Cutting tap

Abstract

A cutting tap includes thread ridges, roots formed between the respective axially adjacent pairs of thread ridges, and a plurality of deburring thread grooves arranged at a constant pitch toward the axial front side of the cutting tap from the rearmost ones of the roots in which the deburring thread grooves are formed, and formed such that a groove bottom diameter of the deburring thread grooves gradually decreases toward the axial front side of the cutting tap. The respective deburring thread grooves have groove bottom diameter reliefs by which the groove bottom dimeter gradually decreases from the front side toward the rear side of each deburring thread groove in the rotation direction of the cutting tap, the groove bottom diameter reliefs being set to be larger than effective diameter reliefs of the thread grooves.

Claims

1. A cutting tap comprising: a plurality of thread ridges arranged at a constant thread ridge pitch along an axial direction of the cutting tap, the thread ridges being formed such that an effective diameter of the thread ridges is uniform along the axial direction, and such that a major diameter of the thread ridges gradually decreases in a direction toward an axial front side of the cutting tap, the effective diameter of the thread ridges being defined as a diameter of an imaginary cylinder passing through a portion of each of the thread ridges at a location where a width of the portion of each respective one of the thread ridges is equal to a width of a thread groove adjacent to the respective one of the thread ridges; and roots formed between respective axially adjacent pairs of the thread ridges, wherein the respective thread ridges have effective diameter reliefs by which the effective diameter gradually decreases from a leading side toward a trailing side of each of the thread ridges in a rotation direction of the cutting tap, and wherein the respective roots have root diameter reliefs by which a root diameter of the roots gradually decreases from a leading side toward a trailing side of each of the roots in the rotation direction of the cutting tap, the root diameter reliefs being equal to the effective diameter reliefs, wherein the cutting tap further comprises a plurality of deburring thread grooves formed in at least some of the roots and spaced at a constant deburring thread groove pitch along the cutting tap such that a groove bottom diameter of the deburring thread grooves gradually decreases toward the axial front side of the cutting tap, and wherein the respective deburring thread grooves have groove bottom diameter reliefs by which the groove bottom diameter gradually decreases from a leading side toward a trailing side of each of the deburring thread grooves in the rotation direction of the cutting tap, the groove bottom diameter reliefs being set to be larger than the effective diameter reliefs of the thread grooves.

2. The cutting tap according to claim 1, wherein each of the deburring thread grooves is a V groove having a V-shaped cross section such that a step is formed relative to a surface of the corresponding one of the roots.

3. The cutting tap according to claim 1, wherein the deburring thread grooves are arranged and shaped such that the closer the deburring thread grooves are located to the axial front side of the cutting tap, the deeper the deburring thread grooves are relative to the roots.

4. The cutting tap according to claim 2, wherein the deburring thread grooves are arranged and shaped such that the closer the deburring thread grooves are located to the axial front side of the cutting tap, the deeper the deburring thread grooves are relative to the roots.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front view of a cutting tap according to an embodiment of the present invention.

(2) FIG. 2 is a sectional view taken along line II-II of FIG. 1.

(3) FIG. 3 is an enlarged sectional view of a cutting portion and a complete thread portion of the cutting tap illustrated in FIG. 1.

(4) FIG. 4 is an enlarged sectional view illustrating the vicinity of deburring thread grooves formed between respective adjacent pairs of thread ridges of the cutting portion of FIG. 3.

(5) FIG. 5 is a sectional view of a portion of a nut blank.

(6) FIG. 6 is a sectional view illustrating the state in which the front end portion of the cutting tap of FIG. 3 is engaged with the inner periphery of the nut blank of FIG. 5.

(7) FIG. 7 is a sectional view illustrating the state in which the cutting tap of FIG. 6 is advanced while being rotated.

(8) FIG. 8 is a sectional view illustrating the state in which the cutting tap of FIG. 7 is further advanced while being rotated.

(9) FIG. 9 is a sectional view illustrating, when a first experiment was performed so as to form an internal thread by use of the cutting tap of FIG. 4, the actual shape of the prepared hole for the internal thread, and the actual shape of the internal thread.

