Everyone who works in machining knows that there will always be several situations that the tap will break when tapping, especially in CNC machining, it is very easy to break, and some of them are deep holes, which is a very annoying thing. so today we have compiled 25 ways to remove broken faucets for you!
1. Pour a little lubricating oil, use a sharp hairpin or chopper to slowly drop the fracture surface in the opposite direction, and pour iron filings from time to time (the most common method in workshop, but for threaded holes with too small diameter or broken taps and too big, it may not suitable if it is too long, but you can try).
2. Weld a handle or hex nut onto the broken section of the faucet, then gently reverse it (this is a good method in the first place, but welding is a bit awkward and not suitable for smaller diameter faucets) . .
3. Use a special tool: the broken faucet extractor. The principle is that the workpiece and the faucet are connected to the positive and negative electrodes respectively, and the electrolyte is filled in the middle, causing the workpiece to discharge and the faucet to corrode. then needle-nose pliers to remove it, which will cause little damage to the inner hole.
4. Hold the steel roller against the faucet crack and tap it slowly with a small hammer. The faucet is relatively brittle and will eventually break into slag. Or, even simpler, drill or drill directly into the threaded hole of the broken faucet and. re-expand and tap (method) It’s a bit barbaric If the diameter of the tap is too small, it won’t work. If the diameter is too large, it will be quite tiring to type.)
5. Weld the threaded hole where the broken tap is located flat, grind it flat and re-drill the hole. Although it is difficult, you can drill it slowly (if the threaded hole can be changed, it is recommended to change it). when drilling and tapping again on the side of the original threaded hole).
6. Drill a slot in the cross section of the broken faucet and turn it in the opposite direction with a screwdriver (it is difficult to cut the slot, especially if the diameter of the faucet is small).
7. Drill the threaded hole of the broken faucet into a larger size, then insert a threaded sleeve or pin or something, then weld, grind, re-drill and tap. You can essentially achieve the same result (this method is troublesome). , but it is very practical, the size of the tap does not matter).
8. Use an electric pulse to remove it, an electric spark or wire cut can be used. If the hole is damaged, you can enlarge the hole and add a threaded insert (this method is simpler and more convenient. As for coaxiality, don’t do it. I’m not thinking about it at the moment, unless your threaded hole is the same. Axiality directly affects the quality of the equipment).
9. Make a simple tool and insert it into the chip groove of the broken tap section at the same time. Remove it carefully in the opposite direction. You can use a broken square tenon tap to screw 2 nuts into it. thread (the number is the same as the number of grooves of the faucet) to insert the broken faucet and the empty slot of the nut, then use the hinge lever to pull it in the direction of the outlet. Square tenon, remove the broken tap (the main idea of this method is to open the chip groove of the broken tap, and use steel wire, preferably a steel needle, to make a specially used wrench to remove broken wires of course, if this kind of thing happens often in the workshop (in case of broken wire, it is better to make a tool wrench like this).
10. Nitric acid solution can corrode high speed steel taps without scrapping the part.
11. Use an acetylene flame or blowtorch to anneal the tap, then use a drill bit to drill. At this point, the diameter of the drill bit should be smaller than the diameter of the bottom hole. Aligned with the center to prevent the thread from being drilled. Once the hole is drilled, drive a flat shape or use a square punch and wrench to unscrew the faucet.
12. Use the pneumatic drill to reverse the movement, and it all depends on the hand feeling, because the tap is not drilled directly, but the tap is turned with a slow speed and a little friction (similar to a half -round). -clutch in a car).
13. You can use a grinder to smooth the broken thread, then use a small drill bit to drill first, and then gradually use a larger drill bit. The broken wire will gradually fall off. After falling, use a tap of the original. size to tap the tooth again, like this. The advantage is that there is no need to increase the hole diameter.
14. Weld an iron rod to the broken object and unscrew it. (Disadvantages: a. The broken object is too small to be welded; b. The welding skills are extremely demanding and the workpiece is easily burned; c. The solder joint is easy to break and the chances of removing the object broken are very small.)
15. Use a tapered tool that is harder than the broken object. (Disadvantages: a. It is only suitable for broken and fragile objects. Crush the broken objects, then remove them slowly; b. The broken objects are too deep and too small to remove; c. It is easy to damage the original holes.)
16. Make a hexagonal electrode smaller than the diameter of the inserted object, use an EDM machine to machine a hexagonal countersink on the inserted object, and then use an internal hexagonal wrench to unscrew it. (Disadvantages: a. Useless for rusty or stuck sharp objects; b. Useless for large parts; c. Useless for cutting parts that are too small; d. Time-consuming and tedious.)
17. Directly use an electrode smaller than the object to be cut, and use an EDM machine to punch. (Disadvantages: a. It is useless for large parts and cannot be placed on the EDM machine table; b. It is time-consuming; c. When it is too deep, it is easy to deposit carbon and cannot be pierced.)
18. Use alloy drill bit (disadvantages: a. It is easy to damage the original hole; b. It is useless for hard cutting objects; c. The alloy drill bit is brittle and easy to break.)
19. Now there is a portable machine tool designed and manufactured according to the principle of electric machining, which can easily and quickly remove broken screws and broken tap bits.
20. If the screw is not too hard, you can file the end face flat, then find the center point, use a sample punch to drill a small point upward, use a smaller drill bit to drill first, make sure it is vertical, then use a broken wire puller to twist it in the opposite direction.
21. If you can’t buy a broken wire extractor, use a larger drill bit to continue widening the hole. When the hole diameter is close to the screw, some threads will fall off due to force. then use a tap to reshape the hole.
22. If the broken screw thread is exposed or the broken screw is not strict, you can still use a handsaw to cut it. You can cut the slots and even the outer casing and then remove it with a flat blade screwdriver. .
23. If the broken wire is exposed to a certain length and the melting point of the mechanical material is not too low, you can use electric welding to weld a T-shaped elongated rod on the screw, so that it can be easily screwed. out of the welded rod.
24. If the screws are very rusty and cannot be treated with the above method, it is recommended to roast them red, then add a little lubricating oil, and then use the corresponding methods below. above to process them.
25. After a lot of effort, although the screws were removed, the holes were now useless, so we simply drilled a larger hole and tapped it. If the original screw position and size were limited, we could also drill a larger hole. or tap it directly by soldering it, then drill a small hole in the center of the big screw and tap it. However, it is sometimes difficult to tap the internal metal structure after welding.
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