Tapping graphite, a notoriously soft and brittle material, presents a significant challenge. Finding reliable information on how to tap graphite is difficult; even Google search results are limited. However, one of our customers encountered this challenge and sought an effortless tapping solution to deliver precise and consistent threads. After thorough online research yielded little information, they discovered the perfect fit for their tapping needs: the FlexArm tapping machine. Our customer tested it with our free Tap Test to ensure that the FlexArm could handle tapping graphite without causing damage.
Tapping Graphite with the FlexArm
Our customer tested the FlexArm on four different graphite grades: POCO3, recycled POCO3, AF5, and C200, using an Emuge 1/4-20 bottoming spiral flute tap. Graphite is a soft material requiring minimal torque, so theA-32, our smallest pneumatic model, was a perfect match for this application.
For testing, the customer provided test pieces with two blind holes in each graphite grade. We used the FlexArm tapping machine and quick-change clutch tap holders to tap each piece. These tap holders feature an adjustable torque clutch that prevents tap breakage. The clutch ensures the tap stops turning upon encountering obstructions like the hole bottom. We set the clutch to a loose setting to avoid damaging the threads or material.
The FlexArm tapping arm successfully tapped each graphite grade without any issues. The process produced smooth and consistent threads with no cracking or breakage. The customer was highly satisfied with the results, prompting them to purchase the A-32 pneumatic tapping machine. They plan to use it for processing approximately 60,000 parts annually. By implementing the FlexArm tapping machine, they anticipate increased efficiency and reduced scrap rate.
Tapping Versatility: Meeting your needs
While end users often seek easy-tapping solutions for hard materials, soft materials can pose equally challenging scenarios. The FlexArm tapping machine offers exceptional versatility, easily accommodating both soft and hard materials. If you require an efficient tapping solution, contact us and share your tapping issues. We will identify the ideal solution for your specific needs.
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Auto Stand-Off – This is currently defined to be surface stand-off and not to be confused with vector stand-off in 5-axis mode. The current auto stand-off is based on a changing surface and will adjust vertically based on the angle of the “A” Axis, so there is five (5) axis taken into account during the calculations, but this is not the same as the tool vector stand-off. There is the ability to do the vector stand-off change while the machine is running manually with buttons on the screen.
Z-Reader Probe – The Z-Reader is a device for mapping the location of the surface. It can be controlled manually & programmatically. The option is NOT active while cutting & is retracted out of harm’s way. It can be triggered to verify the surface at every pierce before the cutting process starts, or it could be used to drive surface mapping of the whole part before cutting starts. It begins with initialization or zeroing of the device to the surface at the beginning of a program and then accumulates or tracks the difference from that zeroing effort.
Automatic Edge Finder – The edge finder is or can be utilized manually (Jogging Method & Screen Buttons), programmatically (M & G codes), or fully automatic routine (dedicated program). This option sets offsets & program rotation to match the orientation & location on the cutting table.
AC Unit Installed on Electrical Cabinet – The unit is mounted on the cabinet’s High Power (480v) side. It is close to the location where the drives are mounted. This option keeps the cabinet temperature stable and allows heat dissipation faster. The servo drives for all axes are the most significant contributors to heat inside the electrical cabinet.
5-Axis Renishaw Calibration – The calibration unit is a Renishaw model APCA45 with a modified spherical stylus. The device has a retractable cover and air purge to clear debris & dust during the activation process. It mounts to a swing arm controlled by a pneumatic rotary, so it is out of the way during regular operation and swings into the calibration position for calibration only.