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One of the fantastic aspects of thread cutting is how accessible it is for beginners and amateurs. All you need is the right tap, and you can start cutting threads by hand in your own garage without needing a fully equipped workshop. While this approach works, it’s not very efficient if you’re frequently cutting threads. If you find yourself needing to do this often, you might want to understand how thread cutting with machines works. In this blog post, we’ll explore the basics and clear up some common misunderstandings about machine-based thread cutting.
First off, let’s define what we mean by a “machine tap.†While your cordless drill is technically a machine, it’s not the kind designed for machine-based thread cutting. This process requires precision, and human error needs to be kept to a minimum. Using a handheld drill or cordless screwdriver introduces too many variables—like holding the tool straight—and can result in poorly cut threads or even broken tools. Even a manually operated pillar drill doesn’t completely eliminate these issues since you’re still controlling the feed manually. For optimal results, it’s best to use a thread-cutting chuck.
If you do opt for a pillar drilling machine, consider investing in one with an automatic dip-to-slope program or a thread-cutting device specifically designed for machine-based thread cutting. If you must use a handheld device, set it to the lowest speed and use a machine tap with a long lead (like a Form B) to provide extra guidance. However, remember this is just a temporary fix, and machine taps aren’t designed for this purpose. If you’re cutting many threads, think about investing in a machine with a thread-cutting program or a dedicated thread-cutting device—it could save you time and frustration in the long run!
Now that you’ve got the right equipment, let’s dive into how machine-based thread cutting works. Assuming you have a suitable tool machine, you’re ready to go. Here are a few things to keep in mind.
Firstly, the most critical tool is the machine tap itself. Different types vary primarily in the shape of their lead and the materials they’re made from. Choosing the right one depends on the intended use and the material you’ll be working with.
You’ll also need a proper tool holder to connect your machine tap to the machine tool. What you choose will depend on the type of machine and your setup. Common options include collets with square receptacles that transmit torque. For smaller threads, a cylindrical collet might suffice. Thread-cutting devices also act as tool holders, and tapping heads are particularly useful as they compensate for minor irregularities during cutting, significantly extending tool life.
Lastly, you’ll need tools to prepare the core hole—drill bits and countersinks.
Here’s a step-by-step guide to machine-based thread cutting:
1. **Pre-drill the core hole**: A tap can only work in a prepped hole. Use an ordinary twist drill bit for this. Make sure the diameter is correct! Learn more about this here.
2. **Countersink the core hole**: Chamfer the edges of the core hole with a countersink afterward. This helps with centering and ensures a clean finish.
3. **Cut the thread**: It’s now the machine tap’s turn. Set the correct settings (feed according to pitch per rotation) and apply plenty of lubricant!
When it comes to finding the right settings for machine-based thread cutting, selecting the appropriate program beforehand is key. An important factor is the feed, which is the distance the machine tap moves into the material per rotation. The feed should match the thread’s pitch. You can calculate the correct feed programming by multiplying the rotation speed by the pitch during cutting.
The cutting speed for machine-based thread cutting depends on the drill used and the material being processed. Recommendations can usually be found in the product description of the drill, such as those in our BAER Online Shop. Values typically range from 5 to 15 m/min. We suggest starting at the minimum value or slightly below, then adjusting based on the behavior of the drill. This applies to computer-controlled machines, not manual ones.
Here are some essential formulas for machine-based thread cutting:
- Cutting speed \( v_c \) [m/min] = (outer diameter * π * speed) / 1000
- Rotation speed \( n \) [1/min] = (cutting speed in m/min * 1000) / (outer diameter * π)
- Feed programming [mm/min] = rotation speed * pitch
Ensuring smooth operations: Don’t forget the coolant!
Friction occurs during machine-based thread cutting, which you can counteract using lubricants. The higher the speed, the more critical this becomes, as more frictional energy is released, generating heat.
Not all coolants are the same. Recommended products depend on the application. Coolants are categorized into solutions or dispersions, emulsions, and cutting oils. Various additives can also add extra properties like corrosion protection.
For machine-based thread cutting, lubrication is key, and coolants are typically used in the form of thread-cutting oil or thread-cutting paste. Many machines automatically supply coolant through external nozzles or an internal mechanism within the spindle during drilling. It’s crucial to use enough pressure to ensure sufficient coolant is present.
High-quality machine taps for machine-based thread cutting are available in the online shop of Tap Manufacturer BAER. Check it out!
In conclusion, while hand-thread cutting has its charm, machine-based thread cutting offers efficiency and precision that cannot be matched by hand methods. Whether you're a hobbyist or a professional, having the right tools and understanding the process can make a world of difference in your projects. So, take the time to invest in the right equipment and follow the steps outlined above to achieve perfect threads every time!