I've been meaning to watch through your series for a while, now that I'm getting some hands on experience it's definitely time to do so.

By the way, check out the link in my signature. I've got an entire Basic Post Processing Class which was recorded back in 2016, which I've uploaded to YouTube. Be sure to watch the "Office Hours" video sessions, where we are doing the bulk of the "hands on" post development work.

You've got mail...

Next rounds on me!

Problem with form tapping it I don't find the one size fits all for all materials. Harder metals I might open it up a little more where as with Aluminum or Brass I will hold it almost perfect to the size needed. I have done 12mm x 1.5 mm Rounded Threaded recently and what a nightmare that turned out to be in 7075-T7651. We had to have the Taps EDM drilled so the High Pressure coolant would get to the threads. Without the coolant we could only do two holes before the taps got gummed up with aluminum. Then I have rolled formed Titanium 6al4V #2-56 holes and run 1000 holes with no issue then hit a batch of material no matter what we did they wouldn't thread form and had to be cut tapped. We were working with a customer in the last year having quality issues with a #8-32 thread formed features in HRS. They were not 3 flute drilling or reaming the holes to get a superior finish before form tapping them. They were losing one part in 10 because of this. Once they switched over to a 3 flute drill no more issues. If goes back to there is much art and figuring this stuff out sometimes as there is the science and math of what should work that sometimes doesn't. It takes some good old trail and error to figure it out.