Making threads by various methods

Mechanical ingineering

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 Summary

I. Introduction.................................................................................................................................... 3
II. General equipment needed to make resistance welding ............................................................... 4
III. General vocabulary related to threading ........................................................................................ 5
IV. The various methods for making threads ....................................................................................... 6
A. Threading by turning .................................................................................................................. 6
1. General principle .................................................................................................................... 6
2. Part to be made in the laboratory .......................................................................................... 7
B. Tapping a hole - Drilling .............................................................................................................. 7
1. General principle .................................................................................................................... 7
2. Part to be made in the laboratory .......................................................................................... 8
C. Threading by multi-tool machine ............................................................................................... 8
1. General principle .................................................................................................................... 8
2. Part to be made in the laboratory .......................................................................................... 9
D. Treading by deformation – Rolling machine ............................................................................. 10
1. General principle .................................................................................................................. 10
2. Part to be made in the laboratory ........................................................................................ 10
V. Conclusion .................................................................................................................................... 11

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 I. Introduction
Thread production is a fundamental process in the field of mechanical engineering, essential across
numerous industries for ensuring the assembly and fastening of parts. Creating precise and reliable
threads holds crucial significance in manufacturing components used in various sectors such as
automotive, aerospace, construction, and more.

This report delves into the different methods of thread production, exploring both traditional
techniques and modern advancements that shape this pivotal process.

There are various advantages and disadvantages to making threads, depending on the methods used
and the specific applications. The following is a general list of the advantages and disadvantages
associated with the production of threads:

Advantages:

• Assembly and fastening: Threads allow secure assembly and fastening of mechanical parts,
providing a strong and reliable connection.
• Versatility: Threads find use across various industries and applications, from automotive to
aerospace, construction, and more.
• Standardized compatibility: Standardized threads (like metric threads) offer compatibility and
interchangeability among parts manufactured by different companies.
• Material adaptability: Thread production techniques can be adapted to various materials,
including metals, plastics, and even some composites.
• Automation: Modern methods of thread production, notably with computer numerical control
(CNC) machines, offer increased automation possibilities, enhancing productivity and
precision.

Disadvantages:

• Complexity: Some thread production processes can be complex and require specialized
equipment, leading to high costs and specific expertise.
• Time: Certain thread creation processes may take time, especially for manual operations or
when dealing with difficult-to-machine materials.
• Precision: Thread production requires high precision to ensure compatibility and functionality
of assembled parts. Any lack of precision can compromise assembly quality.
• Costs: Costs associated with purchasing specialized equipment, personnel training, and
maintenance can be significant, especially for advanced or automated methods.
• Material Limitations: Some materials might be challenging to thread due to their composition
or fragility, necessitating specific techniques or adapted tools.

It's crucial to consider these advantages and disadvantages when selecting the method of thread
production, taking into account specific production requirements and the needs of the final application.

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 II. General equipment needed to make resistance welding
The equipment needed to make threads depends on the method used. However, here is a general list
of equipment commonly used in the production of threads:

• Taps and Dies: For manual or automated tapping, sets of taps and dies suitable for the type of
threading (metric, UNF, UNC, etc.) are necessary.
• Tapping Machines: Dedicated machines for tapping, ranging from manual machines to
computer numerical control (CNC) machines for more precise and rapid operations.
• Thread Rolling Machines: These machines are used to roll threads on rotating parts, providing
precise and durable threads.
• Thread Cutting Machines: For producing more complex threads, especially for gears and helical
threads, specialized cutting machines are required.
• Cutting and Shaping Tools: End mills, milling cutters, reamers, and other cutting tools for
creating threads on workpieces.
• Computer Numerical Control (CNC) Machines: Used to automate and precisely control the
thread production process, offering high precision and repeatability.
• Measurement and Control Devices: Vernier calipers, thread gauges, and other measuring
instruments to ensure the accuracy and compliance of threads with required specifications.
• Lubricants and Cutting Fluids: Special lubricants and cutting fluids are used to reduce friction
and dissipate heat during the threading process, improving thread quality and extending tool
life.
• Safety Equipment: Eye protection, gloves, and other safety gear necessary to ensure operator
safety when using manufacturing equipment.

