Is there a way that you can treat normal metal to prevent it from, or at least reduce the effects of, work hardening. Can these be used in headphones commercially?

Thread milling is a modern technique for creating threads in a workpiece using a specialized cutter on CNC machines. These cutters can be made of solid carbide or have replaceable carbide tips.

The process involves a rotating tool that follows a spiral path to cut threads into the material. This method improves accuracy and allows for the creation of threads in various shapes and materials, making it a versatile and effective option for machinists.

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My left earbud recently broke mid-wire: the bit that I like to fiddle with and bend. I fixed it, but I was wondering whether there are metals that don't work harden, or resistant to it?

Flexibility: Thread milling can produce threads of various diameters and specifications with a single tool. It allows for customizable thread depth and handles both blind and through holes. Versatility: One thread milling tool can create both left and right-hand threads, handle multiple thread pitches, and perform thread cropping, removing burrs and ensuring precise angular positioning. Surface Finish: Thread milling offers a superior surface finish by using climb milling motions and producing smaller chips, reducing the risk of leaks compared to the more aggressive tapping process. Small and Large Thread Diameters: Thread milling allows for precise control over cutting data and forces. This reduces the risk of small thread mills breaking in small holes, and medium-sized tools can be used effectively to create large threads.

Work hardening does not cause things to break, but in fact will cause them to resist further plastic deformation increasing their strength. Wires bent back and forth may eventually break due to fatigue. The material at the edge is compressed and stretched resulting in fatigue. How much cyclic stress there is determines how many cycles the material can last its fatigue limit.

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The wires you mention can be produced/manufactured only if they show plasticity(or work hardening) in the first place, if they were perfectly elastic they couldn't be used due to risk of brittle fracture or low toughness.

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Thread milling vs tappingmachine

As someone pointed out , Annealing is majorly used to soften a material so that its more workable. So essentially if you want to reverse the effects of work hardening this is the only route that is viable.

Understanding thread milling opens up new possibilities in machining. This article has provided insights into the mechanics, advantages, and considerations of thread milling compared to traditional tapping. Thread milling’s ability to create customized dimensions, its versatility in handling various thread types, and the elimination of certain limitations associated with taps make it a valuable technique for machinists.

Thread millingdisadvantages

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Thread milling vs tappingsteel

Speed: Thread milling may be slower than tapping due to the need for interpolation and multiple passes, which could impact turnaround time. Machine Requirements: Thread milling requires a CNC machine with three-axis control, which might not be available in all shops. Large Thread Diameters: Large threads require significant power and torque to be cut effectively, which can strain the machine and limit its capabilities.

Just to add to the other answers, you unfortunately will have to replace the whole wire/earbud set. Melting the wire will only fuse the different isolated wires that exist in one cord, and you will have an at best dysfunctional if not dangerous product that works in only one ear. Sorry to be the bearer of bad news.

In the next article, I’ll share more about “hand taps and dies” and examine their functionality, types, and crucial techniques for manually cutting threads. Until then, keep threading and stay tuned for more insights.

As for metals that can recover from being yielded there are shape-memory alloys, though I think they would be cost prohibitive.

Thread milling vs tapping vsthreading

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My left earbud recently broke mid-wire: the bit that I like to fiddle with and bend. I fixed it, but I was wondering whether there are metals that don't work harden, or resistant to it?

Thread milling vs tappingpdf

work-hardening doesn't persist if the service temperature is above 1/3rd to 1/2 of the melt temperature- at which thermally-activated diffusion effects are sufficiently strong to relieve the dislocation pileups via dislocation climb. a thick lead wire cannot be work-hardened at room temperature because its melt temperature is in this range- but neither can it be used as a spring to help hold the earphone in place, for this same reason: it creeps significantly at room temperature.

Thread milling and tapping are two distinct methods for creating threads, each offering different benefits and limitations.

On the other hand, tapping involves creating threads based on the tap's preset dimensions. As the tap wears, maintaining precise tolerances can become challenging, and there is an increased risk of sudden breakages. Tapping is generally faster, as it can create threads in a single pass, providing a quicker turnaround compared to thread milling, which may require multiple passes depending on the material.

Hello David , thanks for sharing this information. Have you tried tapping inconel 718 using solid tap ? Just sharing your experience on this exotic material.

Thread milling provides significant flexibility in terms of thread creation. With thread milling, machinists can produce threads of various diameters and specifications using the same tool. The CNC programming path for thread milling allows for precise control over tolerances and the ability to make adjustments for tool wear through CNC offsets. Moreover, because the thread milling tool’s path is programmed, it ensures consistent angular positioning, enabling machinists to perform thread cropping operations at the start of the thread to meet specific customer requirements. This control helps maintain consistency and achieve precise specifications.

Work hardening leads to essentially hardening or strengthening till no further ductility is produced or material fractures or fails. If the material doesnt work harden or if there is no plasticity it is going to fail by brittle fracture at yield point.

If the stress on the wire at the edge is below the endurance limit then the wire could be bent back and forth indefinitely. One way to reduce stress and allow for more flexible wires is to use braided wires. This works by reducing the cross section of each strand and thus reducing the amount of strain required to produce a certain bend radius.

Of course, if by fiddle with and bend you mean deform past the elastic limit so that there is a kink, then you are inherently exceeding the yield stress every cycle and micro cracks will propagate very quickly. If this is what you'd like to due to your cords and would like a cord to survive this treatment, I would design such a cord with thin braided wires that were surrounded by a self-healing polymer. This would allow you to plastically deform the cord and have the cord heal itself.