The document discusses thread rolling processes, tools, and design considerations. Thread rolling is a cold forming process that hardens and strengthens material, offering benefits like lower costs, faster production, and superior quality compared to cutting threads. Key factors discussed include selecting the proper material, designing the blank and tooling, determining speeds and feeds, and using accurate gaging to verify thread specifications are met. Thread rolling requires consideration of material properties, tooling design, and process parameters to optimize results.
Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts when large numbers are required. Jigs are guiding devices that locate and hold workpieces for machining, while fixtures are holding devices that attach to machines for quick, consistent locating, supporting, and clamping of blanks. Common jig types include plate jigs, box jigs, and indexing jigs. Common fixture types are plate fixtures, angle plate fixtures, and multistation fixtures. The main advantages of using jigs and fixtures are increased productivity, interchangeability of parts, uniform quality, reduced skill requirements, and lower costs.
this file is about the types of dies and also its manufacturing procedure.this is important for the industry and for the industrial and manufacturing engineering..are of this field is manufacturing engineering and die designalso for the blanking dies and punches
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
Machining by broaching removes material in one stroke using a broach tool with gradually increasing cutting teeth. Broaching is used to make holes, slots, gears, and other precision components. Broaching machines come in horizontal and vertical configurations and can be single-station or multi-station. Broaching provides high productivity and precision compared to other machining methods for suitable applications.
Manufacturing technology II 2 marks questions & answersGopinath Guru
This document contains 27 multiple choice questions and answers related to manufacturing technology and metal cutting processes. It covers topics like definitions of metal cutting, tool life, tool geometry, types of chip formation, factors affecting tool life, machinability, shear plane, types of lathes including engine lathes, turret lathes, capstan lathes, and automatic lathes. It also discusses operations performed on lathes, feed mechanisms for automatic lathes, and advantages of sliding head and Swiss type automatic screw cutting machines.
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
The document discusses various methods for manufacturing gears, including:
- Gear shaping and hobbing are generating processes that use rotating cutters to form gear teeth profiles. Gear shaping can produce external and internal spur gears with high accuracy, while hobbing is used for external spur gears and worm wheels.
- Gear milling uses form cutters but requires indexing after each tooth, resulting in lower productivity and accuracy than generating processes.
- Other methods discussed include broaching, rolling, powder metallurgy, casting, and machining smaller gears using EDM or broaching. Finishing processes like grinding, lapping, and burnishing are used to improve gear properties.
jigs and fixtures, types of fixtures, definition of jigs and fixtures, types of jigs, application of jigs and fixtures, difference between jigs and fixtures
Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts when large numbers are required. Jigs are guiding devices that locate and hold workpieces for machining, while fixtures are holding devices that attach to machines for quick, consistent locating, supporting, and clamping of blanks. Common jig types include plate jigs, box jigs, and indexing jigs. Common fixture types are plate fixtures, angle plate fixtures, and multistation fixtures. The main advantages of using jigs and fixtures are increased productivity, interchangeability of parts, uniform quality, reduced skill requirements, and lower costs.
this file is about the types of dies and also its manufacturing procedure.this is important for the industry and for the industrial and manufacturing engineering..are of this field is manufacturing engineering and die designalso for the blanking dies and punches
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
Machining by broaching removes material in one stroke using a broach tool with gradually increasing cutting teeth. Broaching is used to make holes, slots, gears, and other precision components. Broaching machines come in horizontal and vertical configurations and can be single-station or multi-station. Broaching provides high productivity and precision compared to other machining methods for suitable applications.
Manufacturing technology II 2 marks questions & answersGopinath Guru
This document contains 27 multiple choice questions and answers related to manufacturing technology and metal cutting processes. It covers topics like definitions of metal cutting, tool life, tool geometry, types of chip formation, factors affecting tool life, machinability, shear plane, types of lathes including engine lathes, turret lathes, capstan lathes, and automatic lathes. It also discusses operations performed on lathes, feed mechanisms for automatic lathes, and advantages of sliding head and Swiss type automatic screw cutting machines.