This list is not exhaustive and may vary depending on the specific method of thread production as well
as the needs and requirements inherent in each manufacturing process. In this report, we will look at
4 methods of threading that require different equipment.

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III. General vocabulary related to threading
To understand what threading is, you need to understand the vocabulary associated with it. Below is a
list of technical vocabulary related to threading:

• Root: The inner-most part of the thread.

• Crest: The outer-most part of the thread.
• Pitch: The distance from the crest of one thread and the next one (typically measured in mm)
• Thread angle: The angle between the flank of a screw thread and the perpendicular to the axis
of the screw.
• Thread flank: The straight sides that connect the crest and the root.
• Pitch diameter: The distance of two opposite flanks or the distance of the centerline of the
profile.
• Minor diameter: The diameter determined by the groove of the thread.
• Major diameter: The diameter determined by the thread tips.

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IV. The various methods for making threads
A. Threading by turning
1. General principle
The general principle of creating a thread by turning involves several significant steps:

First, the workpiece preparation. Initially, a cylindrical workpiece is secured in a lathe. This piece must
have a diameter suitable for the intended thread. Now we need to select our cutting tool. A cutting
tool suitable for the required thread type is mounted on the lathe's tool post. This tool has a specific
shape corresponding to the profile of the thread to be machined. After that, programming or manual
setting of the lathe. If a computer numerical control (CNC) lathe is used, the threading program is
loaded or programmed into the machine. For a conventional lathe, manual adjustments are made to
determine the rotational speed, feed rate, and cutting depth. The lathe is now started, and the cutting
tool contacts the rotating workpiece. The tool progressively advances along the axis of the workpiece
to cut the thread grooves according to the specific required profile. During the turning process, a
lubricant or cutting fluid may be used to reduce the heat generated by friction, ensure better surface
finishing of the thread, and extend the cutting tool's lifespan. Once the threading is completed, it is
checked using measuring tools such as a thread gauge to ensure compliance with the required
specifications. Finishing operations may be performed to remove burrs or imperfections.

This threading process via turning can be carried out on conventional lathes or computer numerical
control (CNC) lathes, offering high precision and flexibility to produce threads of different sizes and
shapes based on the specific needs of the workpiece being machined.

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 2. Part to be made in the laboratory
To make this first thread by turning, we need to obtain an M20 x 2.5mm thread. This data tells us that
the diameter of the thread must be 20mm and that the pitch must be 2.5mm. After several passes with
the lathe, we obtain the desired thread. To test whether it corresponds to the data, we use a caliper to
check its diameter and screw it into a threaded hole of the correct dimensions. The thread is ground
slightly on the lathe so that it fits perfectly into our template, and the threading of our shaft is complete.

B. Tapping a hole - Drilling

1. General principle
The general principle of creating a thread by drilling involves several key steps:

Initially, a pilot hole is drilled into the workpiece using a drill bit appropriate for the diameter of the
intended thread. This pilot hole serves as a guide for the subsequent threading process. Next, a tap
corresponding to the required thread type is chosen. The tap is a threaded tool that will cut the grooves
inside the hole to create the thread. The tap is carefully inserted into the pilot hole and gradually
rotated using a tapping tool (tap wrench or a tapping machine). During this process, the tap gradually
cuts the thread grooves into the hole walls. It is common practice to use a lubricant or cutting fluid
during the tapping process to reduce friction, dissipate heat, extend the tap tool's lifespan, and improve
the quality of the thread. Once the threading is completed, it is essential to inspect the thread's quality
using a measuring tool, such as a thread gauge, to ensure it meets the required specifications. Finally,
the workpiece is often cleaned to remove any cutting or lubricant residues.

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This drilling-based threading process is relatively straightforward but demands precision and careful
attention to ensure high-quality threads meeting the required standards. Cutting conditions, proper
lubrication, and the use of suitable tools are crucial factors to consider in achieving precise and reliable
threads.

