EMUGE Taptor – Questions and Answers | FAQ

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  • What is Taptor®?
    Taptor® is our brand name for a new type of tool for use in a new technology for machining internal threads.
    Taptor® therefore also stands for the new technology. AUDI AG calls the process Threading 3.0 with Taptor®-Technology.
  • How does Taptor® work?
    With Taptor®, the core hole and the thread are produced simultaneously in one operation.
    In the first step, the movement of the tool corresponds to synchronous tapping.
    The drill feed per revolution therefore corresponds to the thread pitch. In the second step, the tool cuts free at the drilling depth.
    And the thread teeth create a circumferential undercut. The Taptor® is then retracted through the generated thread.
  • Function Phase Model Taptor®

 

  • How is a Taptor® constructed?
    A Taptor® has a drill part and a few threading teeth which are arranged axially at a small distance from the drill tip.
  • Which tool holder is used for Taptor®?
    Taptor® should be used with the Speedsynchro Taptor®
    Taptor® can also be clamped in a rigid holder
  • What is the time advantage compared to conventional thread cutting?
    The time advantage results from several individual elements. On the one hand, the entire pre-drilling cycle including all traverse paths and positioning and tool change is eliminated.
    The Speedsynchro Taptor® also significantly reduces the main time required for individual thread machining. An example application (machining a cylinder head cover side in the dimension M6, 2xD deep) there is a time saving of about 2 seconds per thread.
  • What is the tool life behavior of a Taptor®?
    The tool life is not yet known as experience with serial production is currently being built up.
  • Which technology partners in the production environment have experience with Taptor®?
    AUDI, GROB, MAG
  • Can a Taptor® be reground?
    It can not be reground according to our current assessment.
  • What is the design of a Taptor®?
    Taptor® will be designed like a step drill taking into account thread depth and length of the chamfer.
    Tools are available for tests on customer workpieces.
  • For which hole shapes is the Taptor® suitable?
    For blind hole machining as well as through-hole machining.
  • How large is the thread run-out (pre-drilling depth to usable thread depth)?
    An undercut is created at the bottom of the thread instead of a lead-in chamfer when tapping. The screw can be screwed into this undercut. The axial length of the undercut corresponds approximately to the length of the lead-in chamfer in conventional tapping. (shape E)
  • Which thread systems are possible with Taptor®?
    From today‘s point of view, metric threads and other sharp threads (UNC, UNF, etc.) are possible with Taptor®.
  • Which dimensions are possible with Taptor®?
    At the moment dimensions M4; M5; M6 are available. M8 will follow soon.
  • For which thread depths can a Taptor® be used?
    As per current development the thread depth is up to 3 x D
  • Can Taptor® be used to countersink in the hole?
    Yes, due to the kinematics of relief cutting at the bottom of the thread, a countersink/step can be made at
    the thread entry at the same time, if the tool is designed accordingly.
  • Do thread depths change compared to conventionally produced threads?
    It makes sense to harmonize the threads of one dimension on a component also with regard to length.
    This reduces the number of tool changes and the time advantage can be further increased.
  • How is the thread strength influenced by Taptor®?
    At present, the thread strength has not yet been proven. However, no disadvantage in the thread strength
    is expected as the thread production works analogous to classical tapping. Initial investigations by AUDI AG
    show that the strength is at least equivalent to that of conventionally produced threads.
  • How is the produced thread tested?
    The test is carried out with conventional go/no-go thread plug gauges.
  • Is there a standard for this new technology?
    There is currently no standard available.
  • In which materials can the Taptor® be used?
    Taptor® can be used in cast aluminum alloys and magnesium alloys.
  • Which machine requirements are necessary for Taptor®?
    The machine must be suitable for synchronous tapping.
    For the use of Speedsynchro Taptor®, additionally a spindle with torque support is required.
    The tool magazine should be suitable for holding the Speedsynchro Taptor®.
    Increased demands with regard to machine rigidity or fixture design are not necessary based on current tests.
  • Which forces occur during machining with Taptor®?
    The maximum forces result from the feed during drilling. The force corresponds to the compressive force during drilling with a correspondingly high feed rate.
    The arising forces for threads M6 are in a range between 500-1200N.
  • Which torque can be expected with Taptor®
    The torque is the result of simultaneously drilling and threading, e.g. a torque between 5-7Nm can be expected for M6.
  • With which control units (Siemens, Fanuc, Heidenhain,…) can the technology be used?
    For the current development activities, the NC program was created on the basis of a Siemens control (Sinumerik 840D). With other control units, the motion sequence is basically conceivable, but not yet proven in practice.
  • Which lubrication is possible?
    Taptor® must be used with emulsion or oil with a minimum pressure of 20bar to evacuate the chips from drilling out of the hole.
  • What set-up costs are to be expected?
    If the machine is suitable, additional set-up costs will arise from the purchase of the tool.
    The acquisition costs of the Speedsynchro Taptor® have to be added.
  • Which positioning accuracies can be reliably achieved?
    The drawing requirements for a component from AUDI AG (cylinder head) could be verified by a machine capability test
  • Who can be served with Taptor®
    Taptor® is available for all users.