Tapping Plasma Cut Holes in A36 Steel: Testing the FlexArm REM-16D Electric Tapping Arm
An end user recently approached Flex facing a common challenge: tapping plasma cut holes in A36 Steel. This particular end user is a general fabrication shop that handles a wide variety of projects but is well known for its expertise in fabricating truck beds. As a result, they frequently need to tap holes that come off a plasma or waterjet cutting system, which often requires a secondary tapping operation.
After experiencing the benefits of borrowing a FlexArm from a neighboring shop, the end user realized it was time to invest in one for their operations. The unit they borrowed was an old pneumatic tapping arm, but they were interested in seeing how an electric FlexArm would perform. The convenience of plugging the unit into a standard 110V outlet and immediately start tapping was appealing. Here’s what they tested
The Electric Tapping Arm Test
•REM-16D Electric Tapping Arm •Tapping plasma cut holes with M5, M6, M8 taps into 1/4″ A36 Steel •Tapping plasma cut holes with a M12 tap into 1/2″ A36 Steel •Tapping plasma cut holes with an M8 into 1″ A36 Steel
We demonstrated the electric tapping and its ability to handle plasma cut holes. We also exhibited the usefulness of using the programmable depth stop for through holes. With this feature, the operator can tap without any worries. Once the operator aligns the tap with the hole, they just need to push a button. The tap automatically drives to the correct depth and then backs itself. If you do production runs, this is a handy feature to have.
Overcoming Misshaped Holes and Heat-Affected Edges with FlexArm
One concern often associated with plasma cut holes is the potential for misshaped holes or the heat-affected edge. This makes tapping plasma cut holes difficult even with a high-quality tapping machine. However, with the FlexArm, tapping plasma cut holes should not be a problem, provided you use a new high-quality tap (We recommend OSG taps) and take certain precautions. For example, some people find it helpful to run a reamer through the holes first to extend the life of
the tap. The FlexArm can easiliy accommodate this by placing the reamer into the quick-change drill chuck and using the arm as you would for tapping. Dropping the RPMs can also help to break through the hardened edge.
If you are having issues tapping holes coming off your plasma table. Send in your parts. We would be happy to conduct a tap test and Demonstrate the value of a FlexArm tapping system.
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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.