Thread Milling vs Tapping – The Ultimate Comparison

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Most machinists at times find it difficult to decide whether they should choose thread milling or tapping. Well, this guide compares everything you should know about these machining processes.

What is Thread Milling?

This is a mechanical process that involves using a rotating cutting device to derive threads from various materials.

During the procedure, there is reduced interaction between the piece being worked on and the tool used for this process. This method also you to extract threads both internally and externally

What is Thread Tapping?

This is a process that involves a specialized tool known as tap which is used to create threads from your material.

This tool is fitted with grooves that function by providing a space for the cut material to be dispensed into. The procedure is better suited for internal threads with the tool being pushed into your material at select feeding rates.

Internal Thread Tapping

Internal Thread Tapping

Advantages of Thread Milling vs. Tapping

These threading methods each have their advantages which make them better suited for different applications. You should therefore consider their strengths that will help you determine the best method for you. The advantages include;

Advantages of Thread Milling

  • This method affords you more control over the form of the thread allowing you to handle both internal and external as well as left and right-hand threads. It also uses a bigger opening which is easier to work with.
  • With this procedure, you can design threads of different sizes from various materials without requiring specialized equipment.
  • This procedure produces threads that are of a much higher quality thanks to its seamless operations. With this variation, there is enhanced chip removal, stable operations as well as the ability to work with difficult materials
  • The method is beneficial when it comes to saving both cost and time. The machine does not require any additional specialized tools.
  • This method is ideal for threading holes that cannot be seen which greatly improves its profile from both the head to the base.
  • There is a reduction in damaged tools and vibration when using this method. This increases the durability of the tools.

Advantages of Thread Tapping

  • This variation offers increased speeds of production by minimizing chamfering time. This is ideal if you are dealing with small rough threads
  • It is much easier to carry out operations in this method with an easy and efficient tap that is used to design the threads. The tools used
  • This method is more economically feasible as it utilizes fewer tools compared to its alternatives which reduces its cost of purchase.
  • It is an incredibly versatile procedure that can be used to produce threads with varying sizes designed from various materials.
  • The methodology can be integrated with machines that are not very powerful without affecting its processing as it functions with reduced force when it comes to cutting.
  • This process saves energy as the process does not consume large amounts of energy.
CNC Pipe Threading Machine

CNC Pipe Threading Machine

Disadvantages of Thread Milling vs. Tapping

There are a few limitations that you may experience when using either of these methods. These limitations also allow you to make informed choices when selecting the best method for you. These limitations include;

Disadvantages of Thread Milling

  • This procedure is relatively slower than its alternatives. It is therefore not very time-efficient.
  • The procedure requires integration with computer numerical control for enhanced performance.
  • It therefore requires specialized machines to optimally operate which are expensive to purchase.
  • The specialized equipment requires skill as it has a complex installation process.

Disadvantages of Threat Tapping

  • This method is not well suited for sturdy materials. It is only suitable for easy-to-machine materials.
  • The tools used in this process have a higher risk of quickly undergoing wear. It, therefore increases operational costs as tools are often replaced.
  • The specialized tools such as taps are likely to get chipped given that they are fragile.
  • There is a limitation with regard to the length of the thread that can be produced with this method.
  • The thread produced is not of high quality and is often inconsistent
  • There is an increased possibility for cross-threading to occur

Difference Types of Tools used in Thread Milling and Tapping

There are various tools utilized in this method. The design and features may differ from one manufacturer. the most commonly used include;

Tools used in Thread Milling

  • Straight Flute Thread Mills: used for removing chips featuring perpendicular flutes that are positioned in the middle of the teeth used for cutting.
  • Helical Flute Thread Mills: This design features flutes that helical that are positioned along the circumference as well as several rows of teeth. The flutes help remove chips
  • Single Profile Thread Mills: this variation can only handle a singular thread at a time and features several flutes with one tooth
Thread Milling Tool

Thread Milling Tool

Tools used in Thread Tapping

  • Taps: used to design the female section of the joining pair
  • Tool holder: functions as supporting equipment and is typically with taps
  • Dies: used to design the female portion of the joining pair
  • Thread Cutting Adapters: they are incorporated into the screwdriver used for cutting purposes.

Applications

Both methods of threading are very versatile and can be applied in many fields. You should consider all the benefits and limitations of both processes to make a better choice. These applications

Applications of Thread Milling

  • high-volume part production
  • machining challenging materials
  • creating smooth threads
  • threading blind holes
  • versatile thread creation
  • precision machining
  • custom thread profiles

Applications of Thread Tapping

  • Automotive industry
  • Aerospace sector
  • Electronics industry
  • Medical field
  • Construction industry

Depending on your unique machining needs, TSINFA offers a wide range of CNC machines for your custom fabrication needs – contact us now.

More Resources:

Milling Machine – Source: TSINFA

Pipe Threading Lathe – Source: TSINFA

Dynamic Milling – Source: TSINFA

Thread Milling – Source: XOMERY

Climb Milling Vs Conventional Milling – Source: TSINFA