The technology of front face flow drilling makes it possible to extend the material thickness of thin-walled workpieces. By a following tapping process, threads with high mechanical strength can be manufactured in the hardened deformation zone. In addition to the process design for the formation of the core hole, the process strategy for thread forming has a significant influence on the thread quality. For example, the profile of the internal thread can be influenced by using different tool types, varying the peripheral speed and using different lubricants. In this paper, the results of an extended strategy for thread manufacturing of the aluminum alloy AlSi10Mg are analyzed. For this purpose, the e machining forces were measured in order to specifically conclude on process-related differences with varying taps or lubricants. Finally, the geometric quality of the M6 threads will be evaluated using different methods of visualization, so that the thread manufacturing process can be adapted with regard to the mentioned variables.

Key Words – Front Face Friction-Drilling, Tapping, Aluminum Cast Alloys