Chips are an unavoidable by-product of tapping and other machining processes. If you've ever cut a thread yourself, you might already know how tricky it can be. But they're part of the process — material is removed during machining, and that material has to go somewhere. That's why **effective chip management** is so important: it helps prevent disruptions and avoids damage.
Understanding the causes of chip-related issues is the first step toward solving them. What factors influence chip formation during tapping? What negative effects can they have, and how can you avoid these problems? In this post, we’ll break it all down.
### Different Types of Chips
It would be ideal if chips could be completely avoided during tapping, but that’s not possible. So, the goal is to manage them in the most efficient way. This means distinguishing between **good chips and bad chips**.
In tapping and other machining operations, chips come in various forms. They’re classified based on their length, shape, and whether they form a spiral. Long or irregular chips — like **ribbon chips** or **tangled chips** — are generally problematic. On the other hand, **long, tightly wound cylindrical spiral chips** that help achieve a better surface finish are considered more desirable. Short **spiral chips** or **crumbly chips**, which are easier to remove, are also useful.
The best chip shape lies somewhere in the middle. **Short cylindrical spiral pieces**, **helical spiral chips**, and **short spiral chip fragments** are often the most effective for preventing chip-related issues.
Chip usability is measured using the **chip space number**, which reflects the ratio between chip volume and the material volume. Think of it like an air snake: before use, it’s small and easy to handle, but after blowing it up, it takes up much more space. The **smaller the chip space**, the easier it is to manage.
### Factors Affecting Chip Formation
Now that we understand what good chips look like, let’s look at how to achieve them. The final chip shape during tapping depends on several key factors.
First, **cutting parameters** such as **cutting speed** and **feed rate** play a major role. Generally, increasing cutting speed tends to worsen chip quality, while higher feed rates improve chip breaking — though this may affect surface finish.
The **tool geometry** is also crucial. The **rake angle** on the tap’s cutting edges significantly influences chip length and shape.
Lastly, the **material being machined** has a big impact. Some materials, like stainless steel or aluminum, are harder to machine with standard tools. The **type of cutting tool** used also affects chip formation.
### Common Chip Problems in Tapping
So, what happens when chips cause issues during tapping? In many cases, poor chip control leads to **thread quality problems** or even **tool damage**. Accumulated long chips can leave an **uneven surface** on the thread, and in some cases, the thread may end up too large due to **chip build-up**.
Even worse, **jammed chips** can cause the **tap to break**, resulting in costly repairs and damaged threads. This risk is especially high when working with **blind holes**, where chips can get trapped at the bottom and cause serious issues.
### How to Avoid Chip Problems
If you want to minimize risks, you can consider **non-cutting methods** like **thread forming** or **thread rolling**. However, these are not always practical for everyday use.
There’s no one-size-fits-all solution for chip problems, as each situation is different. But choosing the right **tool for the job** can make a big difference. Ensure your tap is suitable for the material you're working with — not all tools work well with metals like stainless steel or aluminum.
The **geometry of the tap** should also match the application. For blind holes, for example, the **groove design** is essential to ensure chips are properly evacuated.
Proper **cutting speed and feed rate settings** are also critical to keep the tool performing optimally. And don’t forget the **coolant or lubricant** — it helps reduce friction and makes chip removal easier.
At BAER, we aim to make your machining experience smoother. Our **online store** offers high-quality tools for every cutting task, along with detailed guidance on the correct cutting speeds for all materials. If you need help, our customer service team is always here to assist.
Corrugated box/carton,Custom Made White Paper Boxes,White Paper Boxes Pack,White Cardboard Carrier Boxes
Yutian Jifu Paper Products Co., Ltd. , https://www.yutianjifu.com