If chips are building up and not breaking during tapping, what should be done?
Back off the tap to break and clear chips
Tapping cuts an internal thread, and the chips produced must break into short pieces and escape through the tap's flutes; if they stay long they pack the flutes and the hole.
Packed chips wedge the tap, sharply raising the cutting torque and often snapping the slender tap inside the workpiece, which is very hard to remove.
The correct practice is to back off, that is reverse the tap by a part-turn every so often, so the cutting edges fracture the chip and let the pieces fall clear of the flutes before cutting resumes.
Applying more torque to a tap that is already loading up (option 1) only drives it toward breakage rather than clearing the chips.
Increasing the tapping speed (option 3) makes chips form faster and pack the flutes even more tightly, worsening the jam.
Reducing the cutting fluid (option 2) removes the lubrication and flushing that help chips slide out, so it hinders rather than helps chip clearance.
Hence, the answer is Back off the tap to break and clear chips.
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