Analysis of form threads using fluteless taps in cast magnesium alloy (AM60)

► This work shows the influence of the diameter and the forming speed during the tapping process in the AM60 alloy. ► The diameter variation has less influence on thrust force than torque, and the high-speed forming provokes hardening. ► The fill rate of the thread profile according to diameter variation was negligible for intermediate and large diameters. ► The diameter used in the tests according to the tool's supplier could be modified to generate more accurate thread profiles.