Chips during tapping: Problems and solutions

Chips are an unavoidable by-product of tapping and other machining processes. If you’ve ever tried cutting a thread yourself, you might have some firsthand experience with the challenges they bring. But let’s face it—chips are part of the game. When material is removed during machining, it doesn’t just vanish; it has to go somewhere. That’s why effective chip management is so important—it helps prevent damage, keeps your work area clean, and ensures smoother operations.

Understanding the root causes of chip issues can make all the difference in finding the right solutions. What exactly influences chip formation during tapping? What problems can they cause, and how can you avoid them? In this post, we’ll break it all down and give you practical tips for better chip control.

Types of Chips You Might Encounter

While it would be ideal to completely avoid chips during tapping, that’s not always possible. The key is to manage them effectively. So, it’s helpful to understand the difference between good chips and bad chips.

During tapping and other machining operations, chips come in various shapes and sizes. Some are long and spiral-shaped, while others are short and broken. Ribbon chips or tangled chips can be problematic because they tend to get stuck or interfere with the process. On the flip side, long, tightly wound cylindrical spiral chips are more desirable—they help achieve a better surface finish.

Short spiral chips or crumbly chips are also easier to remove, which makes them useful. However, the best chip shape lies somewhere in the middle: short cylindrical spiral pieces, spiral helical chips, and short spiral chip pieces are considered optimal for preventing common chip-related issues.

The usability of chips is often measured by the chip space number, which reflects the ratio between the volume of the chip and the material being cut. Think of it like an air snake: before use, it fits easily in your hand, but after blowing it up, it takes up much more space. So, the smaller the chip space, the easier it is to handle the chip.

What Influences Chip Formation?

We now know what kind of chips are ideal, but how do we actually achieve them? The type of chip produced during tapping depends on several factors.

One of the most important is the cutting parameters, including cutting speed and feed rate. In general, increasing the cutting speed can lead to worse chip formation, while a higher feed rate improves chip breaking—but at the cost of surface quality.

The tool geometry also plays a big role. Specifically, the rake angle on the tap’s cutting edges affects chip length and shape. A larger rake angle can result in longer chips, while a smaller one may produce shorter, more manageable ones.

Lastly, the material being machined significantly impacts chip formation. Some materials, like stainless steel or aluminum, are more challenging to work with due to their properties. The material of the tap itself also matters, as it must be compatible with the workpiece to ensure smooth operation.

Common Chip Problems and Their Consequences

Now that we’ve covered chip types and influencing factors, let’s look at the real-world issues they can cause. Poor chip management during tapping often leads to thread quality issues or tool damage, which can shorten the life of your equipment.

If long chips accumulate and aren’t properly removed, they can leave uneven or unclean threads. In severe cases, this buildup can even cause the thread to become oversized, leading to dimensional inaccuracies.

Even worse, jamming chips can cause the tap to break, resulting in costly repairs and lost time. This is especially common in blind holes, where chips can pile up at the bottom and block the way out. Unlike through holes, where chips can escape more easily, blind holes require careful attention to chip evacuation.

How to Minimize Chip Problems

If you want to avoid these issues, there are a few things you can do. One option is to switch to non-cutting methods like thread forming or thread rolling, which generate fewer or no chips. However, for many home users or small-scale operations, this isn’t always practical.

There’s no single solution that works for every situation, but you can reduce risks by choosing the right tools. Your tap should be suitable for the material you’re working with. For example, standard taps may not perform well on tough materials like stainless steel or aluminum. The geometry of the tap is equally important—especially for blind holes, where the correct groove design ensures chips are efficiently removed from the hole.

Proper cutting speed and feed rate settings are also essential to ensure your tool performs as intended. And don’t forget about coolant or lubricant—it can make a big difference in chip removal and overall machining efficiency.

At BAER, we aim to make your machining experience as smooth as possible. Our online store offers high-quality tools for every application, along with detailed information on the recommended cutting speeds for different materials. If you need help, our customer service team is always here to assist you. Let us help you tackle those chip problems head-on!