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
The document discusses various methods for manufacturing gears, including:
- Gear shaping and hobbing are generating processes that use rotating cutters to form gear teeth profiles. Gear shaping can produce external and internal spur gears with high accuracy, while hobbing is used for external spur gears and worm wheels.
- Gear milling uses form cutters but requires indexing after each tooth, resulting in lower productivity and accuracy than generating processes.
- Other methods discussed include broaching, rolling, powder metallurgy, casting, and machining smaller gears using EDM or broaching. Finishing processes like grinding, lapping, and burnishing are used to improve gear properties.
jigs and fixtures, types of fixtures, definition of jigs and fixtures, types of jigs, application of jigs and fixtures, difference between jigs and fixtures
Single point cutting tools have a single cutting edge used to remove material from a workpiece. They are used in lathe and shaper machines for operations like turning, facing, and boring. The tool has a shank, rake surface, flank surface, and a single cutting edge where the rake and flank surfaces intersect. Rake angle, which indicates the orientation of the rake surface, can be positive, negative, or zero, and influences factors like required cutting force, tool life, and machinability.
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
The document summarizes the key steps in the fixture design procedure: 1) locating, 2) clamping, 3) supporting, 4) applying cutter guides, and 5) drawing the fixture outline. It discusses locating and degrees of freedom, describing how locating elements are used to restrict the six degrees of freedom of an object. Specific examples are provided to illustrate how locating points can be applied to a rectangular block to restrict its motion and rotations. The document also discusses clamping elements, support, cutter guidance, and completing the fixture body. Common locating principles like six-point location, 3-2-1 principle, and 4-2-1 principle are explained.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
This document provides an overview of sheet metal forming processes. It discusses that sheet metal forming is used to produce parts with versatile shapes and is lightweight. Common materials used are low-carbon steel, aluminum, and titanium. The main forming processes discussed are shearing, punching, bending, deep drawing, and stamping. It covers the characteristics of sheet metal that influence formability like elongation, anisotropy, and springback. Forming parameters that affect processes like deep drawing are also summarized such as blankholder pressure, draw ratio, and clearance.
The document discusses various metal forming processes including forging processes like open die, closed die, and impression forging. It describes types of rolling processes and defects in rolled parts. It also covers principles of extrusion, types of extrusion, and tube drawing. Different metal forming techniques like forging, rolling, and extrusion are discussed along with their advantages in shaping metals and improving mechanical properties. Key terms related to forging like dies, forgings, and defects in forged parts are also summarized.
What does clamping mean in context of jigs and fixtures?
Principles of Clamping
Different types of Clamping Devices, their advantaged and disadvantages
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Introduction to brakes and its classificationNavroz Navodia
This presentation contains a brief introduction to brake and its principle.Along with that it contains a detailed classification of all the brakes which are as follows
1 mechanical brakes
2 hydraulic brakes
3 disc brakes
4 pneumatic brakes
As this presentation mainly focuses on mechanical brakes hence subtype of following brake are also discussed.they are
1 SINGLE SHOE AND DOUBLE SHOE BRAKE
2 DIFFERENTIAL BRAKE
3 INTERNAL EXPANDING BRAKES
4 PIVOTED SHOE BRAKE
5 BAND BRAKES
A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials .The liquid hardens or sets inside the mould, adopting its shape. A mould is the counterpart to a cast.
Mould or Mould cavity contains molten metal and is essentially a negative of the final product.
Mould is obtained by pattern in moulding material (sand).
Mould material should posses refractory characteristics and withstand the pouring temperature.
