If you haven't needed to use a tap and die before, the process can seem a little confusing and the tools themselves even more so. However, by understanding exactly what the process of use entails, everything else will start to make sense. The ultimate goal of using these tools together is to create a screw thread that bolts can grip into. The entire process is known as threading. Here is a quick look at the basic functions of a tap and die as well as how these tools work together.
When using a tap and die to create bolt threads, the first step is known as tapping. This is when you will cut threads into some type of hole or nut. You can not only cut new threads, but can also use a tap to re-thread as well. During this process, it is important to make sure that you are using the tap correctly; otherwise your threads will be misaligned. Common problems that could cause this include: using drills or reamers that will harden the inside of the hole, creating poorly proportioned holes (multi-sided or oval), and using a drill that doesn't have enough torque to complete the task effectively.
A tap and die works together because the tap creates female portion of the pair and the die creates the male portion. Once you have finished with the tap, it is time to move onto the die. When using the die, it is important to make sure that the bolt is completely secured. It is also beneficial to add some lubricant to help reduce friction, which causes heat buildup when you are creating the threads. In most cases, lubricant will need to be applied several times throughout the threading process. It is likely that as you are using the die it will catch once in a while. If this happens, you should back out a little bit, add some more lubricant instead of forcing your way through it. By backing out a little, you will be clearing out threads, which will make the cutting process smoother.
Now that you understand the basics of how a tap and die work together, there are some additional factors to keep in mind. One of the most important things to do is make sure that the TPI or Threads Per Inch are the same on both the male and female portions when you are done. Most sets will include a gauge with several different blades that can be used to calculate the TPI of a bolt or nut in the event that you only need to re-thread one or the other, such as rethreading a stripped bolt.
Hopefully you have a much better idea about what a tap and die set is and how it works. Combined, the set can be used to thread or re-thread both male and female portions. In some situations you may only need to use one tool or the other, which is often the case when rethreading. If you are creating a completely new set of threads, then choose a TPI and stick with it. If you are rethreading a single piece, such as bolt, make sure to use the gauge that is included with your tap and die set so that you will know the correct TPI to create.
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