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Implementations of the present invention include a thread-rolling tap, which is designed and intended for the non-cutting finishing of a previously created thread, in particular internal thread. For example, one implementation of such a tool includes at least one thread-forming portion that rotates

Implementations of the present invention include a thread-rolling tap, which is designed and intended for the non-cutting finishing of a previously created thread, in particular internal thread. For example, one implementation of such a tool includes at least one thread-forming portion that rotates about a tool axis, the thread-forming portion having multiple forming wedges. The forming wedges in cross-section include two flanks that diverge from one another beginning at a forming wedge tip. The forming wedge tip can be shaped as any of an acute angle, a rounded region, or a flattened region. At least one of the two flanks also include at least one expansion for positioning the forming wedge in the previously created thread. Additional implementations of the invention relate to a methods of manufacturing such a tool, as well as to methods of creating a thread.

대표청구항 ▼

We claim: 1. A tool for finishing a previously created thread, such as an internal thread, without cutting, comprising: a) at least one thread-forming portion that rotates about a tool axis, the thread-forming portion having multiple forming wedges; b) wherein the forming wedges in cross-section co

We claim: 1. A tool for finishing a previously created thread, such as an internal thread, without cutting, comprising: a) at least one thread-forming portion that rotates about a tool axis, the thread-forming portion having multiple forming wedges; b) wherein the forming wedges in cross-section comprise two flanks that diverge from one another beginning at a forming wedge tip, the forming wedge tip being shaped as any of an acute angle, a rounded region, or a flattened region; c) wherein at least one of the two flanks include at least one expansion for positioning the forming wedge in the previously created thread; d) wherein the plurality of forming wedges exhibits substantially the same expansion with substantially the same cross-sectional shape in a forming region that extends from the forming wedge tip of each forming wedge to the expansion, such that the cross-sectional shape is convexly curved in a first section, concavely curved in a second section, and convexly curved again in a third section. 2. The tool as recited in claim 1, wherein a radial distance of the forming wedge tip from the tool axis increases in a direction opposite to a direction in which the tool is moved forward. 3. The tool as recited in claim 1, wherein one or more of: (i) the at least one expansion in two or more forming wedges has one or more of substantially the same cross-sectional shape, profile, or dimensions for each flank in each of the two or more forming wedges; or (ii) a diameter of the forming wedge at a given height above the tool axis in a region of expansion is substantially the same for all of the multiple forming wedges that have an expansion of the flanks. 4. The tool as recited in claim 1, wherein transitions of the two flanks between the forming region and the at least one expansion are at least partially rounded. 5. The tool as recited in claim 1, wherein the multiple forming wedges are disposed in succession along a forming curve that runs around the tool axis in a spiral, screw-thread, or helical shape. 6. The tool as recited in claim 5, further comprising multiple thread-forming portions that follow one another axially with respect to the tool axis, the multiple thread-forming portions being spaced apart from one another, extending perpendicular to the tool axis, and possessing at least one forming wedge, such that each at least one forming wedge of each of the multiple thread-forming portions is disposed one after another axially with respect to the tool axis in an arrangement that is any of (i) substantially parallel to the tool axis, (ii) substantially turning or twisted around the tool axis, or (ii) in the form of a screw thread. 7. The tool as recited in claim 1, wherein a cross-sectional shape of a forming region in the multiple forming wedges, increases progressively and/or linearly, such that the forming regions corresponding to the multiple forming wedges follow each other in a direction opposite to a direction in which the tool is pushed forward. 8. The tool as recited in claim 1, wherein the two flanks exhibit a conical nature, such that an angle formed thereon is different from one pair of flank points to another pair of flank points in any one or more of (i) at the forming region, (ii) at the wedge tip between about 5�� and about 20��, or (iii) in the region of the at least one expansion between about 0�� and about 2��. 9. The tool as recited in claim 1, wherein the at least one thread-forming portion comprises a tool core that extends along the tool axis, the tool core having a constant diameter along any of (i) the tool axis, or (ii) along the outer surface of which the forming wedges are disposed, such that a height of the multiple forming wedges increases along a forming curve in a direction opposite to a direction in which the tool is pushed forward. 10. The tool as recited in claim 1, wherein the at least one expansion comprises a pedestal of a corresponding one of the multiple forming wedges. 11. The tool as recited in claim 1, wherein the at least one expansion for each of the multiple forming wedges is engaged in a corresponding recess of the previously created thread, such that the corresponding forming wedge for the at least one expansion is positioned in the corresponding recess in the previously created thread. 12. The tool as recited in claim 11, wherein a forming wedge tip of at least one of the multiple forming wedges penetrates into a ground section of the corresponding recess in the previously created thread as the tool is advanced into the previously created thread. 