PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Thread-Cutting Tools
and Procedures
Unit 24

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
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Objectives
• Calculate the tap drill size for inch and
metric taps
• Cut internal threads using a variety of taps
• Know the methods used to remove broken
taps from a hole
• Cut external threads using a variety of dies
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Hand Taps
• Cutting tools used to cut internal threads
• Made from high quality tool steel, hardened
and ground
• Two, three, or four flutes cut lengthwise
across threads to form cutting edges
– Provide room for chips
– Admit cutting fluid to lubricate tap
• End of shank square so tap wrench can be
used to turn tap into hole
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Hand Taps
• Inch tap markings
– Major diameter
– Number of threads per inch
– Type of thread
½ in.—13 UNC
½ in. = major diameter of tap
13 = number of threads per inch
UNC = Unified National Coarse (type of thread)
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Hand Taps: Sets of Three

• Taper
– Tapered from end six threads
– Used to start thread easily
– Used for tapping hole that goes through
work as well as blind hole
• Plug
– Tapered for three threads
– Tread hole through workpiece
• Bottoming tap
– Not tapered but chamfered at end
– Used for threading to bottom of blind hole

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 24-6

Another Method of
Identifying Taps
• Use of annular ring(s) cut around top of shank
One – taper tap

Two – plug tap

Three – bottoming tap

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Tap Drill Size

• Hole drilled to correct tap
drill size
– Leave proper amount of
material for tap to cut
thread (75%)
1 A = body size
TDS  D -
N B = tap drill size
Find tap drill size for a C = minor diameter
7/8 in. –9NC tap
7 1 TDS = tap drill size
TDS  -
8 9 D = major diameter of tap
 .875  .111  .764 in. N = number of threads per inch

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
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Metric Taps
• Several thread forms and standards in metric
thread system
• International Standards Organization (ISO)
has adopted standard metric thread
– Will be used in US, Canada and other countries
– Have only 25 thread sizes (1.6 to 100 mm)
• Available in sets of three: taper, plug and
bottoming taps
– Identified by letter M followed by nominal
diameter of thread in mm times pitch in mm
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Tap Drill Sizes for Metric Taps

Tap drill size for metric taps calculated in 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
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Tapping a Hole
• Operation of cutting internal thread using
tap and tap wrench
• Taps hard and brittle
• Easily broken
– Extreme care used to prevent breakage
– Broken tap in hole difficult to remove and
often results in scrapping work
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To Tap Hole By Hand

1. Select correct taps and tap wrench for job
2. Apply suitable cutting fluid to the tap
• No fluid required for tapping brass or cast iron
3. Place tap in hole as vertically as possible;
press downward on wrench, applying equal
pressure on both handles; turn clockwise
(for right-hand thread) for two turns
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4. Remove tap wrench and check tap for

squareness
• Check two positions at 90º to each other
5. If tap not entered squarely, remove from
hole and restart it by applying pressure in
direction from which tap leans
6. When tap properly started, feed it into
hole by turning tap wrench
7. Turn tap clockwise one-quarter turn, and
turn it backward about ½ turn to break the
chip (must turn with steady motion)
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Removing Broken Taps

• Several methods may be used to remove
broken tap (some successful, others not!)
– Tap Extractor
• Tool with four fingers that slip into flutes of broken
tap; wrench fitter to extractor and turned to extract
– Drilling
• Drill through broken tap
– Acid Method
• Acid acts on steel and loosens tap for extraction
– Tap Disintegrators
• Uses electrical discharge principle to cut through tap
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To Remove Broken Tap Using a

Tap Extractor
1. Select proper size extractor for tap
2. Slide collar, to which fingers attached,
down body so fingers project well below
end of body
3. Slide fingers into flutes of broken tap,
making sure they go down into hole as far
as possible
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4. Slide body down until it rests on top of

broken tap
• Give maximum support to fingers
5. Slide collar down until it rests on top of
work
• Also provides support for fingers
6. Apply wrench to square end of body top
7. Turn wrench gently in counterclockwise
direction

Note: Do not force extractor – will damage fingers

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To Remove Broken
Tap (Carbon Steel) By Drilling
1. Heat broken tap to bright red color and allow it
to cool slowly
2. Center-punch tap close to center
3. Using drill smaller than distance between
opposite flutes, carefully drill holl through
broken tap
4. Enlarge hole to remove as much of metal
between flutes as possible
5. Collapse remaining part with punch and remove
pieces
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To Remove Broken Tap (High-

speed Steel) Using the Acid Method
1. Dilute one part nitric acid with five parts
water
2. Inject mixture into hole; acid will act on
steel and loosen tap
3. Remove tap with extractor or pliers
4. Wash remaining acid from thread with
water to neutralize acid
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Threading Dies
• Used to cut external threads on round work
• Most common threading dies
– Adjustable split die
– Adjustable screw plate die
– Solid die
• Used for chasing or recutting damaged
threads
• May be driven by suitable wrench
• Not adjustable
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Threading Dies
• Adjustable split die
– Has adjusting screw that permits adjustment
over or under standard depth of thread
– Fits into die stock
• Adjustable screw plate die
– Two die halves held in
collet by threaded plate
– Adjusting screws against
each die half
– Greater adjustment than split die
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 24-20

To Thread With a Hand Die

1. Chamfer end of workpiece with file or on
grinder
2. Fasten work securely in vise
3. Select proper die and die stock
4. Lubricate tapered end of die with suitable
cutting lubricant
5. Place tapered end of die squarely on
workpiece
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6. Press down on die stock handles and turn

clockwise several turns
7. Check die to see that it has started
squarely with work
8. If not square, remove die and restart
9. Turn die forward one turn and reverse it
approximately one-half turn to break chip
10. During threading process, apply cutting
fluid frequently
If thread must be cut to shoulder, remove die and restart it
with tapered side of die facing up (complete the thread)