11/17/2018 | 2 MINUTE READ

Add Punch Tapping to the List of Thread-Machining Options

Originally titled 'Punch Up the Volume'
Facebook Share Icon LinkedIn Share Icon Twitter Share Icon Share by EMail icon Print Icon

Emuge has introduced the Punch Tap, a new class of tool for rapidly threading holes in aluminum.

Share

Facebook Share Icon LinkedIn Share Icon Twitter Share Icon Share by EMail icon Print Icon

A new tool offers a fundamentally different method for forming internal threads in aluminum and other lightweight alloys. Emuge Corp. developed the Punch Tap in conjunction with Audi, which held exclusive rights to its use in the automotive industry until its wide-market debut at the International Manufacturing Technology Show (IMTS) 2018. While other threading techniques slowly enter and exit the hole to avoid damaging the threads, the Punch Tap is designed for quickly plunging into the material to thread depth, cold-forming the threads with a single twist and exiting—all in a fraction of the time it takes to using a traditional tap, cold-forming tap or a thread mill. Thanks to its atypical geometry, it can move quickly without damaging the threads it forms.

The tool has two helical rows of flutes with thread-forming teeth, offset 180 degrees from each other, traveling down the length of the tool. Two pilot edges, one at the tip of each flute, create two helical clearance grooves for the flutes to follow. These grooves ensure the thread-forming teeth do not touch the interior wall as the tool rotates clockwise into the hole. Once the tool reaches full depth, it stops, then rotates 180 degrees counterclockwise. Only then do the teeth contact the hole wall to cold-form all of the threads. After the 180-degree rotation, the rows of flutes are aligned with the clearance grooves opposite of those they followed plunging into the hole. The tool continues a counterclockwise rotation as it exits the hole to keep the flutes inside the helical clearance grooves. After the Punch Tap exits the hole, the clearance grooves remain, but are said to have a negligible effect on thread function. (The process is demonstrated in this video.)

The company says this tool can improve hole-threading speed by 75 percent compared to conventional and cold-forming taps, which require precise rotation to prevent damage to the newly created threads as the tool exits the hole. In demonstrations at this year’s IMTS, the Punch Tap took less than half a second to completely thread and exit a hole in an aluminum workpiece. This speed can translate into substantial time savings for any manufacturer needing to thread large numbers of holes in lightweight metal parts.

Unlike many tools, the Punch Tap is only available as a customized product. “It is an engineered product that has design features which are application-specific to an end-user’s component design and material composition,” says Emuge Product Director Mark Hatch. He says the company will work with customers to perform detailed analysis and adjustments, depending on a broad range of technical issues.

The Punch Tap requires a specialized toolholder called the PT Synchro. This holder provides force-locked rigid clamping via a cylindrical ER collet that enables high torque and reduces the stress on the tool. The standard surface treatment is a TIN-T26 coating, and it forms threads in sizes ranging from #8 through 5/16. 

The tool is unsuitable for metals much stronger than aluminum, both because it creates threads via cold forming and because the cutting edges that produce the entry grooves can take only a limited amount of shearing force. Additionally, the plunging motion of the tool path requires a the manufacturer use a CNC machine with a control capable of performing the specialized Punch Tap cycle, currently available in the latest generations of Heidenhain, Siemens and FANUC controls.

Hand holding a crystal ball

We’d rather send you $15 than rely on our crystal ball…

It’s Capital Spending Survey season and the manufacturing industry is counting on you to participate! Odds are that you received our 5-minute Metalworking survey from Modern Machine Shop in your mail or email. Fill it out and we’ll email you $15 to exchange for your choice of gift card or charitable donation. Are you in the U.S. and not sure you received the survey? Contact us to access it.

Help us inform the industry and everybody benefits.

RELATED CONTENT

  • How To Machine Aircraft Titanium: The 8-To-1 Rule For Finishing Walls And Ribs

    Part of a series of articles on more efficient machining of pockets in titanium parts, this article makes the case for a tool with many cutting edges, and describes how best to apply it.  

  • Rolling Threads Has Advantages

    With macros and canned cycles resident in the CNC on most contemporary turning centers, single point turning of OD threads can seem like almost a default process decision. However, for numerous applications, OD thread rolling has inherent advantages as an alternative to cutting threads.

  • Start With The Right Speeds And Feeds

    Running rotary milling cutters at the proper speeds and feeds is critical to obtaining long tool life and superior results, and a good place to start is with the manufacturer's recommendations. These formulas and tips provide useful guidelines.

Related Topics

Resources