(10) FIG. 10 is a sectional view illustrating, when a second experiment was performed so as to form an internal thread by use of the cutting tap of FIG. 4, the actual shape of the prepared hole for the internal thread, and the actual shape of the internal thread.

DETAILED DESCRIPTION OF THE INVENTION

(11) FIG. 1 illustrates a cutting tap 1 according to the embodiment of the present invention. This cutting tap 1 is a nut tap used for manufacturing nuts in a tapping machine, and includes a cutting portion 2 formed such that the outer diameter of the cutting portion 2 gradually decreases toward the axial front side of the cutting portion 2, a complete thread portion 3 formed such that the outer diameter of the complete thread portion 3 is uniform in the axial direction, and a columnar shank 4. The complete thread portion 3 is continuous with the axial rear side of the cutting portion 2. The shank 4 is continuous with the axial rear side of the complete thread portion 3.

(12) The cutting portion 2 is formed with a plurality of thread ridges 5 arranged at a constant pitch in the axial direction. The complete thread portion 3 is formed with a plurality of thread ridges 6 arranged at a constant pitch in the axial direction. The cutting tap 1 is formed in its outer periphery with a plurality of grooves 7 extending from the axial front end of the cutting tap 1 to the shank 4 through the cutting portion 2 and then the complete thread portion 3 so as to circumferentially divide a single thread into the thread ridges 5 of the cutting portion 2 and the thread ridges 6 of the complete thread portion 3. A cutting edge is constituted by the ridgeline at which the surface of each thread ridge 5 intersects with the inner surface of one of the grooves 7. As illustrated in FIG. 2, the grooves 7 are circumferentially spaced apart from each other at regular intervals.

(13) As illustrated in FIG. 3, the thread ridges 5 of the cutting portion 2 have an incomplete shape, that is, the crests of the thread ridges 5 are obliquely cut such that the major diameter of the thread ridges 5 gradually decreases toward the axial front side of the cutting portion 2. The effective diameter d.sub.1 of the thread ridges 5 is uniform in the axial direction. As illustrated in FIG. 2, the crests of the respective thread ridges 5 of the cutting portion 2 have major diameter reliefs such that the major diameter of the thread ridges 5 gradually decreases from the front (leading) side to the rear (trailing) side of each thread ridge 5 in the rotation direction of the cutting tap 1. (In FIG. 2, the cutting tap 1 rotates in the clockwise direction, so that the major diameter decreases in the counterclockwise direction at each thread ridge 5.) In order to ensure sharpness of the crests of the thread ridges 5, the major diameter reliefs of the thread ridges 5 are set to be larger than the below-described effective diameter d.sub.1 reliefs of the thread ridges 5.

(14) The effective diameter d.sub.1 of the thread ridges 5 corresponds to the diameter of an imaginary cylinder (or cone) that passes through the portions of the thread ridges where their widths are equal to the widths of thread grooves formed between the respective axially adjacent pairs of thread ridges 5. Though it is described above that the effective diameter d.sub.1 of the thread ridges 5 is uniform in the axial direction, the effective diameter d.sub.1 thereof does not need to be uniform in a strict sense. More specifically, in order to reduce cutting resistance when forming an internal thread, the imaginary cylinder (or cone) having the effective diameter d.sub.1 may be slightly tapered or inclined (by about 1/1000 to 3/1000) such that the effective diameter d.sub.1 decreases from the axial front side of the cutting portion 2 toward the axial rear side thereof.

(15) As illustrated in FIG. 3, the thread ridges 6 of the complete thread portion 3 have a complete shape, that is, the outer diameter of the complete thread portion 3 is uniform in the axial direction. The effective diameter of the thread ridges 6 of the complete thread portion 3 is uniform in the axial direction, and equal to the effective diameter d.sub.1 of the thread ridges 5 of the cutting portion 2. In order to enable the cutting tap 1 to be accurately guided, the respective thread ridges 6 have major diameter reliefs (i.e., reliefs by which the major diameter of the thread ridges 6 gradually decrease from the front (leading) side toward the rear (trailing) side of each thread ridge 6 in the rotation direction of the cutting tap 1) that are set at 0 (zero) or a minute value.

