What Is Thread Rolling and Why Is It a Popular Choice Among ...

Thread rolling is cold metal or cold forming process that produces threads by the means of precision thread rolling dies that are the replicated image of the thread generation. This a different process from others such as grinding, chasing and cutting since it does not eliminate metal in order to produce the intended profile. In this process, these hardened steels dies move and quickly form ductile metals in a precision fashion that achieves the intended form. At ITW Shakeproof Industrial, we can help you find the right steel thread rolling screw for plastic or metal you need for your application.

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Higher Quality and Accuracy

Thread form rolling is a highly accurate method of producing thread form geometry and usually surpasses thread form requirements, due to the finish and accuracy in the thread roll dies used. As a result of the accuracy and high precision in the thread rolling tools, thread rolling naturally preserves the accuracy of the original arrangement during high speed production long runs.

Produce Higher Strength Joints

The cold working process increases tensile strength at least 30 percent more than cut thread, which raises the thread strength. In addition, the rolling thread process increases fatigue strength in the range of 50% to 75%. Even when threads are heated up to 500° F for multiple hours they retain their fatigue strength. Selecting a rolled thread process instead of a cut thread process produce strong threads with the requirement for external heat treating. With the production of thread rolling screws, metal is not removed and high joint strength is achieved.

Higher Quality Finish

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The process of rolling generates an exceptional burnished finish. The mechanical polishing process of burnishing enhances the quality of the surface as the dies compress and shape the rolled material. Enhanced wear resistance comes from a high-quality finish and this is important since many of the nuts engaging a leadscrew are plastic.

Lowers Costs

Compared to full size cutting stock, thread rolling stock has a smaller diameter and none of the wasted material. As a result, regular processing does not produce scrap. The speed of a thread rolling surface feeds per minute can be as high as 10 times the speed of single point thread cutting feeds. The higher production per roll set results in significantly lower costs per thread.

When it comes to the production of true thread profiles, thread rolling is much more efficient of a process than thread chasing. Lower costs result from lower cost of tool per thread, less labor, and no scrap.

When the quality of connections is vital, thread rolling and thread forming screw manufacturers can provide various screw solutions. Rolled threads, in particular, provide exceptional finish, enhanced mechanical properties, economy, finish, accuracy, and excellent quality.

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Does anyone here have any experience with thread rolling on a CNC lathe. What are the pros and cons of thread rolling, compared to regular threading with a threading tool. The threads we cut are no larger than 2", so nothing to big. Just looking for some info. as i have no experience with thread rolling but have heard it is way quicker, and produces a stronger thread.

Have you ever Knurled on a cnc lathe?? if you have you know how much pressure that requires.... Now imagine the pressure required to roll a thread?

Have you ever seen a Thread Rolling Machine?...
Remember the little old lady that asked.. WHERE's the BEEF ????
The BEEF is in the Thread Rolling Machinery.
Now go look at your lightweight cnc lathe and ask yourself... WHEREs the Beef?

Have you ever Knurled on a cnc lathe?? if you have you know how much pressure that requires....

Whether it's on a manual or CNC lathe, I think this antiquated process should be avoided whenever possible. At our school, we have simply been designed it out of student projects and replaced it by milled grooves which look nicer and are far easier to repeat.

Like you, I would be reluctant to apply the required pressure for either knurling or rolling due to the lack of "feel" on a CNC. I've done a lot of small-diameter thread rolling on CNC Swiss type lathes. No problem at all, as long as the driving spindles and axis servos have torque. The biggest I've done personally was a M12 x 1.0 in S-7 shock steel, using a Fette head very similar to the one in the photo. For threads under 5mm (.200"), I used the Habbeger rolling heads available in the US from Allouette Tool of NY. Great stuff, and a nice strong thread.