This document discusses different types and properties of grinding wheels. It describes 10 types of grinding wheels based on their shape and intended use. It also covers the Indian Standard coding system used for grinding wheels which includes 6 symbols to indicate characteristics like abrasive type, grain size, grade, structure and bond. Different abrasive materials, bonds, grain sizes, grades and structures are defined. Guidelines for selecting the appropriate grinding wheel for different metals and operations are provided. Glazing and loading effects on wheels are described along with their causes and remedies. Steps for properly mounting grinding wheels are outlined.
Fasteners are hardware devices that mechanically join or affix objects together. There are many types of fasteners including threaded and non-threaded. Threaded fasteners have external or internal threads and are defined by properties like pitch, diameter, and thread angle. Fasteners can be removable, semi-permanent, or permanent. Manufacturing processes for threaded fasteners include forging, rolling, and turning. Standards organizations define specifications for fastener design. Special fasteners may require unique designs or coating for corrosion resistance. The fastener industry is important for automotive, industrial, and construction applications.
The document discusses different aspects of threaded fasteners including types, materials, tightening torque, and manufacturing processes. It notes that a Boeing 747 uses around 2.5 million fasteners including 70,000 titanium bolts costing $150,000. Tightening bolts to the specified torque is important as it ensures proper preload and prevents loosening over time. Common bolt manufacturing methods include forging, rolling, and thread rolling which strengthen the material compared to conventional machining.
The document discusses the process of sand casting. It describes the key steps which include preparing the mould and molten metal, pouring the molten metal into the mould, solidification, and removing the cast part. Several types of patterns are discussed along with their materials and uses. The document also covers moulding sand properties and testing methods. Common defects in castings are described. The overall document provides details on the sand casting manufacturing process.
The document discusses different types of lathes used to shape metal parts including engine lathes, bench lathes, tracer lathes, automatic lathes, turret lathes, and computer controlled lathes. It also describes common lathe operations like turning, facing, boring, drilling, threading, and knurling. Methods for securely holding workpieces like chucks, collets, and magnetic chucks are presented. Finally, it provides examples of simple calculations for determining spindle speed for a given cutting speed and feed rate and calculating the angle to swivel the compound rest to cut a taper.
The document describes a project report on the design of a common bending tool for two sheet metal components (left and right). It discusses the history of metal shaping tools and introduces press tools and their types like blanking, piercing, bending, etc. It also covers topics like strip layout, types of strip layout arrangements, factors that affect strip arrangement, die design parameters and calculations. The key objectives are to maximize material utilization, reduce production costs, and increase part output through an efficient strip layout and tool design.
The document discusses bending processes and springback issues. It covers bending, bending processes, factors that influence springback like size effects, methods for predicting and compensating for springback like die design and the displacement adjustment method. It also applies these methods to the bending of 304 stainless steel tubes and discusses the results.
The document discusses thread rolling, including:
- Thread rolling strengthens material without cutting, lowering costs and speeds production.
- Proper material selection, tooling, speeds and feeds, and gaging are required for quality threads.
- Common issues like slivers, incorrect pitch, and mismatched helix angles can be avoided through optimization of rolling conditions, tool synchronization, and material selection.
The document discusses thread rolling, including its benefits over cutting threads, material considerations, design factors, and tooling techniques. Thread rolling strengthens materials without metal cutting and allows for lower costs, faster production, and superior thread quality compared to cutting. The formability of different materials impacts thread finish and die life. Designing the blank diameter, chamfer angle, and thread/roll length properly optimizes the rolling process. A variety of tooling techniques like in-feed dies and skewed roll axes can be used to roll internal and external threads of different lengths and pitches.
Single point cutting tools have a single cutting edge used to remove material from a workpiece. They are used in lathe and shaper machines for operations like turning, facing, and boring. The tool has a shank, rake surface, flank surface, and a single cutting edge where the rake and flank surfaces intersect. Rake angle, which indicates the orientation of the rake surface, can be positive, negative, or zero, and influences factors like required cutting force, tool life, and machinability.
