Tap Phase Compensation for Torsional Deformation Control

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Solution Overview

Problem

Tap breakages occur during machining due to insufficient synchronization between the main spindle rotation phase and the workpiece position in the rotation axis direction, especially at the thread bottom, and existing solutions rely on mechanical elasticity or specialized holders, leading to accuracy and versatility issues.

Innovation Solution

A tap machining method and apparatus that synchronize the rotation phase of the main spindle with the workpiece by adjusting the torsional deformation of the tap based on cutting speed, using calculations from material mechanics or finite element methods, to prevent breakages without relying on mechanical elasticity or specialized holders.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a holder with an elastic body is used to absorb synchronization insufficiency, then tap breakages are prevented, but manufacturing precision degrades due to secular change in elastic body rigidity

Engineering Contradiction:

Improvetap breakage preventionVSAvoidthread machining accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical elastic holder system with a computational synchronization adjustment system. Instead of using an elastic body to physically absorb synchronization errors, the invention calculates the torsional deformation angle of the tap based on cutting speed and material properties, then adjusts the rotation phase of the main spindle accordingly to compensate for the deformation, thereby preventing tap breakages while maintaining machining accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent dynamically adjusts the rotation phase parameter of the main spindle based on cutting speed variations. By changing the synchronization parameters (rotation phase angle) according to actual cutting conditions, the system compensates for torsional deformation without requiring mechanical elasticity, thus preventing tap breakages while maintaining continuous accuracy

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a special holder with elastic body is used, then tap breakages are prevented, but versatility decreases due to need for different holders for each tap size

Engineering Contradiction:

Improvetap breakage preventionVSAvoidholder compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal solution that works with standard tool holders for all tap sizes. Instead of requiring specialized elastic holders for each tap size, the invention uses a general-purpose holder combined with a computational synchronization adjustment system that calculates and compensates for torsional deformation based on cutting speed and tap parameters, making the system universally applicable while preventing tap breakages

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If synchronization is maintained without adjusting for torsional deformation, then machining simplicity is maintained, but tap breakages occur at thread bottom due to phase misalignment

Engineering Contradiction:

Improvemachining process simplicityVSAvoidtap breakage prevention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent performs preliminary calculation of the torsional deformation angle based on cutting speed and material properties before the actual machining operation. This pre-calculated angle amount is then added to or subtracted from the rotation phase of the main spindle in advance, ensuring that the synchronization is already adjusted when machining begins, thereby preventing tap breakages without complicating the actual machining process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements a feedback mechanism where the rotation phase of the main spindle is continuously adjusted based on the calculated torsional deformation angle that corresponds to the actual cutting speed. This closed-loop synchronization adjustment ensures that the tap remains properly aligned with the workpiece throughout the machining process, preventing breakages while maintaining operational simplicity

Inventive Principle:

Principle #23Feedback

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 approach ensures continuous high accuracy and versatility in tap machining by preventing tap breakages through mechanical control, allowing the use of standard tool holders and eliminating the need for specialized designs, thereby maintaining precision and adaptability.

Implementation Method 1

adding or subtracting an angle amount of torsional deformation of the tap generated according to a cutting speed to or from the rotation phase of the main spindle

Methodology Applied

Scientific EffectTorsional deformation: Deformation

Data Source

PatentUS20240399479A1Tap machining method and tap machining apparatus

Publication Date: 2024.12.05 OKUMA CORP

AI summary

A tap machining method includes: forming a female thread by cutting while synchronizing a rotation phase of a main spindle with positions of a workpiece to be machined by the tap and the main spindle in a rotation axis direction of the main spindle, the main spindle rotating while holding a tap with a tool holder mounted on a distal end portion; and adding or subtracting an angle amount of torsional deformation of the tap generated according to a cutting speed to or from the rotation phase of the main spindle during the synchronization.