As for knurling, I've had to do that just as often as threads. I don't understand why something that fundamental would be removed from a trade school curriculum. Many parts we make have knurls, and that is not ever going to change in favor of "cool looking little grooves." Dumbing down our students, way to go. Thread rolling

As Pixman said, thread rolling makes a great thread. We have used a Fette head for threads up to 1/2 on our Okuma lathes. I have had no problems with excessive torque, rather with the set-up of the tool itself. Stock must be turned under-size and if the thread length is long can pose a problem if done on other than swiss machine due to part deflection. Fette has provided us formulas for starting diameter and speed for various materials. We have successfully rolled threads on copper, nickel, mild steel and 300 series stainless. The biggest pain for us has been the adjustment of the rolling head to get the thread to gage properly. If you get anything wrong, your part length can grow, the thread be too loose or even snap off. If you get everything right, you get a perfect, strong thread in one very quick pass. We generally only use the head for high volume jobs. I too can't imagine rolling a thread as two inches, at least not with our equipment.

BTBB

I've As for knurling, I've had to do that just as often as threads. I don't understand why something that fundamental would be removed from a trade school curriculum. Many parts we make have knurls, and that is not ever going to change in favor of "cool looking little grooves." Dumbing down our students, way to go.

Ok, here's the deal:

Suppose you have 50 hours of shop time with these students over the space of a year. What skills should take priority during this modest time frame?

Knurling generates terrific side loads on the tailstock center and tends to force work into a chuck, which may cause the center to stop supporting the work.

Knurling tools at a school are usually DULL, same as the bench files.

Knurling tools have to be "phased" with the diameter or the pattern will be poor.

At semester's end, the student with the best knurl is probably one of the worst machinists, as the instructor made the knurl.

So, in a trade school with considerably more shop hours, knurling could still be taught but only after more basic skills like turning an accurate diameter, grooving, setting a boring bar and producing single point threads are mastered.

To me, all of those skills should take precedence over knurling. Gee, guess where I learned to take my time to understand why a knurl didn't come out right? Where did I learn the limits of tool pressures on a belt-driven South Bend lathe while trying to knurl steel running on non-carbide tipped dead centers with dull knurls and crappy scrap bin material?

Trade school. And I am VERY grateful for that opportunity. As a matter of fact, I graduated from that school in . One of my most motivating teachers rarely gave me answers, but asked me LOTS of questions that usually started with "Why do you think that..."

I went to visit him just yesterday to again thank him for inspiring me to strive for excellence. He had retired 21 years ago. Teach as much as you can by getting the students to think, and solve problems by understanding the mechanics of machining. Good grief guys .... I've been werkin eh?

I ran out of April hrs the first week of, and I keep git'n more stuff in every day that is HOT!

Anyway - Yeah - I roll some threads jist over 1" on the lathe - and that is a BIG head for flinging around on a turret!

For smaller threads 3/4 and especially 5/8 and smaller it would be much more feasible. I beleive the Fette make cross werking tools specifically for the CNC lathes. (I think I saw them at a show once all loaded up. (IMTS?) Maybe 6-8 yrs ago?)

I would also reccommend Reed units. (B10, B13) You may hafta design/build your own holder? I don't know if they have designed anything up for the lathes or not.

I have not seen hardly any rolling advertised for CNC's ever. Other than the dedicated units from Landis that they came out with a cpl yrs ago now. (I have never used)

Of course the endwerking units are simple and werk well for smaller sizes.

Anyone that thinks that this is an antiquated process, produces sub standard quality threads, or is somehow hard on the machine - obviously has had zero experience with this subject.


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Think Snow Eh!
Ox

How close would you be able to thread to a shoulder with thread rolling? And can you have any type of interrupted "cut" like a cross hole pre-drilled on the surface to be threaded. Also, if you had a 1.25" pin with a 3/4" thread on one end, could the 1.25" dia. actually go oversize near the thread?

Rolls typically have a 1+ lead chmfr. How close you want to try to git it to the shoulder is your business.

Shirley never tried rolling over top of a cross hole. I would expect no damage to the tool, the hole to be partially filled in, and the crests nearby to be cavitated.


BTW - 3 roll endwerking heads are dirt simple to set-up/run.

2 roll cross werking units can cause brain damage some days.


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Think Snow Eh!
Ox