Thread Cutting

FUNDAMENTAL SHOP SKILLS

HDER 1010
Heavy Duty/Truck &Transport Repair
Objectives
• Identify and define taps and dies.
• Practice calculations for inch and metric
threads .
• Explain the use of taps and dies.
Thread Cutting

Cutting Internal and External Threads

1. Taps are cutting tools used to cut internal threads .

2. They are made from high quality tool steel, hardened and ground.

3. Two, three, or four flutes are cut lengthwise across the threads to form
cutting edges, provide room for the chips, and admit fluid to lubricate
the tap (Fig.1).

Fig.1
Thread Cutting

Cutting Internal and External Threads

1. The end of the shank is square so that a tap wrench can be used to turn the
tap into a hole (Fig.2).

Fig.2
Thread Cutting

Cutting Internal and External Threads

Inch Threads

1. For inch taps the major diameter, number of threads per inch, and type of
thread are usually found stamped on the shank of a tap ,

Example: ( 1/2 in. - 13 UNC tap ) repersents:

1/2 inch = major diameter of the tap.
13 = number of threads per inch.
NC = Unified National Coarse (a type of thread)

2. Hand taps are usually made in sets of three, called taper, plug, and bottoming
(Fig.3).

Fig.3
Thread Cutting

Cutting Internal and External Threads

1. A taper tap is tapered from the end approximately six threads and used to
start thread easily.

2. It can be used for tapping a hole which goes through the work, as well for
starting a blind hole ( one that does not go through the work) (Fig.4)

Fig.4 Taper tap (Starting tap)

Thread Cutting

Cutting Internal and External Threads

1. A plug tap is tapered for approximately three threads.

2. Sometimes the plug tap is the only tap used to thread a hole going through
a piece of work ( Fig.5).

Fig.5 Plug Tap

Thread Cutting

Cutting Internal and External Threads

1. A bottoming tap is not tapered but chamfered at the end for one thread.

2. It is used for threading to the bottom of a blind hole.

3. When tapping a blind hole, first use the taper tap, then the plug tap, and
complete the hole with a bottoming tap (Fig.6)

Fig.6 Bottoming tap

Thread Cutting
Calculations for Cutting Internal Threads

1. Before a tap is used, the hole must be drilled to the correct tap drill size
(Fig.7).

2. This is the drill size that would leave the proper amount of material in the
hole for a tap to cut a thread.

3. The tap drill is always smaller than

the tap and leaves enough material
in the hole for the tap to produce
75 percent of the thread (Fig.7)

Fig.7 Determining tap drill size.

Thread Cutting

Calculations for Cutting Internal Threads

(Inch Threads)

1. Changing a decimal to a fraction can be done easily by applying this simple

formula:
A. Multiply the decimal by 64.
B. Put answer over 64 and reduce to smallest possible fraction.

Example: .125 X 64 = 8

= 8 reduced to 1
64 8

2. Changing a fraction to a decimal can be done easily by dividing the

numerator by the denominator.

Example: 1 = 0.125
8
Thread Cutting

Calculations for Cutting Internal Threads

(Inch Threads)
1. When a chart is not available, the tap drill size for any American, National,
or Unified thread can be found easily by applying this simple formula:

TDS = D – 1
N
TDS = tap drill size
D = major diameter of tap
N = number of threads per inch

EXAMPLE : Find the tap drill size for a 7/8 in. 9 NC tap.
TDS = 7/8 - 1/9
TDS = 0.875 - 0.111
TDS = 0.764 in.

2. The nearest drill size to 0.764 in. is 0.765 in.(49/64).

3. Therefore, 49/64 in. is the tap drill size for a 7/8 in. – 9 NC tap.
Thread Cutting

Calculations for Cutting Internal Threads

(Metric Threads)
1. Like inch taps, metric taps are available in sets of three: the taper, plug, and
bottoming tap.

2. They are identified with the letter M followed by the nominal diameter of
the thread in millimetres times the pitch in millimetres.

3. A tap with the markings M 4 X 0.7 would indicate: . .

M- A metric thread.
4- The nominal diameter of the thread in millimeters.
0.7- The pitch of the thread in millimeters.

4. The tap drill size for metric taps is calculated in the same manner as for U.S,
Standard threads.
TDS = major diameter (mm)-pitch(mm)

EXAMPLE: Find the tap drill size for a 22-2.5 mm thread.

TDS = 22-2.5 = 19.5 mm
Thread Cutting

Tapping a Hole
1. Tapping is the operation of cutting an internal thread using a tap and tap
wrench( Fig.8).
).
Note: Taps are hard and brittle, they are easily broken. Extreme care
must be used when tapping a hole to prevent breakage. A broken
tap in a hole is difficult to remove and often results in scrapping the
work.

Fig.8 Tapping a hole.

Thread Cutting

Tapping a Hole by Hand

1. Select the correct taps and tap wrench for the job.

2. Apply a suitable cutting fluid to the tap.

).

