HAND THREAD CUTTING TOOLS
There are numerous ways in which threads may be cut. In a fabrication shop, threads may be
cut using lathe machine, special tread cutting machines or through the use of taps dies. In this
module, we will deal with the process of cutting threads with taps and dies
The threads on bolts and nuts are formed by a number of specialised processes.
However, from time to time it may be necessary to produce threads in the field. The
method used by trades people is hand threading using taps and dies.
Process of thread cutting
The process of cutting threads is divided into two:
Internal (female ) thread cutting (the process is also referred to as tapping). Internal
threads are the threads cut on a nut
External (male) thread cutting (the process is also referred to as Dieing) External
threads are the threads cut on a bolt or screw
Taps and dies
A tap is the cutting tool used to form an internal thread such as in a nut. The tap has a
square ended shank for attachment of a tap wrench.
Each size of tap will comprise three taps which are known as:
taper
intermediate
plug.
Figure 1 Set of taps, (a) taper, (b) intermediate, and (c) plug
Taper tap
The taper has the last five or six threads ground away in taper fashion. This is to
enable the tap to enter the clearance, or tapping-size hole in the part to be threaded,
each succeeding tooth of the tap deepening the cut of the thread until the tap has
entered to the end of the tapered portion, and then begins to cut the full section of the
thread. For this reason, the taper tap is always the first one to be used.
In the case of ‘blind’ holes (a hole that does not penetrate right through the work), the
tap is screwed down to its full extent then removed, and the intermediate and plug taps
used to finish the thread to its final shape and size.
The intermediate tap
This tap is tapered for approximately three threads, and is used after the taper in order
to avoid undue strain on to the plug tap.
Plug tap
This normally has the first thread ground to a taper, and is mainly used to ensure the
tapping of a full thread in blind holes.
Materials used for making taps and dies
Taps and dies are generally made from the following two materials:
High carbon Steel (HCS) and
High Speed Steel (HSS)
High Speed Steel taps and dies are more expensive than High Carbon Steel because
HSS is able to cut accurate threads and its able to cut even hard materials at high
speed. This is on account of exceptional hardness, abrasion resistance and resistance
against softening at high temperatures, owing to the alloying metals and heat
treatment used
Using hand operated taps
1 Refer to a thread tapping drill size chart for the size hole to be drilled
2 Drill the hole, making sure it is square to the surface of the work.
3 Check that correct taps are being used.
4 Use a correct tap wrench NOT a spanner.
5 Use the taper first and confirm that the tap enters the hole correctly by checking
with a try square See. Figure 2
6 Use a lubricant, if applicable, to the material into which the thread is being cut.
7 After each clockwise turn, give a quarter reverse turn (anticlockwise) to break the
chips into the flutes.
8 When tapping a ‘blind’ hole, be sure the tap does not ‘bottom’ on the hole or on
the accumulation of chips.
9 When tapping a ‘blind’ hole, follow the taper tap with the intermediate tap and
then the plug tap.
Table 1; Thread Chart Showing Tapping size drill
Figure 2 Using an engineers square to check entry of tap for squareness
Types of Tap wrenches
Tap wrenches are used for holding and rotating taps during thread cutting operations. there
are two types of tap wrenches which will be dealt with in this module. these are bar tap
wrench and T tap wrench.
Figure 3
Figure 4
Dies
Hand threading of studs and bolts is commonly carried out by means of a split button
die (Fig 5 ) mounted in a die holder or stock (Fig 6). The split in the die allows a slight
adjustment, which is carried out by the conical
pointed adjusting screw in the stock. The cutting teeth of the die are chamfered on one face to
allow an easy start to the
thread. The face with the chamfer is known as the ‘leading face’ and is often the face
opposite to the size and name markings.
Figure 5 Button die
Figure 6 Die Stock and Die
The Die stock or die holder is used for holding dies
Die nut
A damaged external thread may be repaired by use of a die nut, which is a hexagonal
non-adjustable die turned by use of a spanner.
Die nuts should not be used to cut an original thread.
Figure 7 Die Nut
The process of Cutting threads with a Die
1. Cut the bar square and prepare a small chamfer to assist in starting the thread
Figure 7 Chamfer prepared on the end of around rod
2. Select the correct die and install it in the die holder.
3. Tighten the adjusting screw fully to open the die to its maximum.
4. Tighten the locking screws.
5. Lightly lubricate the bar with oil, grease or a specialised thread cutting compound.
6. Place the die and holder over the bar with the leading face of the die towards the
chamfer.
7. Being careful to keep the die holder square to the work, turn the holder clockwise
until two or three threads are completed.
8. Continue cutting the thread, allowing a quarter turn anticlockwise after each turn,
to break off the chips.
9. After the full length of the thread has been cut, remove the die from the bolt and
try the bolt into its nut or stud hole. If the thread is too tight, the die may be closed
slightly by releasing the adjusting screw and tightening the locking screws. Again,
apply the die to the bolt.
10. After completing the thread, it may be necessary to reverse the die so that the
leading face is uppermost in order to cut the chamfered threads closest to the bolt
head to the full depth.
EXERCISE
1 Illustrate the difference between internal and external threads (2)
2 A set of taps has three taps. Name each of the taps and when they are used. (6)
3 Explain why High Speed Steel is a more superior than High carbon steel in the
manufacture of taps (3)
4 i Name each of the tools shown below (2)
ii State the use of each of the tools (2)
(a) (b)
5 Briefly describe how external threads are cut on a rod 10mm in diameter (5)
Due date 11/06/2021
