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A Comprehensive Guide on How to Remove Broken Taps

Step-by-step guide on removing broken taps

In various industries, tapping is a commonplace procedure in mechanical work. However, the removal process can pose a significant challenge when taps break. 

Surprisingly, broken drills are often easier to extract from holes than broken taps. The good news is that it’s possible to remove broken taps safely with the right tips and tricks. 

Do you know?

Professional intervention may have a success rate of 80% or higher, as these individuals often have access to specialized tools, expertise, and experience in dealing with such situations.

Employing techniques such as using tap extractors or tap pullers can make the extraction process more manageable. These tools provide the necessary grip and leverage to unscrew and eliminate the broken tap. It ensures a smoother and more efficient resolution to this common issue in mechanical work.

Let’s dive into this comprehensive guide on how to remove broken taps! 

Taps In Machining | A Know-How:

A close-up of a tap being used in machining process, creating threads in metal

In Machining, taps are essential tools that create threads in materials like metal or plastic. These threads enable screws or bolts to fasten into the material securely. 

Taps have cutting edges that gradually carve out the threads, turning them into a pre-drilled hole. They come in various sizes and types, each suited for specific applications. 

Taps are crucial for creating accurate and durable connections in manufacturing and construction. As they cut into the material, taps produce threads that match the profile of the screw or bolt. It ensures a precise fit and reliable mechanical joints.

What is the Importance of Understanding Removal Techniques?

Graph highlights the Importance of Understanding Removal Techniques
  • Efficient Resolution 
  • It helps to control damage 
  • Cost Saving 

Understanding broken tap removal techniques is crucial for several reasons in Machining. 

Firstly, it allows for efficient resolution when taps inevitably break during operations. This knowledge empowers machinists to address the issue promptly, minimizing downtime and potential disruptions to the manufacturing process. 

Secondly, familiarity with removal techniques helps prevent further damage to the workpiece. Using the wrong methods may cause additional harm, complicating the situation. 

Thirdly, knowing how to remove broken taps properly can save costs associated with replacing expensive tools. Moreover, it enhances overall efficiency and productivity in the workshop by providing machinists with the skills to tackle unexpected challenges swiftly. 

Why Taps Break? | Exploring the Reasons:

Broken taps can occur in various ways, leading to different challenges. Understanding these types is crucial for developing effective strategies to address and prevent broken taps in machining processes.

Excessive Force:

Taps can’t handle the pressure and might break when you use too much force while threading. It’s like pushing too hard on something fragile.

Improper Alignment:

 If the tap isn’t aligned correctly with the hole you drilled, it puts uneven stress on the tap. This stress can lead to the tap breaking as it tries to cut the threads.

Material Hardness:

Taps are like tools designed for specific jobs. Using a tap meant for softer materials on a hard one can make it snap because it’s not built for that toughness.


Think of a tap-like metal. If it gets rusty or corroded, it weakens. So, a corroded tap can break when you’re trying to thread because it’s not as strong as it should be.

Stuck Taps:

Sometimes, taps get stuck in the material. Trying to force them out without the proper techniques can make them snap. It’s like trying to pull something out that’s stuck. It might break if you need to be more careful.

Inadequate Lubrication:

When you’re threading, it can get hot. If you don’t use enough lubrication (like oil) to cool things down, the tap gets too hot and weakens. It’s like a car engine needing oil to stay cool.

Tool Wear:

Tools wear out over time, and taps are no different. If a tap is damaged or worn out, it’s more likely to break during use. Regularly checking and changing worn-out taps is like changing a tire on a car. It keeps everything running smoothly.

Top 10 Techniques to Remove Broken Taps:

The practical techniques employed to remove broken taps are crucial in minimizing downtime. They prevent further damage and ensure the continuity of manufacturing processes.

Bar chart displaying Techniques to Remove Broken Taps

Use Lubricating Oil:

The initial technique for removing broken taps involves using lubricating oil. First, generously apply the lubricating oil to the broken tap and the surrounding area. Let the oil soak for several hours or overnight. The oil works to weaken the grip of the tap on the material.

Don’t Forget:

After sufficient soaking, use an appropriate tool, such as a tap extractor, to attempt to turn the broken tap. The lubrication helps reduce friction, making it easier to unscrew and remove the broken tap without causing additional damage to the material.

Tap Extractors: 

Choose an appropriate tap extractor based on the size and type of the broken tap. Insert the tap extractor into the broken tap, ensuring a secure fit. 