(16) The cutting portion 2 has a root 8 between each axially adjacent pair of the thread ridges 5. Each root 8 has a cross section extending straight in the axial direction, and both ends connected to respective flanks of the corresponding pair of the thread ridges 5. The complete thread portion 3 is also formed with a root 9 similar to the root 8, between each axially adjacent pair of the thread ridges 6. The root diameter d.sub.2 of the cutting portion 2 is uniform in the axial direction. The root diameter of the complete thread portion 3 is uniform in the axial direction, and equal to the root diameter d.sub.2 of the cutting portion 2.

(17) The thread ridges 5 of the cutting portion 2 and the thread ridges 6 of the complete thread portion 5 have effective diameter d.sub.1 reliefs by which the effective diameter d.sub.1 gradually decreases from the front (leading) side toward the rear (trailing) side of each thread ridge in the rotation direction of the cutting tap 1, the effective diameter d.sub.1 reliefs being set at 0 (zero) or a minute value. The reason why the effective diameter d.sub.1 reliefs are set at 0 (zero) or a minute value is because if the effective diameter d.sub.1 reliefs are set at a large value, when the cutting tap 1 is used to form an internal thread, the cutting tap 1 will not be able to be guided accurately, so that the thread ridges of the internal thread will be deformed (i.e., expanded).

(18) The roots 8, formed between the respective adjacent pairs of thread ridges 5 of the cutting portion 2, have root diameter d.sub.2 reliefs by which the root diameter d.sub.2 gradually decreases from the front (leading) side toward the rear (trailing) side of each root 8 in the rotation direction of the cutting tap 1. The root diameter d.sub.2 reliefs are set to be equal to the effective diameter d.sub.1 reliefs of the thread ridges 5, namely, set at 0 (zero) or a minute value.

(19) The cutting portion 2 is formed with a plurality of deburring thread grooves 10 in some of the roots 8, formed between the respective axially adjacent pairs of thread ridges 5. The deburring thread grooves 10 are arranged at a constant pitch toward the axial front side of the cutting portion 2 from the rearmost ones of the roots 8 in which the deburring thread grooves 10 are formed. The pitch of the deburring thread grooves 10 is set such that each deburring thread groove 10 is located between the corresponding adjacent pair of the thread ridges 5, and does not necessarily need to be equal to the pitch of the thread ridges 5. However, it is preferable that the pitch of the deburring thread grooves 10 is set to be equal to the pitch of the thread ridges 5, because by setting in this way, the deburring thread grooves 10 can be reliably located between respective adjacent pairs of the thread ridges 5. The deburring thread grooves 10 are formed such that the groove bottom diameter d.sub.3 of the deburring thread grooves 10 (which corresponds to the diameters of the deepest portions of the respective thread grooves 10 in the cross section along the center axis of the cutting tap 1) gradually decreases toward the axial front side of the cutting portion 2. Similar deburring thread grooves 10 are also formed at a constant pitch in the areas located axially forward of the frontmost thread ridges 5 at the axial front end of the cutting portion 2. Though this embodiment exemplifies that the rearmost deburring thread grooves 10 at the axial rear end of the cutting portion 2 (i.e., the deburring thread grooves 10 in which the groove bottom diameter d.sub.3 is the largest) are arranged in roots 8 located midway in the cutting portion 2, the rearmost deburring thread grooves 10 may be located in roots 9, i.e., the roots formed between respective adjacent pairs of the thread ridges 6.

(20) As illustrated in FIG. 4, the deburring thread grooves 10, formed between respective adjacent pairs of some of the thread ridges 5, are formed such that the closer the deburring thread grooves 10 are located to the axial front side of the cutting portion 2, the deeper the deburring thread grooves 10 are relative to the roots 8. Each deburring thread groove 10 comprises a V groove having a V-shaped cross section such that a step or steps are formed relative to the surface of the corresponding root 8.

