Taps are the tools that cut metal and make internal threads in holes. Machine taps, used for producing numerous screw holes, are one of the most common tools used in producing mechanical parts. The process performance is strongly affected by the lubrication efficiency. Current methods of lubricant supply, by either pouring the cutting fluid from outside of the hole or transport the fluid into the hole through the tap, do not effectively deliver cutting fluid to the cutting edges, due to the material and chip surrounding the cutting edges. Inside the holes, if the cutting fluid is released closer to the cutting edges, where the heat and resistance is produced, the cutting speed and tool life will be significantly increased. In addition to machine taps, industries of offshore oil, marine, and wind energy require large hand taps for repair and maintenance work. Field workers need to carry heavy and chunky hand taps, weighing up to 10 kg, to towers exposed to harsh environment. Reducing the tool weight can reduce the their stress, thus reducing the risks.
Thürmer aims to develop both kinds of taps with the latest additive manufacturing (also mentioned as 3D-printing). The technology enables producing complex geometry suitable for highly functional structures. On machine taps, the technical break-through is the innovative cooling and lubricating channels and nozzles that deliver the cutting fluid to the cutting edges, where it is need the most. The importance is not only the economic benefits resulted by the increased cutting speed and tool life, but also the minimized consumption of cutting fluid, which significantly reduces the impact to the environment and worker’s health.
AM is one of the core enabling technology that will upgrade the manufacturing industry towards high-performance, functionality, and environmentally friendly production. The machine tool industry is the sector that has broad impact on other sectors, such as consumer products, general machines, and transportation. We expect the success of the project to disseminate the knowledge and experience of AM adoption to a spectrum of industries, thus maintaining the competitiveness of the European manufacturing industry.
The development of 3D-printed machine taps aims to achieve:
• 100% increase of tool life,
• 20% increase of cutting speed,
• reduced power consumption during material removal,
• reduction of cutting fluid consumption significantly compared to conventional flood cooling
• The goal is a serial production of 200.000 tools/year by 2023.
