Stepped Thread Forming Tap for Reverse-Rotation Rubbing

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Solution Overview

Problem

Existing thread forming taps experience rubbing phenomena during reverse rotation, leading to deformation and abrasive wear of the inside diameter finishing blade, particularly affecting the crest of the machined female threads.

Innovation Solution

The thread forming tap design includes a male thread portion with a chamfer portion and a complete thread portion, featuring a groove and an inside diameter finishing blade with a stepped configuration, where the height of the chamfer portion side is lower than the complete thread portion side, and a back taper to minimize interference and friction during reverse rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the inside diameter finishing blade is provided with a back taper to maintain approximately the same diameter from the chamfer portion, then the blade can finish the inside diameter portion of the female thread, but the blade causes rubbing phenomenon against the female thread during reverse rotation

Engineering Contradiction:
Improveinside diameter finishingVSAvoidrubbing phenomenon
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The inside diameter finishing blade is segmented into multiple sections along its length, with each section having a different height. The blade height decreases from the rear end toward the tip end, creating distinct functional zones. The rear sections contact the female thread during forward rotation to perform finishing, while the tip sections are positioned lower to avoid contact during reverse rotation, thus eliminating the rubbing phenomenon.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The inside diameter finishing blade is designed with predetermined height variations before the threading operation. The stepped configuration is pre-established so that during forward rotation, the appropriate blade sections are positioned to finish the inside diameter, and during reverse rotation, the lower tip sections prevent harmful contact. This preliminary structural arrangement proactively prevents the rubbing phenomenon.

Inventive Principle:
Principle #10Preliminary action

2Manufacturing precision

If the inside diameter finishing blade has uniform height to maintain consistent diameter, then the blade can effectively cut and remove the crest portion of the female thread, but the blade deforms the crest of the female thread when reversed and returned

Engineering Contradiction:
Improvethread crest finishingVSAvoidthread crest deformation
Core Design Contradiction:
Manufacturing precisionVSShape

Solution Approach 1:

The inside diameter finishing blade is divided into multiple height levels along its axial length. The rear sections with greater height are positioned to contact and finish the crest portion of the female thread during forward rotation. The tip sections with reduced height are positioned lower to avoid contact with the female thread during reverse rotation, preventing crest deformation while maintaining effective finishing capability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Instead of designing a uniform height blade that contacts during both forward and reverse rotations, the invention inverts the approach by creating a non-uniform height profile where the contacting sections are positioned to engage only during forward rotation. The blade geometry is designed so that the effective finishing sections are at the rear, while the forward-facing tip sections are recessed to avoid harmful engagement during reverse motion.

Inventive Principle:
Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design reduces deformation of the female thread crest and minimizes friction and heat generation by ensuring the inside diameter finishing blade does not interfere with the formed threads during reverse removal, enhancing the precision and durability of the thread forming process.

Implementation Method 1

a male thread portion that forms a female thread by plastically deforming a pilot hole in a workpiece

Methodology Applied
Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

minimizes friction and heat generation by ensuring the inside diameter finishing blade does not interfere with the formed threads during reverse removal

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentUS20250387842A1Thread forming tap
Publication Date: 2025.12.25 OSG
  • US20250387842A1 patent drawing
  • US20250387842A1 patent drawing
  • US20250387842A1 patent drawing

AI summary

A thread forming tap (1) is provided with a male thread portion (3), a groove, and an inside diameter finishing blade (61). A chamfer portion (31) of the male thread portion (3) is provided continuous with the complete thread portion (32) and decreases in diameter toward a tip end. The groove is provided parallel to a shaft center spanning the complete thread portion (32) and the chamfer portion (31) so as to divide a thread (71) of the male thread portion (3). On the chamfer portion (31) and the complete thread portion (32), the inside diameter finishing blade (61) is provided along an open edge of the groove on the side opposite the rotational direction of the thread forming tap (1). The inside diameter finishing blade (61) cuts and removes a crest portion of the female thread formed on a surface layer of a pilot hole (90). The height of a first step finishing blade (611) of the inside diameter finishing blade (61) on the chamfer portion (31) is lower than the height of a second step finishing blade (612) of the inside diameter finishing blade (61) formed on a portion corresponding to a thread (71) on the tip-most end of the complete thread portion (32).