(21) The deburring thread grooves 10 have groove bottom diameter d.sub.3 reliefs by which the groove bottom diameter d.sub.3 gradually decreases from the front (leading) side toward the rear (trailing) side of each deburring thread groove 10 in the rotation direction of the cutting tap 1. The groove bottom diameter d.sub.3 reliefs are set to be smaller than the major diameter reliefs of the thread ridges 5, and to be larger than the effective diameter d.sub.1 reliefs of the thread ridges 5. By setting the groove bottom diameter d.sub.3 reliefs to be smaller than the major diameter reliefs of the thread ridges 5, the cutting tap 1 can be guided accurately. The groove bottom diameter d.sub.3 reliefs may be set, for example, to be about to of the major diameter reliefs of the thread ridges 5. By setting the groove bottom diameter d.sub.3 reliefs to be larger than the effective diameter d.sub.1 reliefs of the thread ridges 5, it is possible to ensure sharpness of cutting when the deburring thread grooves 10 deburr/cut a prepared hole 11 (see FIG. 5) to form an internal thread thereon, and to reduce the rotational resistance of the cutting tap 1.

(22) The above cutting tap 1 can be manufactured, for example, as follows: First, the grooves 7 are formed in the outer periphery of a tap blank having a round rod shape. Second, the thread ridges 5 of the cutting portion 2 and the thread ridges 6 of the complete thread portion 3 are formed by removing, from the outer periphery of the tap blank, portions corresponding to the thread grooves between respective axially adjacent pairs of the thread ridges 5, and portions corresponding to the thread grooves between respective axially adjacent pairs of the thread ridges 6. At this time, the thread ridges 5 and 6 are formed such that the effective diameter d.sub.1 reliefs of the thread ridges 5 and 6 are set at 0 (zero) or a minute value. Third, the crests of the respective thread ridges 5 of the cutting portion 2 are obliquely cut. At this time, these crests are cut such that the major diameter reliefs of the thread ridges 5 of the cutting portion 2 are larger than the effective diameter d.sub.1 reliefs of the thread ridges 5. Lastly, the deburring thread grooves 10 are formed in some of the roots 8, between respective adjacent pairs of the thread ridges 5, and in the areas located axially forward of the frontmost thread ridges 5 at the axial front end of the cutting portion 2. At this time, the deburring thread grooves 10 are formed such that the groove bottom diameter d.sub.3 reliefs of the thread grooves 10 are larger than the effective diameter d.sub.1 reliefs of the thread ridges 5.

(23) It is now described how an internal thread is formed by the cutting tap 1 in the inner periphery of a nut blank 12 illustrated in FIG. 5. The nut blank 12 is formed by forging or pressing, and formed in its center with the prepared hole 11. The prepared hole 11 comprises a through hole having a cylindrical inner peripheral surface. Though it is ideal that the inner diameter of the prepare hole 11 is uniform in the axial direction, it is difficult to make the inner diameter thereof uniform in a strict sense, because an error tends to occur when the nut blank 12 is manufactured. In the nut blank 12 illustrated in FIG. 5, the inner diameter of the prepared hole 11 varies midway. Namely, a minute step 13 varies the inner diameter of the nut blank 12 by 0.1 mm or over (e.g. by about 0.2 mm) in diameter. The inner diameter of the prepared hole 11 is smaller over its entire area than the root diameter d.sub.2 of the cutting tap 1.

(24) When the front end of the cutting tap 1 is inserted in this nut blank 12, and the cutting tap 1 is axially advanced while being rotated, as illustrated in FIG. 6, the portions of the cutting tap 1 located axially forward of the frontmost thread ridges 5 at the axial front end of the cutting tap 1 engage with the inner periphery of the prepared hole 11. At this time, the deburring thread grooves 10 located axially forward of the frontmost thread ridges 5 also engage with the inner periphery of the prepared hole 11.

