The capacity to mass-produce fasteners at a reasonable cost is the first prerequisite for thread rolling flat dies.Precision lead screws can be produced at a reasonable cost by flat thread rolling dice. Long threaded lengths can be produced using it perfectly.Several feet can be rolled of precision threads per minute.However, due to machine capabilities and length-to-diameter ratios, machining and grinding procedures are slower processes for making threads and more challenging when threading lengthy lengths.In high-speed, low-accuracy processes like threading fasteners, mechanical screws, and bolts, flat rolling plates are used.
What is thread rolling?
In the metal forging process known as thread rolling, the material is forced through a set of hardened dies under high pressure to create screw threads.In the metal forging process known as thread rolling, the material is forced through a set of hardened dies under high pressure to create screw threads.Die axes are not parallel in the thread rolling machine because dies are skewed or pitched about one another.In what is known as a thru-feed operation, the skew is in charge of moving the material through the dies.
The feed rate of the material moving through the rolling dies can be controlled, which determines how long the rolled material stays in the dies and how quickly the thread is created.Because there are so many different thread sizes, depths, forms, and materials that can be rolled, rolling dies are a crucial component of the die design process.Nowadays, the rolling dice industry and thread rolling die manufacturer in India is increasing with each passing day.
Benefits of using flat thread rolling dice
While cutting and grinding procedures may need several passes to achieve complete thread depth, rolling creates the final thread in a single pass through the dies.Even more, time is lost when creating threads with several starts.Many lead screws have two to four starts, while some have up to sixteen starts.No matter how many beginnings there are, they are all generated at once during the thread rolling process.
However, each thread must be made separately when employing machining or grinding techniques, which increases the amount of time needed to create the threads.Cutting the threads individually can result in thread-to-thread or pitch-to-pitch mistakes in addition to time savings.
High standard finish
The burnished finish produced by rolling is excellent.As the dies compress and shape the rolled material, the surface quality is improved by burnishing, a mechanical polishing process.Because many of the nuts that engage a lead screw are made of plastic, the surface smoothness is crucial because it improves wear resistance.
The friction coefficient is also decreased by the burnished finish, enhancing overall efficiency by 8% to 9%.Additionally, this procedure produces lead screws that are smoother and more durable because oftheir accuracy and finish.
The rolling process does not remove any material, but it alters the material’s physical characteristics, which causes the metal to become work-hardened.This results in a more substantial thread and raises the lead screw’s surface hardness.