Broken Tap Removal by Metal Disintegration Machine (MDM)

good morning my name is Tom Grafton I'm the owner and operator of Jerry's broken drill and tap removal I've owned and operated this same business for 40 years everything on the table is grounded because this is sitting on wood we need to run an auxilary ground to it this port down here accepts the auxilary ground strap so we don't need to be touching metal to metal we don't need the piece that I'm working on to be touching the base of the machine in order to get a ground and grounds it directly through an auxilary ground being the cable now this particular part or steel casting has a 5 16 to 18 broken tap located right here in this circle so at this point is when you determine what size electrode which is molybdenum tubing a hole through the tab that gets you into the fluted area of the tap basically burning out the tap hole large enough through there that doesn't touch the threads but makes a hole big enough so that you have just pieces of the tap which are called flutes that are left and at that point we take small hardened round chisels and knock the remaining pieces out okay the electrode size is 5/32 or 0.15 6 diameter that will give me a large enough hole inside this tab to leave the remains of the flutes of the tap after this hole is burnt through the tab staying completely away from the threads it will leave flutes okay the next step would be to measure the depth in this in this particular job we don't need a print if this was one single hole in this part and I need a print that would specify the depth of the hole we can find our depth for the hole with the broken tab by checking one of the other holes so the maximum depth at this tap could be broken would be one inch between the surface and the depth of that hole could be halfway through it could be broken off on the bottom but it's important to know how deep to go this putty or clay that I put up here is not necessary I do it only to divert the water from flooding the entire part and direct it more towards this side makes it less of a mess and that's the reason for the putty now at this point we line the electrode up with the center of the tab we have already adjusted our vibration the next step is to select a heat range with this dial right here we'll probably will pull not probably will positively pull between 125 and 150 amps which is exactly what we need for burning the size hole with this electrode okay the next step I need to cover the the electrode because there's water what what burns the hole is the action of the heat the very tip of the electrode and and water come through the center of hollow electrodes at about 15 pounds psi and the action of the the and the water does the burning or powder powder ization of the of the material that's in here in this case the tap what I'll do now is make one burn turn the Machine off you always double-check the center which is perfect so at this point we wrap it back up and we continue burning I'll show you a little bit of the parking that's going on that's burning a hole through the tab I just fell through the tap so that tells me that the tap is broken off shallow not near the finish depth of 1 inch 100 smooth the machine out of the way and we'll blow out the hole grab the hardened round chisels that is equal to the hardness of the tap these are made out of a material called m2 and are heat treated to about 62 Rockwell so it doesn't just bust the end off it keeps it fairly clean end and grabs the tap without doing too much damage to the to the rod you have to grind this rod so it has a clean corner grind it at approximately 45 degrees so that's one rod I'll use two different sized hardened rods for this job this size I'll use to get started tapping out the remaining portion of the of the threads what we have remaining are the remnants which are basically the flutes of the tap we take our sharp round hardened chisels and we start picking the pieces of the tap out these are also magnetized as you can see they grab those pieces not all of them but some of them one more time there there's pieces of the tap you can see the flutes the threads that's what's known as the flute of the tap right there that's left those little pieces you can see the threads on the inside you can see where the burn took place there's one more piece I'm glad a little bit left in this hole we'll take the larger and chisel blow it out one more time just use me then just to ensure that the hole is clean I'll grab a tap and chase the thread now that we have all the tap out of there that the hole is clean of all debris and the tap we will put a new tap in there to the point where that tap broke ensuring that all the tap is out and the threads are clean after that well I'm so that the whole thing will draw a little circle around it so the customer knows exactly which hole we worked on and that job is finished except for taking it off the machine so now it's on to the next tab thank you very much got one more coming your way you

Channel: JerrysBrokenTap

Views: 857,811

Rating: 4.825181 out of 5

Keywords: Broken Tap, Broken Tap Removal, How to remove a broken tap, Broken Tap Disintegration, EDM, Jerrys Broken Tap, Tom Grafton, Broken Tap Removed, Electric Discharge Machine, Metal Disintegration Machine, Metal Disintegration

Id: YbeKxFBZrF8

Length: 9min 56sec (596 seconds)

Published: Sat Apr 06 2013

Reddit Comments

[u/tickle_mittens]

I was building a PVD chamber and broke a tap in a hole. The Instrument Maker supporting the department welded a bead in the end of it, drew the bead up out of the hole, gave himself something to grip on to, got some vice grips, put them on his welding job, hits the work piece with and acetylene torch just to warm/expand it a little and backed the tap out. and that's how I learned the difference between science, engineering, and art.

[u/normber]

Eventhough I dont know what he is doing I just watched the whole thing. His voice and demeanor are really relaxing to watch.

[u/majorkev]

I like how he used his calipers to measure the depth, but then measured his calipers with his ruler...

[u/OrangeTreetrunk]

His dad strength looks to be over 9000. Got damn.

[u/3Vil_Admin]

And this video shows why you never wipe your face with shop towels from a towel service.

[u/__Shake__]

how much does he charge for that job?

[u/guywithcrazyideas]

Cool video except for his chewing sounds.

[u/hydrogen_wv]

"Jerry's", owned by Tom.

[u/CuntHunter]

Youtube comment "wonder if they could have used this technology to burn up the core of the twin towers." had me rolling