13. The tool as recited in claim 11, wherein a side of the at least one thread-forming portion, as it is disposed in a tool-advancing direction, further comprises an insertion portion having one or more forming wedges, each forming wedge having at least one expansion, such that the forming wedge tip of the at least one thread-forming portion does not penetrate into a ground section of the recess in the previously created thread as the tool is advanced into the previously created thread, and such that an insertion portion of the thread-forming portion includes a first forming wedge in a direction opposite to a tool-advancing direction. 14. The tool as recited in claim 13, wherein a diameter of at least one of the one or more forming wedges in a sub-region of the at least one expansion is any of at least 90% of, or substantially equal to, the diameter of the corresponding recess in the previously created thread at a corresponding height above the tool axis of the inserted tool. 15. The tool as recited in claim 13, wherein one or more of: (i) a diameter of at least one of the one or more forming wedges in a forming region that extends from the corresponding forming wedge tip to the corresponding at least one expansion, insofar as it does not penetrate into the ground section of the recess of the previously created thread, is less than about 90% to less than about 80% of the diameter of the recess in the previously created thread at a corresponding height above the access of the inserted tool; or (ii) the difference between the recess diameter and the corresponding forming-wedge diameter is at least about 25% to less than about 10% smaller in the region of the at least one expansion than in the forming region. 16. The tool as recited in claim 1, wherein a diameter of any of the multiple forming wedges in a forming region increases in a direction opposite to a direction in which the tool is advanced, such that the increase corresponds to an increase of a radial distance between the forming wedge tips and the tool axis, such that the diameter is linearly dependent on the radial distance. 17. The tool as recited in claim 1, wherein a last forming wedge of the thread-forming portion, in a direction opposite to a tool-advancing direction, has no at least one expansion of its corresponding two flanks, and wherein its cross-sectional dimension corresponds substantially to a cross-sectional dimension of a finished thread recess. 18. The tool as recited in claim 1, wherein: in a direction opposite to a tool-advancing direction, the thread-forming portion is followed by a calibration portion having forming wedges disposed in succession along a curve that passes around the tool axis, the curve having a spiral, screw-thread, or helix shape; and a curve in the thread-forming portion merges continuously with the curve of the calibration portion, such that both curves exhibit the same pitch along the tool axis, and such that one or more of: (i) a cross-sectional dimension of one or more multiple forming wedges in the calibration portion is substantially the same as a cross-sectional dimension of a finished thread recess; (ii) the radial distance of the forming wedge tips from the tool axis in the calibration portion is substantially the same, or decreases, in the direction opposite to the tool-advancing direction; or (iii) the radial distance of the forming wedge tips at the transition to the thread-forming portion corresponds to the largest radial distance of the tips of the forming wedges in the thread-forming portion (3). 19. The tool as recited in claim 1, wherein at least the thread-forming portion and/or a calibration portion, in its cross-section perpendicular to the tool axis, has an approximately polygonal shape having a number of e corners equal to one of three, four, five, six, or seven, such that every eth one of the immediately consecutive forming wedge tips is disposed in a single plane containing the tool axis. 20. The tool as recited in claim 1, wherein the forming wedges are produced at least partially by any one or more of grinding and wheel dressing. 21. A method of creating a screw thread in a work piece, in particular an internal thread comprising the steps of: a) creating an initial thread by one of cutting means or non-cutting means, wherein the non-cutting means include any one or more of tapping, milling, turning, grinding, winding, or rolling; and b) finishing the initial thread without cutting by using a tool that has a plurality of forming wedges that, in cross-section, exhibit two flanks, such that at least one of the forming wedges is centered in the previously created initial thread by at least one of the exhibited two flanks, the at least one of the exhibited two flanks including an expansion for positioning the at least one forming wedge in the previously created thread; c) wherein the plurality of forming wedges exhibits substantially the same expansion with substantially the same cross-sectional shape in a forming region that extends from the forming wedge tip of each forming wedge to the expansion, such that the cross-sectional shape is convexly curved in a first section, concavely curved in a second section, and convexly curved again in a third section. 22. The method as recited in claim 21, wherein creating the initial thread further comprises the steps of: a) producing an initial cylindrical bore; and b) tapping the initial cylindrical bore with a thread tapper to create the initial thread, such that an outside diameter of the initial thread is smaller than an outside diameter of the finished thread that is created. 23. The method as recited in claim 21, wherein the step of finishing the initial thread further comprises: a) rotating at least one thread-forming portion of the tool about a tool axis; b) pushing forward in a tool-advancing direction the at least one thread-forming portion, the at least one thread-forming portion having one or more forming wedges disposed consecutively along a forming curve that passes around the tool axis in the shape of any of a spiral, a screw thread, or a helix; and c) finishing the initial thread by engaging the previously created thread with the one or more forming wedges, such that one or more of the one or more forming wedges are pressed into a work piece surface in a region of the previously created thread. 