1. step in the production of taps: Production of the raw material
For a first-class tap, of course, we also need first-class starting material. Good taps are usually made of high-speed steel, a high-quality steel alloy. This is initially still in a solid state and must first be melted for the manufacture of a tap. The molten steel is then cast or pressed into bar form. The steel bars then cool and become hard. Other than the rough shape, steel bars don't have much in common with taps at this point. However, that is about to change!
2. step in the production of taps: machining of blanks
In this step of the production of taps, the steel bars become blanks. A lathe or milling machine mills the basic shape of a drill from the steel. CNC machines are usually used, which can be programmed very precisely and then work more accurately than a human could ever do.
After this station, the blank already looks distinctly like a tap. The basic shape of the head, the shank and the square are already there.
3 step in the production of taps: hardening of blanks
And the blanks remain in this form for the time being, because now it's time for hardening. This step in the manufacture of taps is particularly important so that you later receive hard and durable tools that you can always rely on.
The hardening process in tap manufacturing begins in a vacuum furnace. Here, the blank is first heated to a high temperature and then quenched, i.e. quickly cooled. But this is not the end of the process. The blank is now tempered at least three more times. Tempering is a heat treatment in which a blank is heated and cooled several times. The tempering temperature is significantly lower than the temperature during initial heating. Tempering relieves stresses in the steel and ensures that the hardness is evenly distributed.
4. step in the production of taps: grinding
The next step in the manufacture of thread cutters is grinding. This is where the blank is given its final shape. Grinding is the heart of tap manufacturing, as this is where important quality factors are determined. A perfect grinding pattern is important for the sharpness of the tap and reduces friction during subsequent use, allowing the tool to slide effortlessly through the material.
Grinding takes place in several steps as part of the tap manufacturing process and is performed using state-of-the-art machines. First, the grooves are ground into the blank. This is followed by the actual thread. Here, very special care is required in the manufacture of thread cutters. Profile and size are refined until everything fits perfectly. Only then can the gate be ground. And at the very end, the shank is also ground during cylindrical grinding.
Now the tap already looks to the naked eye as you know it from our store!
5. step in the production of taps: Superfinishing
Superfinishing, also called microfinishing, is the freestyle in the manufacture of thread cutters. In this step, final blemishes such as burrs or grinding residues are removed and cutting edges are prepared. Special processes such as sandblasting or drag grinding are used. However, we cannot go into this in such detail. Because how we at BAER as a tap manufacturer proceed exactly is a well-guarded company secret. The preparation of the cutting edges is a decisive quality criterion that separates the wheat from the chaff. No wonder that no manufacturer of thread cutters likes to be shown their cards!
The changes caused by ultra-fine machining can hardly be seen without a magnifying glass. But you will notice them during use at the latest, when your tap glides through the material like through butter.
6. step in the production of taps: Quality control and measurement
Whatever exactly happens during precision machining, in the end it must ensure that the tap successfully passes the in-house quality control. Here, every tool is once again put through its paces and measured. Here, too, we employ state-of-the-art methods and use CNC measuring machines that use laser technology to detect even the smallest inaccuracies. In some cases, however, it also makes sense to use analog methods. It's a good thing that we still know how to use traditional measuring instruments, such as a micrometer!
When the tap leaves quality control, it meets all specifications and is ready for use.
7. step in tap production: labeling/storage
As a tap manufacturer, we are proud of our products and can claim with a clear conscience that the manufacture of our taps meets the highest standards. That is why we also like to write our name on every tool. This is done with a laser marking system that also applies other markings to the shank, such as the material quality, dimensions and thread tolerance. So in the end, you always know which tap you have in your hand.
Now the production of the tap is finally completed and it is ready for storage. For this purpose, the tools are carefully packed in boxes and stored in shelving systems with pull-out drawers. This way we always keep an overview and have quick access to every tap.
8. step in the manufacture of taps: Shipping
The taps remain in the warehouse until an order is received. Thanks to a sophisticated inventory tracking system, we always know exactly how many taps of a type we have in stock and where they are stored. This enables us to react quickly and soon after the order is received, the desired tools then already find their way into the shipping carton. We attach great importance to packing everything safely and stably. We are supported by packaging machines, which take over part of this task. We are also happy to accommodate customer requests. For urgent orders we ship by courier and even bulk orders on a pallet basis are no problem thanks to modern logistics!
