Threads have been around for thousands of years, crafted by human hands over countless generations. Over time, various manufacturing techniques have emerged, each with its own unique strengths and limitations. Although our hearts lean toward thread cutting, we couldn’t leave out thread rolling—it’s just too important! Both methods have their merits and are ideal for specific industries or applications.
Today, let’s delve into the chipless manufacturing process of thread rolling—or thread forming, as it’s also known. The two terms refer to the same technique, with thread rolling being the more commonly used term in everyday conversations. We’ll explore what makes thread rolling stand out, how it functions, and whether it deserves a spot in your workshop.
### Thread Rolling: A Chipless Manufacturing Process
At its core, thread rolling sets itself apart from thread cutting because it’s a chipless manufacturing process. Unlike thread cutting, where material is removed to create the desired thread profile, thread rolling employs cold forming. This means the material is compressed and shaped into the appropriate form without cutting away any pieces. As a result, the fibers in the material remain intact, leading to superior surface quality and durability. Importantly, no chips are produced during this process.
### Varieties of Thread Rolling Techniques
Thread rolling can be achieved through several methods, all of which rely on rolling dies or thread rolling dies. These cylindrical tools feature the desired thread profile engraved on their surface. When rotated, they apply pressure to the workpiece, displacing the material into the grooves and forming the thread peaks. High frictional forces are involved, making proper lubrication essential for all rolling methods. Two of the most common approaches are the plunge method and the through-feed method.
#### Plunge Method in Thread Rolling
In the plunge method, the blank is positioned between open rolling dies. As the rotating dies approach the blank, they exert frictional pressure, plunging the thread profile directly into the workpiece. One key limitation of this method is that only a single thread length, equal to the width of the dies, can be created in one operation. However, it offers exceptional precision in terms of pitch and profile, and the processing speed is impressively fast.
#### Through-Feed Method in Thread Rolling
With the through-feed method, the blank moves continuously through the rolling dies instead of remaining stationary. These dies consist of three distinct sections: an entry cone, a calibration area, and an exit cone. This setup allows for the production of longer threaded rods, limited only by the size of the blank. It’s a versatile approach for creating extended threads.
### Benefits of Thread Rolling
One of the standout advantages of thread rolling is the preservation of the material’s integrity during formation. Rolled threads boast excellent surface quality and are highly resistant to wear. Processing time per thread is minimal, making it ideal for mass production. Thread rolling is widely adopted in industrial screw manufacturing for these reasons. Additionally, it significantly reduces raw material usage since the blank is smaller than the finished product, unlike thread cutting tools that save less material. Furthermore, the absence of chips eliminates chip-related issues and cuts down on cleanup efforts.
### Challenges of Thread Rolling
A notable quirk of thread rolling is its inability to produce internal threads. Due to the rolling die-based process, thread rolling is strictly for external threads. Not all materials are suitable for this technique, as the material must be easily cold-formable and possess a high elongation at break. Elongation at break measures a material’s deformability, expressed as a percentage. Materials with 12% or higher elongation are ideal for thread rolling, while those below 8% generally yield poor results. Hardened steel, cast iron, titanium, and some aluminum alloys fall outside the range of materials that can be effectively rolled due to their low elongation values.
Another challenge lies in the thread profile. Since the profile is created by pressing the material into the grooves of the rolling dies, not all profiles are equally compatible. Standard sharp threads with 60° or 55° flank angles, such as those found in fastening screws, are straightforward to roll. Trapezoidal and saw threads are slightly more complex but still manageable as long as their flanks are adequately inclined. Creating round threads requires immense rolling force to achieve optimal results, while vertical-flank profiles are entirely incompatible with this method.
### Should You Opt for Thread Rolling?
Clearly, if you’re occasionally threading items for personal projects or in a small workshop, sticking with traditional taps and dies is the way to go. While thread rolling offers benefits, they become relevant primarily in large-scale production settings. The substantial investment in specialized rolling machinery might not justify itself for smaller operations. For external threads requiring rolling, outsourcing to a professional manufacturer is often the best option.
For all other scenarios, high-quality threading tools remain the superior choice. As a manufacturer of thread taps, we’re here to help address any queries you may have. Visit our BAER online shop to explore our offerings!
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