Thread manufacturing

Processes
- Viral Patel
 Introduction:
 Thread is ridge of uniform cross section in the form of a helix
provided on the outside or inside of a cylindrical or conical
surface.
 External threads are provided on bolts, screws while internal
threads are on corresponding nuts or any machine members.
 Functionally fasteners are threaded for holding component
securely.
 Thread manufacturing is a very important manufacturing
activity because of huge demand of high precision fastening
devices and power transmission systems.
Elements of Screw thread:
 Major Diameter
 Minor Diameter
 Pitch Diameter
 Pitch
 No. of start ( Independent thread
on job surface)
 Lead hand
 Form
ISO Metric thread
V-Thread
Square thread
British standard Whitworth
British Association
American nationals
Acme thread
Knuckle Thread
Methods of Thread manufacture:
1. Thread cutting on Lathe
2. Thread Chasing
3. Die threading
4. Tapping
5. Thread Milling
6. Thread rolling
7. Thread Grinding
8. Thread casting
9. Thread Whirling
 Thread cutting on Lathe
 Principle is to produce helical groove on a cylindrical or conical
surface by feeding tool longitudinally when job is rotating.

 Steps :
1) Selection of cutting tool
2) Mounting of cutting tool and workpiece
3) Establish relation between longitudinal movement of cutting
tool and work piece rotation.
4) Thread Cutting
5) Tool feeding and Thread catching
 Thread Chasing:
 It is method of thread cutting with the help of multi point cutting
tool called thread chaser.
 Chaser types:
1) Hand Chaser
2) Threading tool Chaser

 Hand chaser is worked manually by hand during operation with

provision of suitable support.
 Threading tool chaser has two useful forms as Flat type and
Circular type. Both are fixed in tool holder and used for cutting
thread in large scale production.
 This chasers consist Cutting teeth for cutting operation and
Sizing teeth for finishing operation.
Arrangement of Thread Chasing on Turret Lathe

 In machine, lead screw is rotated by head stock of machine

by means of changing gears.
 On shaft, feed nut and tool slide are mounted which can
be engaged and disengaged with lead screw by hand
operated lever.
Die Threading:
 External threads cutting on cylindrical or taper surface by
means of Solid and self opening dies is called die threading.
 Dies are look like nuts but it is made of Hardened Steel or HSS
with sharp cutting edges.
 This dies are coaxially rotate around the blank.
 Types of Die
1) Solid die
2) Self opening die
 Solid
dies

Spring Split Pipe

Die die die

In Spring dies elastically

reduction in bore is
possible and cut threads in
number of passes.
In Split die , die is made
in two pieces. One is fixed
and other is moving within
cavity of wrench.
Pipe dies cut threads on
pipes having large
diameter and smaller
pitch.
 Self opening
dies

Radial Tangential Circular

die die die

It opens automatically when

disengage from w/p.
These dies are used in Turret
lathe and special threading
machine.
All dies having four sets of
adjustable multi point cutters
or chasers.
Working:
Mounted in turret and moves
towards w/p, when measured
length completed die gets
pulled and open
automatically for free
returns. video
Tapping:
 Tapping is Thread cutting process for producing internal threads.
 Multipoint cutting ( Tap ) is used like die threading and cutting
may be done manually or on machines.
 In machine , process is similar as manual tapping except feed
being automatic and threads will be high accurate and uniform.
 During machining features like fast retraction of the tool,
automatic loading or unloading, use of multiple spindles;
machining rate will considerably increased.
 Taps are classified as Solid taps and Collapsible taps.
Solid Taps:
 It is one piece construction and
similar to threaded bolt with four
flutes to provide cutting edges.
 It is used for small diameters and
worked manually. So it is also
known as hand taps.
 Taper tap, Plug tap and Bottoming
tap are used as Solid tap.
 Taper tap is tapered at starting for
six threads to make entry easy.
 Plug tap is also chamfered little for
few threads and it is used as
second tap after removing first
tap.
 Bottoming tap is used after second
tap to cut thread up to the bottom
of the hole. Video
Collapsible taps:
 It is tool which collapse inwards
automatic when thread is
completed.
 It permits return without
unscrewing . So speed of
operation is increased.
 Due to machining surface finish is
good .
 The taps are provide with trip
plate which set accordingly the
length of thread to be cut.
 Video
Thread Milling:
 Threads produced by milling
process. By using form cutter (
single form cutter and multiple
form cutter ) threads are
manufactured on rotating work-
piece.
 When milling suitable:
 For producing internal thread
which are not suitable to cut
with tap.
 Work on large diameter
beyond the capacity of die.

