Thread Former Flaring Ridges for Forming Claw Elimination
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Solution Overview
Problem
Existing thread forming methods, such as cold-forming taps, often result in the formation of unwanted 'forming claws' between thread turns, leading to burrs, deformations, and the need for cutting, which can disrupt microstructure hardening and cause chip formation during internal thread production.
Innovation Solution
A novel cold-forming tap design featuring a rotatable forming area with radially protruding pressing lobes arranged in a spiraling pattern, including pressing ridges and flaring ridges, where the flaring ridges have a lower height than the pressing ridges and are designed to eliminate forming claws by sweeping over the thread turns during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cold-forming taps with uniform pitch angles are used for thread production, then the thread formation process is simple and efficient, but forming claws are created between the thread turns
Solution Approach 1:
The pressing lobes are segmented into two distinct types: pressing lobes for thread formation and flaring lobes for claw removal. This segmentation allows each type to perform its specific function optimally without interference, resolving the contradiction between production efficiency and surface quality by adding a specialized component rather than complicating the existing uniform pitch design
Solution Approach 2:
Different regions of the tool are given different functions: pressing lobes with specific pitch angles for efficient thread formation in the primary working area, and flaring lobes with different geometry for localized claw removal between thread turns. This local differentiation maintains overall production efficiency while improving specific problem areas
2Manufacturing precision
If cutting is used to remove forming claws between threads, then the claws are eliminated, but burrs and deformations arise and microstructure hardening is interrupted
Solution Approach 1:
The mechanical cutting process is replaced with a cold-forming process using flaring lobes. Instead of removing material through cutting, the flaring lobes plastically deform the forming claws, redistributing the material to fill gaps and eliminate claws without creating burrs or interrupting the microstructure. This substitution maintains microstructure integrity while achieving claw removal
Solution Approach 2:
The physical state and properties of the material are changed through controlled plastic deformation rather than removal. The flaring lobes apply pressure to change the shape and distribution of material in the forming claw area, transforming it from a harmful protrusion into integrated thread structure, thereby preserving microstructure continuity
3Manufacturing precision
If cutting is used to remove forming claws, then the claws are eliminated, but chips are generated in the tapped hole
Solution Approach 1:
The cutting mechanism that generates chips is replaced with a cold-forming mechanism using flaring lobes. The flaring lobes plastically deform and redistribute the forming claw material rather than cutting it away, completely eliminating chip generation in the tapped hole while still achieving effective claw removal
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
The tool effectively eliminates forming claws between thread turns, preventing burrs and deformations, ensuring uniform microstructure hardening and eliminating the need for subsequent cutting or drilling, thus enhancing thread quality and production efficiency.
Implementation Method 1
the pressing lobes cause cold deformation of the workpiece by pressure
Implementation Method 2
the deformation of the surface and the associated strain hardening increases the hardness of the material in the area of the thread profile
Implementation Method 3
the flaring ridge sweeps over the thread turns with each revolution and thereby presses in a forming claw
Data Source
AI summary
A tool and related method for the non-cutting production or reworking of a thread in/on a workpiece comprises a forming area which is rotatable about a tool axis (A), the forming area having a plurality of pressing lobes protruding or projecting radially outwards away from the tool axis (A) for producing or post-reworking the thread by pressing the pressing lobes into the workpiece surface. The pressing lobes are arranged in succession along a shaping curve which substantially spirally encircles the tool axis (A), and the pitch of the shaping curve corresponds substantially to the pitch of the thread to be produced or reworked. The pressing lobes form at least one pressing ridge, wherein adjacent to the at least one pressing ridge a flaring ridge with a lower height HB than the height of the pressing ridge HD is formed.