardly therefrom and in the direction of the longitudinal axis to define an internal thread forming tool. [9] A method for producing a hybrid threading tool (110) for threading a workpiece (100), comprising: Producing a plurality of cutting teeth (152) to define a cutting portion (122) of the hybrid threading tool (110); Producing a plurality of forming teeth (155) to define a forming portion (124) of the hybrid threading tool (110), the forming portion (124) being arranged with the cutting portion (122) along the longitudinal axis; wherein the plurality of cutting teeth (152) are configured to cut a first thread into a workpiece (100), and the plurality of forming teeth (155) are configured to plastically deform the first thread into a second thread for the workpiece (100); wherein the plurality of cutting teeth (152) are arranged in a first land (118a) and a second land (118b) and further comprising a chip opening (120) defined circumferentially between the first land (118a) and the second land (118b), the chip opening (120) extending along the longitudinal axis through the cutting section (122) and being configured to receive chips from cutting the first thread, the chip opening (120) extending along the longitudinal axis into the forming section (124).

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