(25) When the cutting tap 1 is further axially advanced while being rotated, as illustrated in FIG. 7, the thread ridges 5 of the cutting portion 2 engage with the prepared hole 11 for an internal thread, and cut/remove portions corresponding to the thread grooves of the internal thread, thereby forming surfaces corresponding to flanks 15 of thread ridges 14 of the internal thread. Concurrently with this, the deburring thread grooves 10 gradually deburr/cut the inner periphery of the prepared hole 11. The closer the deburring thread grooves 10 are located to the axial rear side of the cutting portion 2, the shallower/smaller the deburring thread grooves 10 are. As a result thereof, the closer the roots 8 are located to the axial rear side of the cutting portion 2, the deeper/larger the roots 8 are. According to the depths/sizes of the roots 8, surfaces corresponding to the crests 16 of the thread ridges 14 of the internal thread are formed by degrees. At this time, since the major diameter reliefs of the crests of the thread ridges 5 and the groove bottom diameter d.sub.3 reliefs of the deburring thread grooves 10 are larger than the effective diameter d.sub.1 reliefs of the thread ridges 5, the rotational resistance of the cutting tap 1 is not made extremely large. Also, spaces 17 are defined between the inner periphery of the prepared hole 11 and the respective inner surfaces of the deburring thread grooves 10. Therefore, due to cutting oil flowing into the spaces 17, it is possible to effectively reduce the rotational resistance of the cutting tap 1.

(26) When the cutting tap 1 is still further axially advanced while being rotated, as illustrated in FIG. 8, the rearmost deburring thread grooves 10 at the axial rear end of the cutting portion 2 (strictly speaking, the roots 8 located axially rearward of the rearmost deburring thread grooves 10) pass the crests 16 of the thread ridges 14 of the internal thread, so that the crests 16 are completely formed. Also, the rearmost thread ridges 5 at the axial rear end of the cutting portion 2 (strictly speaking, the thread ridges 6 having a complete shape and located axially rearward of the rearmost thread ridges 5) pass the flanks 15 of the thread ridges 14 of the internal thread, so that the flanks 15 are completely formed.

(27) This cutting tap 1 is configured such that when the cutting tap 1 is axially advanced while being rotated, the deburring thread grooves 10 deburr/cut the inner periphery of the prepared hole 11. Since the groove bottom diameter d.sub.3 reliefs of the deburring thread grooves 10 are larger than the effective diameter d.sub.1 reliefs of the thread ridges 5, the rotational resistance of the cutting tap 1 is not made extremely large. As a result thereof, the cutting tap 1 can cut the inner periphery of the prepared hole 11 with a relatively large cutting stock, and thus can form an internal thread with high accuracy even when the prepared hole 11 has an inner periphery of which the dimensional accuracy is low.

(28) Since this cutting tap 1 uses the deburring thread grooves 10, each of which comprises a V groove having a V-shaped cross section such that a step or steps are formed relative to the surface of the corresponding root 8, when the cutting tap 1 is manufactured, it is possible to separately form the deburring thread grooves 10, and the flanks of the thread ridges 5 on the outer periphery of the cutting tap 1. Therefore, it is possible to easily form the deburring thread grooves 10 such that the groove bottom diameter d.sub.3 reliefs of the thread grooves 10 are made larger than the effective diameter d.sub.1 reliefs of the thread ridges 5.

(29) An experiment was performed to confirm that the cutting tap 1 of the above embodiment can form an internal thread with high accuracy in the prepared hole 11 having an inner periphery of which the dimensional accuracy is low. FIGS. 9 and 10 illustrate the actual shape of the prepared hole 11 of the nut blank 12 used in this experiment, and the actual shape of the internal thread formed in this prepared hole 11 by the cutting tap 1. The inner diameter of the prepared hole 11 varies midway. Namely, the minute step 13 varies the inner diameter of the nut blank 12 by about 0.4 mm (in diameter). The pitch of the thread ridges 14 of the internal thread is 1.5 mm. As can be seen from FIGS. 9 and 10, the cutting tap 1 of the above embodiment can cut the inner periphery of the prepared hole 11 with a relatively large cutting stock, specifically, 0.4 mm or over in diameter, and thus can form an internal thread with high accuracy even when the prepared hole 11 has an inner periphery of which the dimensional accuracy is low.

DESCRIPTION OF REFERENCE NUMERALS

(30) 1: cutting tap 5: thread ridge 8: root 10: deburring thread groove d.sub.1: effective diameter of the thread ridges 5 d.sub.2: root diameter d.sub.3: groove bottom diameter