how to get broken tap out

3 min read 06-02-2025

Getting a broken tap out of a workpiece can be frustrating, but with the right techniques and tools, it's often possible. This guide provides a step-by-step approach to tackle this common problem, ranging from simple methods to more advanced techniques. Remember safety first – always wear appropriate eye protection.

Assessing the Situation: Types of Broken Taps and Workpieces

Before attempting removal, carefully assess the situation. Several factors influence the best removal method:

Type of Tap: Is it a high-speed steel (HSS) tap, a carbide tap, or something else? Material strength will impact removal.
Depth of Break: How much of the tap remains embedded? A small fragment is easier to remove than a deeply embedded section.
Material of Workpiece: The material of the workpiece (e.g., aluminum, steel, cast iron) affects the techniques you can safely use. Harder materials pose greater challenges.
Accessibility: Is the broken tap easily accessible, or is it in a tight space? Accessibility significantly impacts your tool choices.

Methods for Removing Broken Taps

Several methods exist, each suitable for different scenarios. Start with the simplest and progress to more advanced techniques if needed.

1. Easy Out Tap Extractor

This is often the first and easiest method to try. Easy-outs are specialized tools designed to grip and remove broken taps.

How it Works: The Easy-Out's reverse-tapered threads engage with the broken tap's flutes, allowing you to turn it out.
When to Use: Best for shallowly broken taps where sufficient tap remains above the workpiece's surface.
Caution: Using excessive force can damage the Easy-Out or the workpiece.

2. Reverse Drilling and Extraction

If an Easy-Out fails, carefully drilling out the broken tap may be necessary.

How it Works: Use a drill bit slightly smaller than the tap's diameter to drill a pilot hole into the center of the broken tap. Then, carefully use a left-hand drill bit to remove the remaining tap.
When to Use: Suitable for larger fragments where sufficient space exists for drilling.
Caution: Precise drilling is crucial to avoid damaging the workpiece. A broken drill bit is an even bigger problem!

3. Tap Extractor Set

These sets often include various sizes and types of extractors to handle different tap sizes and break situations. They offer a wider range of solutions than a single Easy-Out. Consider this a more versatile option for your toolbox.

4. Welding a Nut to the Broken Tap

This is a more advanced method useful for stubborn, deeply embedded fragments.

How it Works: Carefully weld a nut onto the top of the broken tap. Once cooled, use a wrench to turn the nut and remove the tap.
When to Use: Ideal for situations where other methods have failed, especially with larger, deeply embedded fragments.
Caution: Requires welding skills and care to avoid damaging the workpiece. Use a low-heat welding technique to prevent warping.

5. Using a Broken Tap Removal Tool Kit

Several commercial kits contain specialized tools and instructions for removing broken taps. These kits often encompass different methods, offering a comprehensive solution.

Preventing Broken Taps in the Future

Prevention is better than cure! Here are some tips to minimize the risk of broken taps:

Proper Lubrication: Always use sufficient cutting fluid or lubricant when tapping. This reduces friction and heat buildup, preventing tap breakage.
Sharp Taps: Ensure your taps are sharp and in good condition. Dull taps require more force and are more prone to breaking.
Correct Tap Size: Select the right tap size for the job and avoid forcing it.
Proper Technique: Use consistent pressure and avoid excessive force while tapping.
Appropriate Speed: Use the correct tapping speed to prevent overheating and breakage.

Conclusion

Removing a broken tap can be challenging but manageable with the right tools and techniques. Start with the simplest methods and progress to more advanced options if needed. Remember safety precautions and always choose the method best suited for your specific situation. Preventing broken taps is crucial; proper lubrication, sharp taps, and correct technique are key preventative measures. Investing in a good set of tap extractors can significantly aid in future tap removal efforts.