Advanced Process Analysis for High Performance Tapping Technology in Aluminum Cast Alloy AlSi10Mg

In context of industrial mass production, innovative machining technologies offer a potential for significant gain of efficiency and sustainability. Whereas in conventional tapping processes the tool moves in and out in sync with the thread pitch, the kinematics of the novel helical thread forming technology allows to reduce the process time by half. This paper is about an extended process analysis of its specific process characteristics in contrast to conventional tapping. By high-speed-microscopy and advanced analysis of mechanical tool loads, it is possible to evaluate specific differences in the forming process of the thread profile. In context of sustainable production, aluminum cast alloy AlSi10Mg – which represents a recyclable material for near-net-shape components in mobility sector – is regarded in this study. In addition, the resulting quality of the produced M6 threads is evaluated in context of decreased production time and aspects of sustainability.