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
The document summarizes the key steps in the fixture design procedure: 1) locating, 2) clamping, 3) supporting, 4) applying cutter guides, and 5) drawing the fixture outline. It discusses locating and degrees of freedom, describing how locating elements are used to restrict the six degrees of freedom of an object. Specific examples are provided to illustrate how locating points can be applied to a rectangular block to restrict its motion and rotations. The document also discusses clamping elements, support, cutter guidance, and completing the fixture body. Common locating principles like six-point location, 3-2-1 principle, and 4-2-1 principle are explained.
Unit 2 Design Of Shafts Keys and CouplingsMahesh Shinde
This document provides information about the design of shafts, keys, and couplings. It discusses transmission shafts, stresses induced in shafts, and shaft design based on strength and rigidity. It presents formulas for shaft design using maximum shear stress theory, distortion energy theory, and the ASME code. Several examples are provided to demonstrate how to calculate the diameter of a shaft given the power transmitted, loads on the shaft, material properties, and other parameters using these theories and codes. Assignments involving similar calculations of shaft diameters are presented.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
This document provides an overview of sheet metal forming processes. It discusses that sheet metal forming is used to produce parts with versatile shapes and is lightweight. Common materials used are low-carbon steel, aluminum, and titanium. The main forming processes discussed are shearing, punching, bending, deep drawing, and stamping. It covers the characteristics of sheet metal that influence formability like elongation, anisotropy, and springback. Forming parameters that affect processes like deep drawing are also summarized such as blankholder pressure, draw ratio, and clearance.
The document discusses various metal forming processes including forging processes like open die, closed die, and impression forging. It describes types of rolling processes and defects in rolled parts. It also covers principles of extrusion, types of extrusion, and tube drawing. Different metal forming techniques like forging, rolling, and extrusion are discussed along with their advantages in shaping metals and improving mechanical properties. Key terms related to forging like dies, forgings, and defects in forged parts are also summarized.
What does clamping mean in context of jigs and fixtures?
Principles of Clamping
Different types of Clamping Devices, their advantaged and disadvantages
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Introduction to brakes and its classificationNavroz Navodia
This presentation contains a brief introduction to brake and its principle.Along with that it contains a detailed classification of all the brakes which are as follows
1 mechanical brakes
2 hydraulic brakes
3 disc brakes
4 pneumatic brakes
As this presentation mainly focuses on mechanical brakes hence subtype of following brake are also discussed.they are
1 SINGLE SHOE AND DOUBLE SHOE BRAKE
2 DIFFERENTIAL BRAKE
3 INTERNAL EXPANDING BRAKES
4 PIVOTED SHOE BRAKE
5 BAND BRAKES
A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials .The liquid hardens or sets inside the mould, adopting its shape. A mould is the counterpart to a cast.
Mould or Mould cavity contains molten metal and is essentially a negative of the final product.
Mould is obtained by pattern in moulding material (sand).
Mould material should posses refractory characteristics and withstand the pouring temperature.
This document discusses different types and properties of grinding wheels. It describes 10 types of grinding wheels based on their shape and intended use. It also covers the Indian Standard coding system used for grinding wheels which includes 6 symbols to indicate characteristics like abrasive type, grain size, grade, structure and bond. Different abrasive materials, bonds, grain sizes, grades and structures are defined. Guidelines for selecting the appropriate grinding wheel for different metals and operations are provided. Glazing and loading effects on wheels are described along with their causes and remedies. Steps for properly mounting grinding wheels are outlined.
Fasteners are hardware devices that mechanically join or affix objects together. There are many types of fasteners including threaded and non-threaded. Threaded fasteners have external or internal threads and are defined by properties like pitch, diameter, and thread angle. Fasteners can be removable, semi-permanent, or permanent. Manufacturing processes for threaded fasteners include forging, rolling, and turning. Standards organizations define specifications for fastener design. Special fasteners may require unique designs or coating for corrosion resistance. The fastener industry is important for automotive, industrial, and construction applications.
