Thread-Cutting

Tools
and Procedures
Session 9
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
• Provides room for chips
• Admit cutting fluid to lubricate tap
• End of shank square so tap wrench can
be used to turn tap into hole
Shop Tools and Techniques 2
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)

Shop Tools and Techniques 3

Hand Tap Sets
• Taper
• Tapered from end six threads
• Used to start tapping
• Used for tapping through holes
and blind hole
• Plug
• Tapered for three threads
• For Tapping through holes
• Bottoming tap
• Not tapered but chamfered at
end
• Used for threading to bottom of
blind hole
Shop Tools and Techniques 4
Identifying Taps
Use of annular ring(s) cut around top of
shank
One – taper tap

Two – plug tap

Three – bottoming tap

Shop Tools and Techniques 5

Tap Drill Size
• Hole must be drilled
to correct size
• Leaves proper
amount of material
for tap to cut thread
(75%)

A = body size
B = tap drill size
C = minor diameter
Shop Tools and Techniques 6
Tap Drill Size

1 TDS = tap drill size

TDS  D - D = major diameter of tap
N N = number of threads
per inch

Find tap drill size for a 7/8 – 9 NC tap

7 1
TDS  -
8 9
 .875  .111  .764 in.
Shop Tools and Techniques 7
Metric Taps
• Several thread forms and standards in
metric thread system
• International Standards Organization
(ISO) has adopted standard metric
thread
• 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 times pitch
Shop Tools and Techniques 8
Tap Drill Sizes for Metric
Taps
Tap drill size for metric taps calculated in
same as for Inch threads

TDS = major diameter (mm) – pitch (mm)

Find the tap drill size for a 22 x 2.5 mm thd

TDS = 22 – 2.5
= 19.5 mm
Shop Tools and Techniques 9
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
occasionally results in scrapping work

Shop Tools and Techniques 10

Hand Tapping

1. Select correct taps and tap wrench

2. Apply suitable cutting fluid to the tap
• No fluid required for 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 Shop Tools and Techniques 11
Hand Tapping
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

Shop Tools and Techniques 12

Hand Tapping
7. Turn tap clockwise one-quarter turn,
and turn it backward about ½ turn to
break the chip (must turn with steady
motion)
8. Careful not to tap too deep for a blind
hole
9. When finished, clean hole and check
with thread gage or appropriate bolt

Shop Tools and Techniques 13

Removing Broken Taps
• Several methods may be used to
remove broken tap
• Tap Extractor
• Tool with four fingers that slip into flutes of
broken tap; wrench fitted to extractor and
turned to extract
• Drilling
• Drill through broken tap
• Tap Disintegrators
• Uses electrical current to destroy tap

Shop Tools and Techniques 14

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

Shop Tools and Techniques 15

Using a Tap Extractor
4. Slide body down until it rests on top of
broken tap
5. Slide collar down until it rests on top of
work
6. Apply wrench to square end of body
top
7. Turn wrench gently in
counterclockwise direction
Do not force extractor – will damage fingers
Shop Tools and Techniques 16
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
Shop Tools and Techniques 17
Threading Dies
• Adjustable split die
• Has adjusting screw that permits adjustment
over or under standard depth of thread
• Fits into die stock

Shop Tools and Techniques 18

Threading Dies
• Adjustable screw plate
die
• Two die halves held in
collet by threaded plate
• Adjusting screws
against
each die half
• Greater adjustment
than split die

Shop Tools and Techniques 19

To Thread With a Hand Die
1. Chamfer end of workpiece with file or
on disk sander
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
Shop Tools and Techniques 20
To Thread With a Hand Die
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

Shop Tools and Techniques 21

To Thread With a Hand Die
10. During threading process, apply
cutting fluid frequently
11. When finished, check with thread ring
gage or appropriate nut

If thread must be cut to shoulder, remove

die and restart it with tapered side of die
facing up (complete the thread)

Shop Tools and Techniques 22