Then, apply steady and even pressure while turning the tap extractor counterclockwise. The extractor’s gripping mechanism catches onto the tap, facilitating its removal. Continue turning until the broken tap is completely unscrewed from the material.

Tap extractors are specialized tools designed for this purpose, providing an effective and reliable means of removing broken taps without causing further damage.

Use the EDM Machine:

Another technique for removing broken taps involves using an Electrical Discharge Machining (EDM) machine. The EDM machine employs electrical discharges to erode and disintegrate the broken tap in this method. The process begins by creating a small hole in the center of the tap using a specialized electrode. 

Subsequently, the EDM machine generates controlled electrical sparks that gradually break down the tapping material, allowing for its extraction.

Drill another Hole:

The new hole allows access to the tap and relieves the pressure, making it easier to extract. Choosing the right-sized drill bit is crucial to avoid causing additional damage. Once the new hole is drilled, various methods, such as pliers or tap extractors, can be employed to grip and turn the broken tap out of the material. 

Use Die Grinders:

Select an appropriate die grinder with a carbide burr attachment. Carefully grind away the surrounding material around the broken tap. Then, gradually expose the tap and create a flat surface for gripping. Use pliers or a tap extractor to turn and remove the exposed tap.

Die grinders offer precision in material removal, making them practical for extracting broken taps, especially when dealing with delicate workpieces.

Use Oxy-Acetylene Torch:

Another technique for removing broken taps involves the use of an oxy-acetylene torch. 

  • You have to select the appropriate tip for the oxy-acetylene torch based on the material and size of the broken tap. 
  • Apply heat to the surrounding area of the broken tap using the torch.
  • Increase the temperature to expand the material around the tap.
  • Once the surrounding material expands, use pliers or a tap extractor to turn and remove the broken tap carefully. 

This technique utilizes heat to loosen the grip of the tap, making it easier to extract and providing an alternative method for tap removal.

Use A Hammer And Chisel:

You can also use a hammer and chisel to remove broken taps. This technique is convenient.

  • To begin, carefully position the chisel on the exposed part of the broken tap. Use the hammer to apply controlled and precise strikes on the chisel. The goal is to create a minor groove or indentation in the tap material. 
  • Continue this process, gradually working around the circumference of the broken tap. Once a sufficient groove is established, switch to pliers or a tap extractor to grip and rotate the broken tap out of the material. 

This method leverages manual force to weaken the tap’s hold. It helps you to extract the tap while preserving the integrity of the workpiece.

Use Corrosive Chemical Solution:

In this method, you can use a chemical solution, such as a rust dissolver or penetrating oil, to the broken tap and its surrounding area. Allow sufficient time for the chemical to penetrate and weaken the bond between the tap and the material. The corrosive action helps to break down any rust or corrosion that may be holding the tap in place. 

After the allotted time, attempt to turn the broken tap using pliers or a tap extractor. It helps you safely remove the tap. 

Weld To Remove Taps:

Welding can also remove the broken taps. You just have to apply welding heat to the exposed end of the broken tap. This heat causes the tap and the surrounding material to expand. Once the temperature is high enough, use pliers or a tap extractor to turn and remove the expanded broken tap. 

Use Hydraulic Jack:

Hydraulic Jack also helps you remove the broken taps. Place the hydraulic jack in a stable position near the broken tap. Adjust the jack to apply gentle and even pressure to the surrounding material. The pressure helps create a slight gap between the tap and the material.

Utilize pliers or a tap extractor to turn and remove the partially lifted broken tap. Exercise caution to avoid excessive force and potential damage to the workpiece.

The hydraulic jack provides controlled pressure, assisting in lifting the tap and facilitating its removal. This method is particularly useful for taps firmly lodged in the material.

Tips To Create Internal Threads Without Breaking The Taps:

A man in a welding helmet creating internal threads without breaking the taps

Using the right tips, machinists can enhance the success of creating internal threads while minimizing the risk of breaking taps during the tapping process. The following tips are helpful while making internal threads.

Bar chart, % of total transactions, showing efficiency improvement in Internal Threads Without Breaking The Taps

Proper Alignment:

Ensure precise alignment of the tap with the pre-drilled hole. Misalignment can lead to uneven stress on the tap, increasing the risk of breakage. Align the tap carefully to distribute the cutting forces evenly and reduce the likelihood of tap failure.

Appropriate Lubrication:

Use sufficient lubrication during the tapping process. Proper lubrication reduces friction between the tap and the material, preventing excess heat buildup that could weaken the tap. Apply lubricants consistently to facilitate smooth cutting and extend the life of the tap.