The document discusses different aspects of threaded fasteners including types, materials, tightening torque, and manufacturing processes. It notes that a Boeing 747 uses around 2.5 million fasteners including 70,000 titanium bolts costing $150,000. Tightening bolts to the specified torque is important as it ensures proper preload and prevents loosening over time. Common bolt manufacturing methods include forging, rolling, and thread rolling which strengthen the material compared to conventional machining.
The document discusses the process of sand casting. It describes the key steps which include preparing the mould and molten metal, pouring the molten metal into the mould, solidification, and removing the cast part. Several types of patterns are discussed along with their materials and uses. The document also covers moulding sand properties and testing methods. Common defects in castings are described. The overall document provides details on the sand casting manufacturing process.
The document discusses different types of lathes used to shape metal parts including engine lathes, bench lathes, tracer lathes, automatic lathes, turret lathes, and computer controlled lathes. It also describes common lathe operations like turning, facing, boring, drilling, threading, and knurling. Methods for securely holding workpieces like chucks, collets, and magnetic chucks are presented. Finally, it provides examples of simple calculations for determining spindle speed for a given cutting speed and feed rate and calculating the angle to swivel the compound rest to cut a taper.
The document describes a project report on the design of a common bending tool for two sheet metal components (left and right). It discusses the history of metal shaping tools and introduces press tools and their types like blanking, piercing, bending, etc. It also covers topics like strip layout, types of strip layout arrangements, factors that affect strip arrangement, die design parameters and calculations. The key objectives are to maximize material utilization, reduce production costs, and increase part output through an efficient strip layout and tool design.
The document discusses bending processes and springback issues. It covers bending, bending processes, factors that influence springback like size effects, methods for predicting and compensating for springback like die design and the displacement adjustment method. It also applies these methods to the bending of 304 stainless steel tubes and discusses the results.
The document discusses thread rolling, including:
- Thread rolling strengthens material without cutting, lowering costs and speeds production.
- Proper material selection, tooling, speeds and feeds, and gaging are required for quality threads.
- Common issues like slivers, incorrect pitch, and mismatched helix angles can be avoided through optimization of rolling conditions, tool synchronization, and material selection.
The document discusses thread rolling, including its benefits over cutting threads, material considerations, design factors, and tooling techniques. Thread rolling strengthens materials without metal cutting and allows for lower costs, faster production, and superior thread quality compared to cutting. The formability of different materials impacts thread finish and die life. Designing the blank diameter, chamfer angle, and thread/roll length properly optimizes the rolling process. A variety of tooling techniques like in-feed dies and skewed roll axes can be used to roll internal and external threads of different lengths and pitches.
Intro to Rotary Draw Bending: An Engineer’s Guide to Bending Tubes Tube Form Solutions
This guide is an excellent starting point for anyone who has questions or is interested in learning about bending tooling. Easy to understand diagrams and images are accompanied by clear information, walking readers through the basics of bending tooling.
Module 3 covers broaching processes and gear manufacturing methods. It discusses broaching tools and machines, including specifications of broaching machines. It also describes different types of broaching tools and machines. The document then covers gear materials, size, geometry, and manufacturing methods such as casting, die casting, and machining processes like milling, broaching, hobbing and shaping. It provides details on specific gear types like bevel and helical gears and their manufacturing. The advantages and limitations of broaching are also summarized.
We specialize in the manufacturing and rebuilding of screws, barrels, removable mixers, tips, end caps, nozzles, and a large variety of other specialized machining components, including augers, tie bars, and rotors.
The document summarizes information about rivets and gears. It defines a rivet as a metal pin for fastening two pieces of metal together. Rivets are made of materials like steel and are produced via forging. Rivets are used in applications requiring high joint strength, like ships and aircraft. Gears are defined as machinery that transfers motion between components. Gears are usually made of metals and manufactured via processes like molding, cutting, or 3D printing. Gears are used to change motion direction or speed in mechanical devices.
