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Thread production has been a part of human craftsmanship for thousands of years, and over time, various techniques have emerged to create threads. While our passion lies in thread cutting, we believe it's important to share the benefits of thread rolling as well. Each method has its own advantages and is suited to different applications and industries.
Today, let’s take a closer look at **thread rolling**, a **chipless manufacturing process** often referred to as **thread forming**. This technique has become popular due to its efficiency and quality, and it's widely used in industrial settings. We'll explain how it works, what makes it unique, 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, where material is removed to form the thread, thread rolling uses **cold forming** to shape the thread by displacing the material rather than cutting it. This means the **material fibers remain intact**, resulting in a stronger and more durable thread.
During the process, **rolling dies**—which are round rollers with the desired thread profile—are used. These dies apply pressure to the workpiece, forcing the material into the grooves of the dies. This not only creates the thread but also improves the surface finish and mechanical properties of the component.
### Different Methods of Thread Rolling
There are several ways to perform thread rolling, but two of the most common are the **plunge method** and the **through-feed method**.
In the **plunge method**, the blank is placed between open rolling dies, which then rotate and press the material to form the thread. This method is ideal for shorter threads and offers high precision and speed.
In the **through-feed method**, the blank moves through the rolling dies, which are designed with specific sections like an entry cone, calibration area, and exit cone. This allows for the production of longer threaded parts without needing to reposition the workpiece.
### Advantages of Thread Rolling
- **Stronger Threads**: Since no material is cut away, the **integrity of the material fibers is maintained**, leading to better strength and wear resistance.
- **Faster Production**: The process is quick, making it ideal for **mass production**.
- **Material Efficiency**: Less raw material is wasted compared to thread cutting.
- **No Chips Produced**: This reduces cleanup and avoids chip-related issues.
### Challenges of Thread Rolling
Despite its benefits, thread rolling isn't suitable for every situation. For example:
- It **can’t produce internal threads**—it’s only used for **external threads**.
- Not all materials are suitable. The material must be **easily cold-formable**, typically requiring an **elongation at break of 12% or more**.
- Some thread profiles, such as those with **vertical flanks**, are difficult or impossible to roll.
### Is Thread Rolling Right for You?
If you're working on **small-scale projects** or occasional threading tasks, **thread taps and dies** are still the best choice. Thread rolling requires **specialized equipment** and is most cost-effective in **large-scale production**.
However, if you're looking for **high-quality external threads** and need them in bulk, it's worth consulting a professional manufacturer who can handle the process efficiently.
At BAER, we specialize in **threading tools** and are here to help you choose the right solution for your needs. Explore our **online shop** today and find the tools that suit your workshop.