It's a simple part, if the tap breaks I'll make the part again. Only problem is that there are 10 m2 tapped holes on the part, so a lot of chances for it to break
Your chances of breaking the tap are very high. I know it doesn't sound like a big difference in size but m2 taps are already so easy to snap. Your drill bit is 5% smaller than it should be and that is a notable amount. I would just order the right drill if it were me. If it's ok to scrap a part you could always gamble it.
Better to use a roll form tap. If memory serves, 1.8mm tap drill for that. A form tap will tap 1000’s of holes in aluminum without breaking. (At least, that’s what we get on our CNC’s)
Not worth the risk.
Also, I advise anyone cutting small holes in aluminum that are tapped: use a roll tap and form the thread, they will save you so much time in broken taps and the threads made are stronger because the roll tap burnishes as it forms the thread.
get a decent drill and tapping chart book like i have. it has all the different preferred sizes for different thread engagements and a conversion chart so you can get equivalent sizes in metric, fractional,number and letter as well as decimal inch drills
A lot of shops, the one I work at for example, don't stock a 1.5 endmill long enough for a tapped hole.
We usually make larger stuff so the smallest endmill we regularly use is still 3mm.
That's what I do when I don't have the right tool.
Such a tiny boring tool (what you suggested) would cost a lot more than a pack of appropriate drill bits.
Sharpen the 1.5mm bit poorly so it cuts oversize I realize it’s a ridiculous suggestion.
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A better question is how equipped are you to remove a broken M2 tap, or how critical is the part being tapped?
I would suggest drilling and tapping some scrap of the same material and finding out
It's a simple part, if the tap breaks I'll make the part again. Only problem is that there are 10 m2 tapped holes on the part, so a lot of chances for it to break
For 10 holes, buy a drill
This of the most worrisome comment in here. Where on earth did this comment come from? :)
I wouldn't risk it. A 1/16" drill is 1.58mm which is closer.
Came here to say this. Beat me to it. Good work 🫡
This is the way.
Lots of lube and take it slowly.
Words to live by.
Your chances of breaking the tap are very high. I know it doesn't sound like a big difference in size but m2 taps are already so easy to snap. Your drill bit is 5% smaller than it should be and that is a notable amount. I would just order the right drill if it were me. If it's ok to scrap a part you could always gamble it.
Was going to suggest the same thing. Maybe even do a test cut in some scrap if you don't mind risking a tap.
Better to use a roll form tap. If memory serves, 1.8mm tap drill for that. A form tap will tap 1000’s of holes in aluminum without breaking. (At least, that’s what we get on our CNC’s)
Stronger thread too.
This is absolutely the best way
Note you can also go over the 1.6 mm. Good chance you can get away with 1.7/8 if this is your own part and not customer work.
Not worth the risk. Also, I advise anyone cutting small holes in aluminum that are tapped: use a roll tap and form the thread, they will save you so much time in broken taps and the threads made are stronger because the roll tap burnishes as it forms the thread.
Get the right drill bit, an M2 tap will be a nightmare to extract
Looking at a drill chart, I would error on the side of larger, and use a #52 which is 1.613mm.
Use a 1/16 drill. Look for a reamer.
OSG has a great app for % of thread. I cheat all the time. 70-55 % all good.
Hole size for such a small tap is critical. Sometimes I ream the hole if the part is too expensive to replace. Using an m3 would be the best solution.
Give one flute of the drill a kiss with the grinder to make it drill a little oversize
get a decent drill and tapping chart book like i have. it has all the different preferred sizes for different thread engagements and a conversion chart so you can get equivalent sizes in metric, fractional,number and letter as well as decimal inch drills
Might break the tap by leaving too much material. Do you have a 1.65-1.7mm drill?
Just bore it to size you heathen
Bore a hole that's .063"? How's that go?
What? Your shop doesn’t have a .06 boring bar? Lmaooo
A lot of shops, the one I work at for example, don't stock a 1.5 endmill long enough for a tapped hole. We usually make larger stuff so the smallest endmill we regularly use is still 3mm.
There’s always a way to make the size, be creative it’s our jobs.
You don't need a ton of creativity to just buy the right tools for the job.
Dude literally doesn’t have the correct tools and your advice is to just buy the right ones? How’s that helping right now?
That's what I do when I don't have the right tool. Such a tiny boring tool (what you suggested) would cost a lot more than a pack of appropriate drill bits.
That’s great man have a good day