As the most important load-bearing component in the aircraft, threaded connection has a significant impact on the safety of the aircraft. Therefore, it is very important to manufacture high-quality internal threads on Al7075, a commonly used material for aircraft manufacturing. As an important parameter for evaluating the quality of internal threads, the radial pitch diameter difference has a great influence on the quality of internal threads. The hone radius affects the processing quality of the internal thread.In order to study the influence of the hone radius on the radial pitch diameter difference of Al7075 tapping, a quasi-static mathematical model of tapping was established for simulation, and it was verified by experiments. The results show that the model can be used to effectively predict the changing trend of the radial pitch diameter difference; the radial pitch diameter difference first decreases and then increases with the increase of the hone radius, and the smallest radial pitch diameter difference is obtained at the bone radius is 10 μm.