Note: No cutting fluid is required when tapping brass or cast iron.

3. Place the tap in the hole as vertically as possible, press downward on the
wrench applying equal pressure on both handles, and turn clockwise (for
right-hand thread) for about two turns (Fig.9).

4. Remove the tap wrench and check the tap

for squareness.

Note: Check at two positions at 90 degrees

to each other (Fig.9).

Fig.9 Checking a thread tap for squareness.

Thread Cutting

Tapping a Hole by Hand

5. If the tap has not entered squarely, remove it from the hole and restart it by
applying pressure in the direction from which the tap leans.

). Note: Be careful not to exert too much pressure in the straightening process.

6. When a tap has been properly started, feed it into the hole by turning the
tap wrench.

7. Turn the tap clockwise one-quarter turn, and then turn it backward about
one-half turn to break the chip.

Note: This must be done with a steady motion to prevent the tap from
breaking.

8. Remember when tapping blind holes, use all three taps in order: taper, plug,
and then the bottoming tap.

Note: Before using the bottoming tap, remove all the chips from the hole
and be careful not to hit the bottom of the hole with the tap.
Thread Cutting

Using a Pipe Tap ( NPT tap)

1. The pipe tap, which may be stamped NPT (National Pipe Thread), is tapered
along the entire thread length( Fig.10 ).

2. ). The NPT tap taper is approximately 3/4 inch per foot.

3. When threading with an NPT tap, thread the tap in the hole no more than
3/8 of the thread length, before checking the thread fit.

4. check the thread fit often, use the fitting to be used in the threaded hole.

5. Turn the pipe fitting in by hand, it should turn in about two turns before
tightening (hand tight).

6. Finish the fitting tightening with a wrench, the fitting should turn an
additional two to three turns.

Caution : Tapered thread fittings

can split or damage parts like
cylinder heads and hydraulic
pumps.
Fig.10 Using a tap extractor.
Thread Cutting

Removing a Broken Tap

1. Extreme care must be used when cutting a thread, particularly in a blind
hole.

2. ). The tap may break in the hole and considerable work will be required to
remove it.

3. In many cases, it may not be possible and another piece of work must be
started.

4. There are several methods used to remove a broken tap.

5. Some may be successful, others will not ( good luck).

Thread Cutting

Removing a Broken Tap Using a Tap Extractor

1. Select the proper extractor for the tap to be removed.

2. Slide collar A, to which the fingers are attached, down body B so that the
). fingers project well below the end of the body (Fig. 11)

Fig.11 Using a tap extractor.

Thread Cutting

Removing a Broken Tap Using a Tap Extractor

3. Slide the fingers into the flutes of the broken tap, making sure they go down
into the hole as far as possible.

4. ). Slide the body down until it rests on top of the broken tap.This will give the
maximum support to the fingers.

5. Slide the collar C down until it rests on top of the work. This also provides
support for the fingers.

6. Apply a wrench to the square section on the top of the body.

7. Turn the wrench gently in a counter­clockwise direction.

Note: Do not force the extractor, as this will damage the fingers. It may
be necessary to turn the wrench back and forth carefully to free
the tap sufficiently to back it out.
Thread Cutting

Removing a Broken Tap Using a Drill and Heat

1. If the broken tap is made of carbon steel, it may be possible to drill it out.

2. Heat the broken tap to a bright red colour, and allow it to cool slowly.
).

3. Centre-punch the tap as close to the centre as possible,(use transfer

punches).

4. Using a drill considerably smaller than the distance between opposite flutes,
proceed carefully to drill a hole through the broken tap.

5. Enlarge this hole to remove as much of the metal between the flutes as
possible.

6. Collapse the remaining part with a punch and remove the pieces.
Thread Cutting

Threads Cutting Dies

1. Treading dies are used to cut external threads on round work.

2. Common types of dies are solid , adjustable split, and the adjustable (Fig.12).
).

Fig.12 Types of thread dies.

Thread Cutting

Cutting Threads with a Hand Die

1. Chamfer the end of the workpiece with a file or on the grinder.

2. Fasten the work securely in a vise.

).

3. Select the proper die and die stock.

4. Lubricate the tapered end of the die with a suitable cutting lubricant.

5. Place the tapered end of the die squarely· on the work (Fig.13 A & B).

Fig.123 Using a thread die.

Thread Cutting

Cutting Threads with a Hand Die

6. Press down firmly on the die stock handles and turn clockwise several turns.

7. Check the die to see that it has started squarely with the work.
).

8. If it is not square, remove the die from the work and restart it squarely.

9. Turn the die forward one turn and then reverse it approximately one-half of a
turn to break the chip.

10. During the threading process apply cutting fluid frequently.

CAUTION: When cutting a long thread, keep the arms and hands clear
of the sharp threads coming through the die.

11. If the thread must be cut to a shoulder, remove the die and restart it with the
tapered side of the die facing up.

12. Complete the thread, being careful not to hit the shoulder; otherwise the
work may be bent and the die broken.