One of the great things about thread cutting is its accessibility for amateurs and beginners. With the right tap, you can cut a thread by hand even in your home garage, without the need for a fully-equipped workshop. However, this method is not particularly efficient. If you often need to cut threads, you are probably interested in understanding how thread cutting with machines works. In this blog post, we'll explain the basics and address a few common misconceptions about machine-based thread cutting.
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First, we need to clarify what we mean by the term "machine tap". Yes, your cordless drill is technically a machine, but it's not the one meant for thread cutting with a machine.
Machine-based thread cutting is a highly sensitive process where human error should play as minimal a role as possible. When you use a handheld drill or cordless screwdriver, you have many factors literally in your hand. If you don't hold the device perfectly straight, the thread might not be cut correctly, and the tool can easily break. Even a manually operated pillar drill only partially solves the problem because you still manually control the feed. Not to mention that for machine-based thread cutting, it's best to use a thread-cutting chuck.
If you do decide to use a pillar drilling machine, consider investing in one with an automatic dip-to-slope program or use a thread cutting device specifically designed for machine-based thread cutting. If you somehow need to use a handheld device, we recommend setting it to the lowest speed and using a machine tap with a long lead (e.g., Form B) for additional guidance. However, please note that this is just a makeshift solution, and machine taps are explicitly not designed for this. If you have to cut many threads, you should consider whether purchasing a machine with a thread cutting program or a thread cutting device would be a worthwhile investment!
Do you have a suitable tool machine for thread cutting? Great, then you can almost get started. However, there are a few things to keep in mind.
Obviously, the most crucial tool is the machine tap itself. Various types differ mainly in the shape of the lead and the material used. To make the right choice, you should know the intended use of the machine tap and the material you'll be working with.
Additionally, you'll need a suitable tool holder for machine-based thread cutting. Its job is to connect your machine tap to the machine tool. What you use depends on the type of machine and your equipment. Frequently used are collets with square receptacles that also transmit torque. For smaller thread dimensions, a cylindrical collet may suffice. Thread cutting devices also count as tool holders. Specialists in this area are tapping heads, capable of compensating for minor irregularities during machine-based thread cutting, thus significantly extending tool life.
Lastly, you'll need tools to prepare the core hole drilling: drill bits and countersinks.
As we've seen, thread cutting works best when you select the appropriate program beforehand and let the machine do the rest. However, this also means you need to know the necessary programming for machine-based thread cutting. An important value is the feed, i.e., the distance the machine tap moves into the material per rotation. The feed should correspond to the thread's pitch. Obtain the correct feed programming by multiplying the rotation speed by the pitch during thread cutting.
The cutting speed for machine-based thread cutting depends on the drill used and the material being processed. Recommendations can typically be found in the product description of the drill, e.g., in our BAER Online Shop. Values usually range between 5 and 15 m/min. We recommend starting at the minimum value or slightly below, then adjusting the speed based on the behavior of the drill. This information refers to computer-controlled machines, not manual devices.
An overview of the essential formulas for machine-based thread cutting:
Plasma cutting is a significantly important method of cutting any conductive products such as non-alloy steel, stainless steel, iron, and aluminium with minimum effort and expense. The basis of the working logic is to convert an ionized gas into plasma form and create an electrical channel towards the area to be cut. The plasma cutting process is performed by plasma cutting machines developed with the latest technology.
The gas type and pressure to be used during the cutting process inside the machine may vary depending on the material type and thickness to be cut. In addition, some of the compressed gasses such as oxygen and air are ionized by an electric arc. The ionized gas enables the desired cutting process to take place on the line formed between the cutting edge of the plasma machine and the material to be treated.
The most important criterion needed for plasma cutting is known as compressed gas. In addition to using different gases for this process, the most common plasma gas is compressed air. As it is available in many workshops and manufacturing shops, compressed air is very easy to supply. It can be used as an alternative to flammable and combustible due to its easy supply and accessibility.
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Considering both in terms of health and the environment, performing cuttings with compressed gas is a much healthier and environmentally friendly process. As Durmazlar, we are going to discuss how plasma cutting works and the differences between plasma and laser cutting.
During plasma cutting, hot and accelerated plasma is applied to the surface of the material with high electrical conductivity to be cut. Thanks to this cutting method, conductive materials such as aluminium, steel, sheet metal, and copper can be cut very fast and perfectly. Plasma-cutting machines are preferred by large industrial companies and many other areas with their high-speed precision cutting and low operating costs.
The main criterion of plasma cutting is that it creates an electrical channel through the material to be cut by a superheated and electrically ionized gas. This electrical circuit is grounded by the grounding busbar, thus ensuring the operation of the system. In accordance with the material to be cut by the operation of this system, compressed gasses such as oxygen and air are used. The electric arc is shaped between the hole (nozzle) in which the gas comes out and the material. An electric arc ionizes some of the gas and enables the creation of an electrical channel between the plasma and the material.
By using this electrical channel, electrons travel to the material through a cutting torch and create the heat needed to melt the material. During this process, high-velocity plasma and compressed gas spray the molten metals, preventing the formation of any roughness on the surface.
You can perform cuts on both fine and thick materials using plasma cutting. Steel sheets of 38 mm thickness can be cut using manual plasma cutting machines. Moreover, cuttings up to 150 mm in thickness can be performed with plasma cutting machines.
One of the most efficient ways to obtain products in desired sizes and shapes from metals such as steel, iron, and aluminium is plasma cutting. There are many advantages of using this method in manufacturing shops, workshops, and repair shops. One of these advantages is productivity.
It is possible to perform more cuts in a shorter time using this method. Cutting more products in a shorter time means producing more products in a shorter time for a manufacturing shop. This also means more production with less human power. Therefore a manufacturing shop or workshop can produce more with fewer workmanship costs.
Another productivity contribution of plasma cutting is that there is no need for a pre-annealing process before cutting. This means that the material to be cut is not exposed to any heating process before cutting. Heating and cutting the metal to be cut at a certain temperature increases both the time and effort spent on the work. Loss of material due to a possible error that may occur in the heating process can also be prevented.
As it is in the cutting process, plasma cutting offers great convenience after the process. The cutting torches of plasma cutting machines are performing much more precise and smoother works with the technology that has developed recently. Thus, no slag that needs to be cleaned after cutting is created. Since it performs the best cut with the least force on the material to be cut, post-cutting correction is not needed as there will be no adverse conditions such as warping, bending, or distortion on the surface post-cutting.
This cutting method offers advantages regarding health and the environment. Apart from these, the fact that the gas used in the machines is non-hazardous is also a great advantage in terms of occupational safety. The non-explosive and non-flammable gas used prevents an explosion or fire that may occur in the workplace.
Plasma cutting is preferred for cutting many metals thanks to its advantages. Almost all of these advantages also offer advantages for cutting stainless steel. In addition to these advantages, plasma cutting also prevents major workmanship errors in steel cutting.
Another importance of plasma cutting is that it produces accurate results after cutting. Since the measurements determined before the cutting are reflected in the work in the same way, there is no mistake or errors.
In this article, as Durmazlar, we will answer in detail about the advantages of plasma cutting and plasma cutting machines. By using Durmazlar machines, you can overcome all difficulties. We mainly aim to combine business processes by producing durable, flexible, and innovative machines. We aim for perfection in all our machines and attach importance to our communication with our customers in order to produce flawless machines. Please visit our website and contact us if you need further information about our products.
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