This document is a research paper about gears manufacturing and production technique, which is one of the most known domain of industrial engineering and production. since gears are used in many applications to transmit motion and movement. So study about them is a must in industrial engineering application.
The document provides information about wedge wire filter elements produced by Trislot. It discusses why wedge wire is preferable to other filter media due to its strength, lack of maintenance costs, and ability to prevent production stops. It then describes what wedge wire is and the manufacturing process. The document provides details on various wedge wire profiles and materials available. It also discusses different product types like slot tubes and welded screens. Testimonials are included that praise Trislot's quality, services, and partnership. In under 3 sentences, the document summarizes wedge wire filter elements manufactured by Trislot and why they provide advantages over other filter media.
For over 85 years, Roller Die + Forming has been providing custom roll formed, stamped, powder coated and assembled metal parts, using lean manufacturing processes.
For over 85 years, Roller Die + Forming has been providing custom roll formed, stamped, powder coated and assembled metal parts, using lean manufacturing processes.
Design & developement of swing frame testing fixture of Bandsaw Machine.Vaibhav Koli
The document describes the design and development of a testing fixture for the swing frame of a bandsaw machine. Key details include:
- The fixture was created to reduce inspection time and improve accuracy by properly aligning and drilling holes in the swing frame.
- Materials like mild steel, EN24 and EN8 were selected for different fixture components based on properties like strength, machinability and wear resistance.
- The design of the fixture was tested and different plates were allocated to wing positions to locate and securely hold the swing frame for drilling operations.
- The fixture allows for reduced manufacturing cycle time and increased precision, reliability and productivity when inspecting the swing frame.
Gearboxes are used to change speed and torque from a driving component to a driven one. They are commonly used in automobiles and machinery. Gearbox manufacturing involves selecting appropriate materials like carbon steel and casting iron based on the application. Gears can be formed through processes like extrusion, stamping, and powder metallurgy. Common machining processes to cut gear teeth include shaping, hobbing, and milling. Shaping involves a reciprocating cutter that cuts gear teeth individually, while hobbing can cut multiple teeth simultaneously. The summary provides an overview of gearbox uses, manufacturing materials selection, and common forming and machining processes.
Orbital forging is a continuous forging process where one die rotates relative to the other, gradually deforming a small area of the workpiece at a time until final shape is achieved. The tilt angle between dies determines the forging force applied, with larger tilt angles requiring smaller forces but making machine design and maintenance more difficult. Orbital forging allows production of symmetric and some asymmetric parts, has lower forces and costs than other forging methods, and can produce net-shape parts in shorter cycle times. However, it is limited to certain part geometries and requires trial and error to determine suitability.
Turning plays most important role in Machining and Turning is the form of machining process which uses a single-point cutting tool for material removal,from this slide we can get the importance of turning.
Selecting the Right Gear Coupling for your ApplicationDesign World
This webinar will place the spotlight on gear couplings with a focus on factors to consider when making a coupling selection for your application. Topics covered will include basic sizing, application criteria, coupling design features and the variety of coupling types available.
A lathe rotates a workpiece about an axis to perform various operations such as cutting, sanding, knurling with tools. It consists of a headstock, bed, carriage, tailstock. The headstock powers the spindle and workpiece. The carriage moves the tool parallel to the axis of rotation. Turret and capstan lathes allow quick tool changes. Automatic lathes can produce identical pieces without operator attention after initial setup.
Forged stainless steel has several advantages over other materials:
1) It has improved strength and resistance to stress concentrations due to the alignment of the grain structure during the forging process.
2) The forging process produces parts with very high quality and few defects due to the direct deformation of solid steel bars.
3) Forging dies can be made and maintained in-house, reducing tooling costs.
4) The forging process creates parts that are close to their final net shape, requiring less machining and finishing.