Video…
 In case of single form cutter
blank is rotating slowly and
cutter is precisely moved along
the axis of blank.
 Threading is completed in one or
more passes depends on the
depth of the thread.
 The multiple form cutter have
several annular rows of cutting
teeth made by flanks or gashes.
 Same as single form cutter ,
spindle is set parallel to work
axis and this process is suitable
for threads for small distance.

 Thrilling is combined process of

threading and drilling by using
specialized cutting tool on a CNC
milling machine. THRILLING
Thread Grinding
 The principle of thread grinding is similar to thread milling.
Grinding is done by using specially dressed grinding wheels.
 Grinding wheel may be of single rib type or multi rib type and
process is suitable for hard materials for which other methods of
thread cutting is not possible.
 Types of thread grinding
1) Pass over grinding
2) Plunge grinding
3) Centre-less grinding
Pass over grinding
 It is similar to threading on
lathe but single point cutting
tool is replaced with grinding
wheel.
 In single wheel rib wheel
turns against rotation of work
and axial motion is provided
with accurate lead screw.
 Thread is not completed in
single pass. Multiple pass are
required to complete thread
up to certain depth.
 It is also known as transverse
thread Grinding.
Plunge Grinding

 In Plunge grinding , wheel is

having multiple ribs and it is
longer than the length of the
desired thread.
 The Plunge grinding is mostly
used for short length threads.
Example : Thread on shaft
ends.
 Method is suitable when
production is more
important than accuracy.
Centre less thread grinding

 This process is used to make

headless set screws.
 Work is fed between
regulating wheel and
grinding wheel where
threads are fully formed.
 Production rate is 60 to 70
(13 mm long) pieces per
minute.
Thread Rolling
 It is cold forming process used for making external threads on
cylindrical w/p.
 Threads are formed into blank by pressing thread rolling die
against the blank.
 Faster method of production
 Skilled labor not required , so it is economical method of thread
making.
 Chip less operation, no wastage of material.
 Threads produced by rolling have good quality and high
accuracy.
 Thread rolling increase tensile and fatigue strength of work
material but rolling process is limited to ductile materials.
 Thread rolling machines:
1) Reciprocating Flat die machine.
2) Cylindrical two/three die machine.
Flat die machine
 Two dies are used. One is
bottom die which remains
stationary and another is
reciprocating die.
 Blank is placed on stationary
die and then moving die
slides over the blank. Due to
such action blank roll
between two dies and
threads are formed.
Cylindrical die machine
 Cylinder die machine use two
/ three dies.
 Incase of two die machine as
shown in figure work blank is
supported between two dies.
 Incase of three die machine
one die is move radialy
outward for let the work
blank enter between die and
then closes and rotate to roll
threads.
Thread Casting:

 In casting and molding threads are directly formed by

geometry of cavity in the mold or die.
 Thread made by sand casting are rough and not used except
sometimes in vises and rough machinery.
 Compare to other casting method lost wax method produce
more accurate threads with good surface finish but it is costly
process .
 Due to poor accuracy cast threads are used in such cases
where only few threads are required over short length.
Example : Thread on Soda bottle
 Thread Whirling
 Thread Whirling is a form of
the Thread Milling process
with the exception that the
cutters are mounted on the
inside of a Cutting Ring or
Cutter Holder rather than the
outside of a milling tool.
Advantages of Thread Whirling:
 Deep Threads
 Faster Setup
 Increased Productivity
 Increased Tool Life