Common issues and solutions for rigid tapping

During the tapping process, various issues can arise that affect production techniques and efficiency. Today, we will analyze the solutions to common tapping problems.

1. Cannot be detected by thread plug gauge

Severe tap wear, improper tap selection, incorrect thread profile parameters, excessive spindle speed, formation of built-up edges, cutting blockage, burs on the tap, inaccurate positioning and clamping, unstable feed during tapping, improper tap regrinding, excessive axial pressure.

2. Thread Damage and Rough Threads

Improper tap selection, excessive or insufficient spindle speed, severe built-up edges, cutting blockage, burs on the tap, too small a pilot hole, insufficient coolant lubrication, excessive cutting amount per pass.

3. Tap broken and Short Tap Life

Presence of thread damage and rough threads, cutting edge hitting the hole bottom, lack of coating or poor coating quality, annealing during tap regrinding, severe material hardening during drilling.

4. Solutions

Based on the aforementioned issues, the following solutions are provided:

4.1 Choose High-Quality and Reliable Tap Brands

Select high-quality and reliable tap brands and more suitable tap series.

4.2 Use High-Strength Tap Materials

Choose taps made of high-strength materials (such as powder high-speed steel) to enhance tap strength.

Improve the surface coating of the taps to increase surface hardness. In extreme cases, manual tapping may be a feasible method.

4.3 Use V-Holders and Quality Lubricants

It is recommended to use V-holders, which significantly delay tap wear and thus extend the tap's service life.

Additionally, using high-quality tapping lubricants can effectively reduce tap wear.

Employ thread gauges (T/Z) to easily assess tap conditions.

4.4 Utilize V-Holders for Axial Synchronization

Use V-holders to completely solve the issue of axial synchronization error compensation in rigid tapping.

4.5 Adjust Spiral Flute Angle and Cutting Parameters

Consider changing the spiral flute angle of the tap (several different angles are usually available) to ensure smooth chip evacuation.

Adjust cutting parameters to ensure chips can be smoothly evacuated.

If necessary, use taps with variable spiral angles to ensure smooth chip evacuation.

4.6 Choose Correct Pilot Hole Diameter

Select the correct pilot hole diameter based on the type of tap and the material being tapped. If an exact match is not available, choose a slightly larger drill bit.