2. Part to be made in the laboratory

For this method, we need to make an M10 x 1.5mm tapped hole. To do this, an 8.5mm hole is first
drilled in a blank using a conventional drill. Next, a dedicated tapping bit is fitted to the drill to make
the required part.

C. Threading by multi-tool machine

1. General principle
The general principle of thread production with a multi-tool machine involves several steps:

The multi-tool machine is configured for threading by installing appropriate tools on different
workstations based on the required thread type. First, the workpiece is secured within the multi-tool
machine, typically on a chuck or specific clamping device to allow precise machining. If it's a computer
numerical control (CNC) machine, the threading program is loaded or programmed to set parameters

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such as rotational speeds, feeds, cutting depths, etc. Once the machine is prepared, it is activated. The
various tools engage as per the sequence defined in the program to carry out necessary cutting
operations required for creating the thread. The cutting tools within the multi-tool machine work
sequentially or simultaneously to cut the grooves of the thread into the rotating workpiece. Each tool
may perform specific operations, such as facing, chamfering, threading, etc. Like other machining
processes, the use of lubricants or cutting fluids might be necessary to reduce heat and enhance the
quality of the threaded machining. Upon completion of the threading operation, the thread quality is
inspected using measuring tools. Finishing operations may be conducted, if needed, to ensure
compliance with the required specifications.

This threading process with a multi-tool machine combines the ability to perform multiple machining
operations on a single workpiece, offering efficient and precise production of complex or different-sized
threads on various parts.

2. Part to be made in the laboratory

For this process, we need to make an M20 x 2.5mm thread. To do this, a large cylindrical part with a
diameter of 20mm is placed in the multi-tool machine. The necessary parameters are then
programmed into the machine and, when it is switched on, the threading is done automatically. The
result is the threaded part shown below.

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 D. Treading by deformation – Rolling machine
1. General principle
The basic principle of creating threads with a thread rolling machine involves deforming the material
to form the thread crests and roots without removing any material. Here are the general steps:

First, the workpiece preparation. Securely fix the workpiece in the thread rolling machine to ensure
stability during the deformation process. Next, we need to choose an appropriate thread rolling
machine and mount the rolling dies or tools suitable for the size and type of thread to be produced.
Set up the machine to achieve the proper parameters of pressure, speed, and feed according to the
material and type of thread being rolled. Place the thread rolling dies against the surface of the
workpiece to exert controlled pressure, deforming the material to form the thread crests and roots. If
applicable, apply axial force to the rollers as they make contact with the workpiece. In some machines,
the workpiece may be rotated while the rollers exert pressure to facilitate the deformation process.
After the rollers pass, inspect the quality of the formed thread using appropriate measuring tools to
confirm compliance with the required specifications.

Thread rolling machines are widely used to produce high-quality threads on various mechanical parts,
offering excellent precision and increased strength of the resulting threads while maintaining the
structural integrity of the base material. Each thread rolling machine might have specific technical
details and adjustments based on the type of threading, material, and required tolerances for the
workpiece.

2. Part to be made in the laboratory

For this last method of making a thread, we want to make an M16 x 1.5 mm thread. To do this, the
machine is programmed to produce the desired thread. A shaft is then placed between the two rollers.
The base diameter of the blank is slightly smaller than the diameter of the desired thread. This method
of producing threads by deformation makes it possible to increase the diameter of the base shaft. One
of the main advantages of this process is that the thread does not require material to be removed, as
is the case with other methods.

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 V. Conclusion
In conclusion, I was very interested in discovering these different methods of making threads. All I knew
was how to make threads using a manual tap. Discovering these different machines was a great learning
experience for me. In our future jobs as engineers, we'll probably one day have to choose a threading
method to make a part to be marketed or a prototype. With the help of this laboratory, I'm now familiar
with different methods and I'll be able to choose which one to use depending on my needs and the
equipment I have to hand. Infact, it's crucial for manufacturers and engineers to select the appropriate
method based on specific project criteria, considering quality, cost, time, and material characteristics
to achieve reliable threads conforming to the required specifications.

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