Chips during tapping: Problems and solutions

Chips are an unavoidable by-product of tapping and other machining processes. If you've ever cut a thread manually, you know how frustrating it can be. But they’re part of the process — when material is removed during cutting, it has to go somewhere. That’s why effective chip management is so important. It helps keep things running smoothly and prevents damage or downtime.

Understanding the root causes of chip-related issues is key to solving them. What affects chip formation during tapping? What problems can arise, and how can you avoid them? In this post, we’ll break it all down and help you improve your tapping results.

Types of Chips in Tapping

While it would be ideal to eliminate chips completely, that's not possible. So the goal is to manage them as effectively as possible. It makes sense to distinguish between good chips and bad chips.

During tapping, chips come in many shapes and sizes. Long, irregular chips like ribbon chips or tangled chips can cause serious issues. They tend to clog the tap, reduce efficiency, and even lead to tool breakage.

On the other hand, long, cylindrical spiral chips that are tightly wound are much more manageable. They often result in a better surface finish and are easier to remove. Similarly, short spiral chips or crumbly chips are also favorable because they don’t get stuck easily.

The best chip shape for tapping lies somewhere in between. Short cylindrical spiral chips, spiral helical chips, and short spiral pieces are considered ideal for minimizing problems. These types are less likely to jam and make the tapping process smoother overall.

The chip space number is used to measure chip usability. It shows the ratio between chip volume and material volume. Think of it like an air snake: before use, it fits in your hand, but after blowing it up, it takes up much more space. The smaller the chip space, the easier it is to handle — and the better the tapping outcome.

Factors Affecting Chip Formation

We now understand what good chips look like, but how do we achieve them? The type of chip formed during tapping depends on several factors.

Cutting parameters such as cutting speed and feed rate play a big role. Increasing cutting speed tends to worsen chip quality, while higher feed rates can help break chips more effectively — though at the cost of surface finish.

The tool geometry is another critical factor. The rake angle on the cutting edges of the tap influences chip length and shape. A well-designed rake angle can significantly improve chip evacuation and reduce the risk of jams.

The material being tapped also has a major impact. Some materials, like stainless steel or aluminum, produce different chip characteristics compared to softer metals. Additionally, the material of the tap itself can affect performance and chip control.

Common Chip Problems During Tapping

So what happens if chips aren't managed properly? The main issues include poor thread quality, tool damage, and reduced tool life.

Long chips that accumulate in the hole can leave an uneven or dirty surface on the thread. This can even lead to oversized threads due to chip buildup, which compromises the final dimensions.

Even worse, chips getting stuck can cause the tap to break — resulting in costly repairs and lost time. This is especially common in blind holes, where chips have no escape route and can pile up at the bottom.

How to Prevent Chip Problems When Tapping

If you want to avoid these issues, one option is to switch to non-cutting methods like thread forming or thread rolling. While these are great for industrial applications, they may not be practical for home use.

There’s no one-size-fits-all solution for chip problems. Every material and situation is different. However, choosing the right tools and settings can greatly reduce the risks. Make sure your tap is suitable for the material you're working with — some materials, like stainless steel, require specialized taps.

The geometry of the tap is also important. For blind holes, the groove design should allow chips to be expelled efficiently. Proper cutting speed and feed rate settings are crucial too. Don’t forget to use the right coolant, which helps with both cooling and chip removal.

At BAER, we aim to make your tapping experience as smooth as possible. Our online store offers high-quality tools for every application, along with detailed guidance on the right cutting speeds for all materials. If you have any questions, our team is always here to help!