In manufacturing, knurling is a finishing process used to create any combination of

horizontal, vertical or crossing lines on the surface of a workpiece. For example,

if a manufacturing company wants to add a diamond-patterned texture to a product —
or a component of a product — it may use knurling. Knurling can be performed either
by hand or by machine, both of which allow for the creation of a textured surface.

Overview of Knurling
Even if you’re unfamiliar with knurling, you’ve probably seen a knurled product or
object before. Hammers, wrenches and other hand tools are often manufactured with a
knurled grip. When performed on the grip, knurling creates a patterned texture to
prevent hand slippage. Knurling doesn’t add material to the grip. Rather, it
creates the textured surface either through pressure or by cutting away some of the
material.

Knurling tools are designed with a specific pattern that, when pressed against a
workpiece, creates the same pattern. By using a tool with a specific pattern,
manufacturing companies can achieve the same textured pattern on their products.

Hand vs Machine Knurling

There are two primary ways to perform knurling: by hand or by machine. The former
involves the use of a rolling roll that creates the desired pattern as it’s pressed
against the surface of the workpiece, whereas the latter involves the use of a
lathe to cut the desired pattern into the workpiece.

Hand knurling is the most basic method, requiring nothing more than small roller
tool. As the worker runs this tool across the surface of a workpiece, it leaves
behind a textured surface in the pattern of the tool’s indention. Machine knurling,
on the other hand, is a more complex process that requires a lathe. Unlike hand
knurling, machine knurling doesn’t create textured surfaces through pressure.
Instead, it uses a bit to cut the material out of the workpiece.

The Purpose of Knurling

Knurling can enhance the aesthetics of a product by introducing an attractive
pattern to its surface. Most people will agree that textured finishes are more
attractive than smooth finishes. Aside from aesthetics, though, there are practical
reasons for manufacturing companies to perform knurling.

Products that require gripping, such as hand tools, are often knurled to improve
their performance and usability. If a hammer has a smooth grip, the user’s may hand
slip while attempting to hold and use it. Knurling protects against this hand
slippage by creating a textured pattern that’s easier to grip.

KNURLING ON THE LATHE

Knurling is a process of impressing a diamond shaped or straight line pattern

into the surface of a workpiece by using specially shaped hardened metal wheels to
improve its appearance and to provide a better gripping surface. Straight knurling
is often used to increase the workpiece diameter when a press fit is required
between two parts.

Holding Devices for Knurling

The setup for knurling can be made between centers or mounted in a solid chuck.
Never attempt to knurl by holding the work in a rubber or metal collet chuck, since
the great pressures of knurling could damage these devices. It is important to
support the work while knurling. If mounting the work between centers, make the
center holes as large as possible to allow for the strongest hold. If using a chuck
to hold the work, use the tailstock center to support the end of the work. If doing
a long knurl, use a steady rest to support the work and keep the piece from
springing away from the tool.

Knurling Tools

The knurling tool (Figure 3-10) can be designed differently, but all accomplish
the same operation. Two common types of knurling tools are the knuckle joint and
revolving head type of knurling tools. The knuckle joint type is equipped with a
single pair of rollers that revolve with the work as it is being knurled. The
revolving head type of tool is fitted with three pairs of rollers so that the pitch
can be changed to a different knurl without having to change the setup. There are
two knurl patterns, diamond and straight.

There are three pitches of rollers, coarse, medium, and tine (Figure 3-91).

The diamond is the most common pattern and the medium pitch is used most often.
The coarse pitch is used for large-diameter work; the fine pitch is used for small-
diameter work.

Knurling

The knurling operation is started by determining the location and length of the
knurl, and then setting the machine for knurling. A slow speed is needed with a
medium feed. Commonly, the speed is set to 60 to 80 RPM, while the feed is best
from 0.015 to 0.030 inch per revolution of the spindle. The knurling tool must be
set in the tool post with the axis of the knurling head at center height and the
face of the knurls parallel with the work surface. Check that the rollers move
freely and are in good cutting condition; then oil the knurling tool cutting wheels
where they contact the workpiece. Bring the cutting wheels (rollers) up to the
surface of the work with approximately 1/2 of the face of the roller in contact
with the work.

If the face of the roller is placed in this manner, the initial pressure that is
required to start the knurl will be lessened and the knurl may cut smoother. Apply
oil generously over the area to be knurled. Start the lathe while forcing the
knurls into the work about 0.010 inch. As the impression starts to form, engage the
carriage feed lever (Figure 3-92). Observe the knurl for a few revolutions and shut
off the machine. Check to see that the knurl is tracking properly, and that it is
not on a "double track" (Figure 3-93).