Abstract
Synchronizing errors between the spindle motor and the z-axis motor directly influences the cutting characteristics and the thread quality in tapping, because the tapping process is accomplished by synchronizing the movement of the z-axis with the revolutionary spindle motion. Generally synchronizing errors are decided by tile parameters of the servo system and commanded velocity. The excessive synchronizing errors which are induced by the parameter mismatch and high cutting velocity can cause tap breakage due to the abrupt increase of cutting torque or damage the thread accuracy by overcutting the already cut threads. In this paper, the influences of the synchronizing errors on the tapping characteristics in the ultra high-speed tapping will be described and a minimum level of synchronizing errors necessary to maintain the quality of the cut thread will be presented.