Thread Cutting vs Thread Rolling

Do you need precision threaded components (e.g. fasteners, aerospace bolts, nuts, screws) for critical applications in the aerospace industry?

 

Do you need contact us (e.g. fasteners, aerospace bolts, nuts, screws) for critical applications in the aerospace industry?

If you’re accustomed to choosing thread cutting for critical components, you should be aware that these parts fail during destructive lab testing at a much higher rate than a rolled thread. That’s because only thread rolling services can provide the exceptional tensile, shear, and fatigue strength your component requires.

 

Thread Cutting vs. Thread Rolling

Thread cutting involves removing material by physically cutting away at a workpiece, which weakens the component’s structural integrity. Thread rolling, on the other hand, is a cold forging process that actually changes (and strengthens) the material’s physical properties without removing any material.

Sharp Tail Screw Die

The procedure supplants the component’s malleable material with a hardened steel die formed to spec. Unlike the weakening effect that results from removing material during thread cutting, thread rolling literally moves molecules into the thread form. This makes the thread denser, which in turn improves quality and strength. As an additional benefit, burnishing the steel dies used for thread rolling produces a superior micro-finish that reduces wear and further extends component life.

 

The greatest advantage thread rolling holds over traditional thread cutting methods is reduced cost. The reason is three-fold:

Rolling stock has a smaller diameter than full-sized cutting stock, so no leftover material is wasted after a job.

Higher quantities are produced per roll, resulting in lower tooling costs per thread.

Rolled surface feeds per minute are up to 10x faster than cutting, creating shorter labor times and lower costs — plus faster lead times for your clients.

Sharp Tail Screw Die

Benefits of Thread Rolling

The benefits of thread rolling include:

Finish quality. Thread cutting often leaves cut marks and tool lines behind, producing a rough finish and yielding a brittle thread that’s prone to breakage. Thread rolling, however, leaves parts smooth and strong without the need for secondary polishing and finishing operations.

Speed. Thread rolling machines operate at 3+ times the speed of thread cutting machines, which can significantly cut down on lead time.

Strength. Due to material compaction and work hardening, thread rolling increases the tensile strength of a component. The displaced material forms dense layers that are packed tightly together to produce a much stronger thread. Within thread rolling, there are two main thread forms that offer varying degrees of strength:

 

Basic Unified National Thread (UNR classification). These standard threads are typically used in commercial applications where strength is important but safety isn’t necessarily a crucial factor.

J-formed Thread (UNJC or UNJF). These threads have a larger root radius that produces an incredibly strong thread when rolled. They’re ideal for critical applications where people’s lives depend on their functionality. J-formed threads are found in most aerospace applications.

Tool life. Cutting tools are known to wear down easily, but a single set of precision thread rolling dies can roll thousands of precision threaded components without a problem.

 

For more information about the thread rolling dies for sales, welcome to contact us today or request a quote.