Correct Speed and Feed Rates:

Maintain appropriate speed and feed rates while tapping. Adjusting these parameters ensures that the tap encounters the material optimally, preventing excess stress that could lead to breakage. Consistent and controlled speed and feed rates are essential for successful tapping.

Material Selection:

Match the tapping material to the workpiece material. Using the right tap for the material reduces the likelihood of breakage. Different materials require different taps, and selecting the appropriate one is crucial for achieving precise and durable threads.

Regular Inspection:

Periodically inspect taps for signs of wear or damage. Replace worn or damaged taps promptly to avoid breakage during use. Regular inspection ensures the taps are in good condition, reducing the risk of unexpected failures.

Slow and Steady Approach:

Adopt a slow and steady tapping approach. Rushing increases the risk of applying excessive force, leading to tap breakage. A controlled and deliberate tapping speed is essential for maintaining the tap’s integrity and the threads’ quality.

Back Off for Chip Clearance:

Regularly reverse the tap to clear chips during the tapping process. Chip buildup can exert extra pressure, contributing to tap breakage. Clearing chips allows for smoother cutting and reduces the likelihood of chip-related issues that may lead to tap failure.

Use Tapping Fluids:

Apply tapping fluids to dissipate heat. Fluids enhance the tapping process and extend tap life by reducing heat-related stress. Proper cooling with tapping fluids is crucial, especially when working with hard or heat-sensitive materials.

Appropriate Tap Type:

Select the correct type of tap for the job. Different tap types are designed for specific applications and materials. Choosing the right tap ensures efficient cutting and minimizes the risk of breakage associated with an incompatible tap.

Careful Tap Removal:

Exercise caution when removing taps from the completed threads. A careful and controlled removal minimizes the risk of tap breakage. Use proper techniques and tools to extract the tap without causing damage to the threads or the tap itself.

Manual Threading:

Manual threading requires a steady hand and careful control of the turning process to avoid applying excessive force on the tap. You’ll have to follow the same principles of proper alignment, lubrication, and speed control.

CNC Thread Milling:

Programming and toolpath planning are critical when using CNC thread milling. Ensure that the CNC machine is set up to follow the correct thread milling toolpaths with appropriate speeds and feeds. Proper programming reduces the risk of tap breakage by controlling the tool’s engagement with the material.

Adhering to best practices in manual and CNC processes ensures consistency and reliability in thread creation. You can also take guidance from HiTop

Safety First:

When dealing with the removal of broken taps, prioritizing safety is essential. Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves, to shield yourself from potential hazards. Ensure that the workspace is well-lit and organized, reducing the risk of accidents.

Before starting, familiarize yourself with the specific safety guidelines for the tools and techniques you’ll be using. If uncertain, seek guidance or assistance from experienced professionals. Remember, taking precautionary measures is the foundation for a secure and successful tap removal.


Each technique for removing broken taps has its merits, and the choice depends on factors such as the nature of the tap breakage and the material involved. Prioritize safety, exercise patience, and, if needed, seek professional assistance. 

With the right approach, you can overcome challenges, ensuring smooth operations in your workshop or production line.

HiTop Industrial- Your Trusted Partner:

At HiTOP, we take pride in being your go-to partner for all your manufacturing needs. Committed to excellence and precision, we offer reliable solutions to bring your ideas to life. Our team of skilled professionals is dedicated to delivering high-quality injection molding, casting, and mold-making services tailored to meet your unique requirements. 

With years of experience in the industry, HiTop brings a wealth of knowledge to every project. We leverage cutting-edge technology and modern equipment to ensure your injection molding projects are executed efficiently and accurately. 

Choose us as your trusted partner in injection molding and the best guide in removing broken taps. We’re here to bring your visions to reality with precision, quality, and a commitment to excellence. Your success is our priority at HITOPContact us to schedule a consultation. 

Frequently Asked Questions:

What Tool Opens A Broken Tap?

A tap extractor is essential to open a broken tap. This specialized tool grips and turns the remaining threads of the broken tap, allowing for its removal from the material. 

The tap extractor engages with the broken tap and provides the necessary leverage to unscrew and extract the damaged piece.

How Do You Remove A Broken Tap?

To remove a broken tap, use a tap extractor. Insert it into the broken tap and turn it counterclockwise to unscrew and remove the broken piece.

What Is A Tap Puller?

A tap puller is a tool that extracts or removes broken taps, screws, or bolts from materials. It helps to avoid damage and facilitate efficient removal.

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