24. The method as recited in claim 21, wherein the step of finishing the initial thread further comprises: a) rotating axially offset thread-forming portions of the tool about a tool axis; b) moving the tool relative to a work piece by pushing the axially offset thread-forming portions in a tool-advancing direction parallel to the tool axis, thereby causing a circular movement of the tool relative to the work piece, such that the tool axis coincides with a central axis of the initial thread; and c) pressing the at least one forming wedge into a work piece surface to thereby finish the initial thread. 25. The method as recited in claim 21, wherein the step of finishing of the initial thread further comprises: smoothing and/or calibrating the initial thread by advancing one or more forming wedges in a calibration portion of the tool in a direction opposite to a tool-advancing direction, the calibration portion of the tool being adjacent to the thread-forming portion of the tool. 26. The method as recited in claim 21, wherein the step of finishing the initial thread further comprises: engaging the previously created initial thread with one or more forming wedges that include the two flanks, and include the at least one expansion of one or more of the two flanks; wherein the one or more forming wedges are positioned in an insertion portion at a side of the thread-forming portion that faces in a tool-advancing direction, such that the one or more forming wedges are not pressed into a work piece surface in a region of the previously created initial thread. 27. A tool for finishing a previously created thread, such as an internal thread, without cutting, comprising: a) at least one thread-forming portion that rotates about a tool axis, the thread-forming portion having multiple forming wedges; b) wherein the forming wedges in cross-section comprise two flanks that diverge from one another beginning at a forming wedge tip, the forming wedge tip being shaped as any of an acute angle, a rounded region, or a flattened region; c) wherein at least one of the two flanks include at least one expansion for positioning the forming wedge in the previously created thread; d) wherein the plurality of forming wedges exhibits substantially the same cross-sectional shape in a forming region that extends from the forming-wedge tip of each forming wedge to the expansion, such that the forming region has an at least approximately polygonal shape in cross-section, including any of a triangle, quadrangle, or trapezoid shape, the corners of the polygonal shape being any one or more of pointed or rounded. 28. A tool for finishing a previously created thread, such as an internal thread, without cutting, comprising: a) at least one thread-forming portion that rotates about a tool axis, the thread-forming portion having multiple forming wedges; b) wherein the forming wedges in cross-section comprise two flanks that diverge from one another beginning at a forming wedge tip, the forming wedge tip being shaped as any of an acute angle, a rounded region, or a flattened region; c) wherein at least one of the two flanks include at least one expansion for positioning the forming wedge in the previously created thread; d) wherein the plurality of forming wedges exhibits substantially the same cross-sectional shape in a forming region that extends from the forming-wedge tip of each forming wedge to the expansion, such that the cross-sectional shape of the forming region is one of an isosceles triangle, a triangle with a 60�� internal angle, or an equilateral triangle, the triangle having a rounded or flattened tip. 29. A method of creating a screw thread in a work piece, in particular an internal thread comprising the steps of: a) creating an initial thread by one of cutting means or non-cutting means, wherein the non-cutting means include any one or more of tapping, milling, turning, grinding, winding, or rolling; and b) finishing the initial thread without cutting by using a tool that has a plurality of forming wedges that, in cross-section, exhibit two flanks, such that at least one of the forming wedges is centered in the previously created initial thread by at least one of the exhibited two flanks, the at least one of the exhibited two flanks including an expansion for positioning the at least one forming wedge in the previously created thread; c) wherein the plurality of forming wedges exhibit substantially the same expansion with substantially the same cross-sectional shape in a forming region that extends from the forming wedge tip of each forming wedge to the expansion, such that the forming region has an at least approximately polygonal shape in cross-section, including any of a triangle, quadrangle, or trapezoid shape, the corners of the polygonal shape being any one or more of pointed or rounded. 30. A method of creating a screw thread in a work piece, in particular an internal thread comprising the steps of: a) creating an initial thread by one of cutting means or non-cutting means, wherein the non-cutting means include any one or more of tapping, milling, turning, grinding, winding, or rolling; and b) finishing the initial thread without cutting by using a tool that has a plurality of forming wedges that, in cross-section, exhibit two flanks, such that at least one of the forming wedges is centered in the previously created initial thread by at least one of the exhibited two flanks, the at least one of the exhibited two flanks including an expansion for positioning the at least one forming wedge in the previously created thread; c) wherein the plurality of forming wedges exhibits substantially the same expansion with substantially the same cross-sectional shape in a forming region that extends from the forming wedge tip of each forming wedge to the expansion, such that the cross-sectional shape of the forming region is one of an isosceles triangle, a triangle with a 60�� internal angle, or an equilateral triangle, the triangle having a rounded or flattened tip.