Every Machinists NIGHTMARE… Have YOU BROKEN a TAP in a Part???

How to use the ONA DR-2 EDM Hole Popper to fix a broken tap. CNC Machining techniques revealed.

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[JShinn]

Sweet, got a broken tap in a part, now all I need is a edm hole popper.

[massimilianocipriani]

So you're telling me that cursing all the saints on the calendar, spending hours trying to loose the tap and ending up slam dunking the part in the scraps barrel isn't the correct way? *surprised
pikachu face*

[tarehjernetarehjerne]

I have another way, use a center punch and fracture it into pieces and fish those out. It may sound dumb but it works if you don't have any edm stuff

[hiemabedrog]

or, you can just tap properly? My journeyman used to say, "you have all this time to mess on taking out a broken thing, but if only you did it properly, you'd have all that time for the next job" but also shit happens!

[jimturkington]

When I was a 17 year old Apprentice Fitter . I was very good at removing broken taps and sheared bolts. My foreman got me to do it for the shop. 1975 made myself prongs etc for the fiddly bits. Belfast UK

[brett]

Smallest I got out is a m2 using lead from a clicky pencil, on a sparker. Took its time but it was all removed and no damage to the threads.

[sintaxera]

My method involves a lot of swearing. I should get one of those hundred thousand dollar machines!

[DR.BELJAN]

You guys are at a whole new level in manufacturing.

[Fat_Ninjah]

glad I worked with parts with large tolerances, tapped a m2.5 tap out by tapping it with a spare scriber and mallet

[ambydaly]

Nice to see not a lot has changed since being an apprentice in the early 1960s. We manufactured precision aluminium components for the aerospace industry. There were two 10ba. Tapped holes to finish the part. Each was carefully tapped by hand using a tapping block for alignment. You needed a very delicate touch to tap these holes. Not every apprentice had the knack and we ended up with lots of components with broken taps. One day a sales person arrived to show os a very simple machine called a “Tap-O-Matic”. It was a small spark eroder. Every component with broken taps was saved. Your machine is more advanced but does the same job.

[ryanfield]

I do this all the time in my garage! Works great

[SGIABC]

I always just knab a smaller carbide end mill and plunge cut it out. Edm would be nice though.

[nicholaspayne]

Yea I don’t have one of those. I chip them out with a broken end mill that I ground into a punch. Sometimes you can get them turning

[saschafunk]

The same systemis in use at our mashineshop. However, the electrode is clamped in the spindle of the Z axis of the machine. So the part does not have to be dismantled. It happens quite often that taps or drills break off and get stuck in the part. We uses electrodes with diameters up to 20 mm. Our boss always say: once unclamped is thrown away.

[evolution]

I love how every know it all says "throw it in the EDM" when you got a busted tap. I never knew that. Too bad most shops don't have one.

[TechMasterRus]

Thank you! I never thought about that. Now I'll sell my house and buy EDM.

[ehamann]

As a tool shop:
If you don't have this machine at least you should know someone who has one

[manofausagain]

Oh gosh what a brilliant idea in a conditioned world.
Metal rod and silver solder. Put blob of silver solder on end of rod. Cool rod. Use vice grips hold rod with blob on end touching broken tap. Heat rod. Heat travels down rod to blob and sticks to tap. Cool down. Back out tap.

[duckslayer]

When I read the title I thought, wow this video will be useful. Once I discovered the solution was to use a piece of equipment most shops don't I was disappointed. Do better

[CooklamuK]

Aah yes. My favorite way to remove a tap. Let someone else deal with it.