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Note that spiral fluted taps are not as strong as the more common spiral point taps, which is why they’re not used all the time. Just use them on blind holes.

The reason is the machine is limited by acceleration of spindle and axes on how closely it can synchronize the tap to the threads it’s making. There’s always some axial force pushing or pulling.  A floating holder will relieve stress from lack of perfect synchronization.

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Here’s what’s key—a 100% thread is only 5% stronger than a 75% thread, but it requires 3 times the torque. So, for just a tiny bit stronger thread you wind up with a much greater chance of breaking your tap.  The chart on this slide shows the relationship:

Crashing a CNC machine in a way that does costly damage is worse, certainly. But breaking a tap off in an expensive part that’s nearly finished has got to come in a close 2nd place.

The red-orange dots are tapping torque. Look how fast it climbs when thread percentage gets above 60%.  The blue dots are thread strength—it flattens out just when the torque starts climbing. The recommended drill size is almost always a 75% thread. Great strength, but well into that too much torque zone.

Be sure to check the requirements on the job—your customer may require a particular thread percentage. But if they don’t, or if it’s within the ranges in this chart, dial back the thread percentage and your taps will thank you.

Speaking of blind holes, my 7th and last tip is to mind the depth on blind holes. Crashing the tap into the bottom of the hole will almost certainly break it.

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Every machinist hates breaking taps. It’s a real pain to extract a broken tap without damaging the part. Plus, tapping always seems to be one of the last operations done on a part, which just ensures the highest cost if you need to scrap the part.  But, there are 7 things I’m going to show you in this video that will great reduce the number of broken taps you have to deal with.

First, form taps can’t be used on hard materials. You can only form tap up to 36 HRC hardness materials. That’s a lot more materials than you’d think, but there’s definitely materials that can’t be form tapped. Second, some industries don’t allow form taps because the process can create voids that trap contaminants on the threads. Form Tapping can also create stress risers on the threads.

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Good video. I’m having problems tapping 4-40 blind holes in 6061-T6. Snapping the taps off so much I’ve switched to tapping by hand. Roll forms bulge the material out because it’s only .188 thick. Your tip about a Dip Cup is great, we would stop the machine and hand lube the taps. Never thought of a Dip Cup.

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Most machine coolants, especially water soluble, are not as good for tapping. If you’re having problems, try using special tapping lubricant. Put it in a spill proof cut that sits on the machine table and program the g-code to dip the tap automatically in the cup.

It’s important to realize there is no one drill size for a tap. Different drill sizes result in different thread percentages.

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I just finished the 11th episode of CNC Chef for Cutting Tool Engineering. This video gives you 7 ways to avoid breaking taps:

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I walk you through the math below and you can see that for the example ¼-20 roll form tap we needed not quite a ¼ inch of clearance from where the tap stopped to the hole bottom.

To start, use a holder that locks the square shank on a tap so it can’t twist in the holder. Tapping uses a lot of torque, so having a positive lock on that shank is helpful.

Many are not aware, but you can calculate how much clearance to leave at the bottom and it’s probably more than you’d think.

Mar 11, 2020 — As a starting point, however, 55% for maximum drill size and 75% for minimum drill size can be used as a guide. Any desired percent of thread ...