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Thread rolling: chipless production of threads
Thread has been in use by humans for thousands of years, and over time, various manufacturing techniques have emerged. While we are passionate about thread cutting, we believe it's important to share the benefits of thread rolling with you. Each method has its own strengths and is suited for different applications and industries.
Today, we're focusing on **thread rolling**, a **chipless manufacturing process** also known as **thread forming**. Though "thread forming" is still used, "thread rolling" has become more common in everyday language. We'll explain what makes thread rolling unique, how it works, and whether it's worth considering for your workshop.
### What Makes Thread Rolling Unique?
The key feature of thread rolling is that it’s a **chipless process**. Unlike thread cutting, which removes material to create the thread profile, thread rolling uses **cold forming**. This means the material is **re-shaped without cutting**, and the **fibers remain intact**. As a result, there are **no chips produced**, making it a cleaner and more efficient method.
### Different Types of Thread Rolling
There are several ways to roll threads, all involving **rolling dies or thread rolling tools**. These are round rollers with the desired thread profile. As they rotate, they apply pressure to displace the material into the grooves, forming the thread. Because of the high friction involved, **lubrication is essential** for smooth operation.
The two most common methods are the **plunge method** and the **through-feed method**.
#### Plunge Method
In the plunge method, the workpiece is placed between open rolling dies. The rolls rotate and press into the blank, creating the thread profile in one pass. This method is ideal for shorter threads and offers **high precision** and **fast processing times**.
#### Through-Feed Method
With the through-feed method, the workpiece moves through the rolling dies. The dies have three sections: an **entry cone**, a **calibration area**, and an **exit cone**. This allows for the production of **longer threaded parts**, limited only by the length of the blank.
### Advantages of Thread Rolling
One of the biggest benefits of thread rolling is that it **preserves the material fibers**, leading to **better surface quality** and **increased wear resistance**. It’s also very fast per thread, making it ideal for **mass production**. Additionally, since no chips are created, it reduces cleanup and waste.
Another advantage is **material savings**. The blank used in thread rolling is smaller than the finished part, which helps reduce raw material usage compared to cutting.
### Challenges of Thread Rolling
Despite its benefits, thread rolling has some limitations. For example, it **can't produce internal threads**, as it’s designed for **external threads only**. Also, not all materials are suitable—only those that can be **cold-formed** and have **sufficient elongation at break** (typically 12% or more) work well. Materials like hardened steel, cast iron, or titanium may not be ideal due to their low ductility.
Additionally, certain thread profiles are harder to roll. Sharp, standard screw threads (like 60° or 55°) are easy to roll, but **round or vertical-flank profiles** require much higher force and often don’t yield good results.
### Is Thread Rolling Better Than Thread Cutting?
If you're doing occasional threading in a DIY project or small workshop, traditional taps and dies are still the best choice. Thread rolling requires **specialized equipment**, which can be costly and take up space. Unless you're producing large volumes, the investment may not be justified.
However, if you need **rolled external threads**, it's usually best to **consult a professional manufacturer**. In most cases, using **high-quality threading tools** will give you better results.
As a **thread tap manufacturer**, we’re here to help. If you have any questions, feel free to explore our **BAER online shop** today!
Filtration wire cloth is a type of metal mesh used for various filtration applications. It's made by weaving or drawing wires into a mesh structure, which can then be used to filter out particles from liquids or gases.
Here are some key aspects of filtration wire cloth:
1. Materials: The wire used can be made from a variety of metals including stainless steel, brass, bronze, copper, and nickel. Each has its own characteristics in terms of corrosion resistance, strength, and conductivity.
2. Weaving Techniques: Filtration wire cloths are woven using different techniques like plain weave, twill weave, and reverse weave. These techniques affect the pore size and overall structure of the mesh.
3. Pore Size: The size of the openings (or pores) in the wire cloth determines its filtering capability. Smaller pore sizes are needed for finer filtration, while larger pore sizes are sufficient for coarser materials.
4. Applications: Filtration wire cloth is used in a wide range of industries including food processing, pharmaceuticals, chemical processing, and oil & gas. It can be used in filters for water purification, air filters, coffee filters, and more.
5. Quality Control: The quality of the wire cloth is important as it affects the efficiency of filtration. Factors like mesh count (number of openings per linear inch), wire diameter, and weave pattern all contribute to its performance.
6. Customization: Wire cloths can be customized to meet specific needs, such as custom dimensions, materials, and surface treatments (e.g., electroplating, anodizing).