5) Overall, forging stainless steel provides cost savings through reduced machining needs and shorter lead times.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
6th International Conference on Machine Learning & Applications (CMLA 2024)ClaraZara1
6th International Conference on Machine Learning & Applications (CMLA 2024) will provide an excellent international forum for sharing knowledge and results in theory, methodology and applications of on Machine Learning & Applications.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
We have compiled the most important slides from each speaker's presentation. This year’s compilation, available for free, captures the key insights and contributions shared during the DfMAy 2024 conference.
Low power architecture of logic gates using adiabatic techniquesnooriasukmaningtyas
The growing significance of portable systems to limit power consumption in ultra-large-scale-integration chips of very high density, has recently led to rapid and inventive progresses in low-power design. The most effective technique is adiabatic logic circuit design in energy-efficient hardware. This paper presents two adiabatic approaches for the design of low power circuits, modified positive feedback adiabatic logic (modified PFAL) and the other is direct current diode based positive feedback adiabatic logic (DC-DB PFAL). Logic gates are the preliminary components in any digital circuit design. By improving the performance of basic gates, one can improvise the whole system performance. In this paper proposed circuit design of the low power architecture of OR/NOR, AND/NAND, and XOR/XNOR gates are presented using the said approaches and their results are analyzed for powerdissipation, delay, power-delay-product and rise time and compared with the other adiabatic techniques along with the conventional complementary metal oxide semiconductor (CMOS) designs reported in the literature. It has been found that the designs with DC-DB PFAL technique outperform with the percentage improvement of 65% for NOR gate and 7% for NAND gate and 34% for XNOR gate over the modified PFAL techniques at 10 MHz respectively.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Harnessing WebAssembly for Real-time Stateless Streaming Pipelines
Basics of Thread Rolling
1. The Basics of Thread Rolling
Tools, Tips & Design Considerations
Liberato Pietrantoni - Director of Global Sales, ME
liberato@cjwinter.com www.cjwinter.com
2. What is thread rolling?
• Thread rolling is NOT a metal cutting process
• Rolling changes physical properties, hardening and
strengthening the material
Cut Thread Rolled Thread
CJWinter | www.cjwinter.com
3. What are the benefits?
• Lower costs
• Increased production
• Faster lead times
• Superior quality and accuracy:
• Stronger threads
• Improved finish
• More accurate profile
CJWinter | www.cjwinter.com
4. Where to start:
Material Selection & Properties
Design Considerations
Correct Tooling
Speeds & Feeds
Accurate Gaging
Common Issues & Troubleshooting
CJWinter | www.cjwinter.com
5. The Formability Index
• The softer the material, the easier it is to roll
threads
• Harder materials result shorter die life
• Some hard-to-roll material, such as stainless
steel, produces excellent thread finish with a
compromised tool life
CJWinter | www.cjwinter.com
6. The Formability Index
Hardness Thread Finish Die Life
Brass
(345, 360)
< Rb 75, 70 Good, Poor Medium/High
Aluminum
(2024-T4, 6061,T-6)
< Rb 120, 17
Excellent,
Good
High
Stainless
(302, 440)
< Rc 32 Excellent Medium/Low
Steel
(1018, 12L14)
< Rc 24 Excellent, Fair Medium
• Examples:
CJWinter | www.cjwinter.com
8. Blank Design – part prior to rolling
Blank Diameter Chamfer Angle
CJWinter | www.cjwinter.com
Max.
*CJWinter offers blank and thread roll
design as a free service to optimize the
thread roll process
9. Blank Diameter Properties
o When cutting a thread, the
major diameter = the blank
diameter of the threads.
o When thread rolling,
material below the pitch
diameter is displaced during
cold form process and the
excess material is squeezed
up into the new major
diameter.
Blank diameter of rolled thread = Max pitch diameter - .002”
CJWinter | www.cjwinter.com
10. Blank Diameter Properties
o For every .001” that the blank diameter is adjusted,
the thread major diameter will change by .003”.
o This ratio only applies when rolling close to the major
diameter.
3:1 Ratio between Major and Blank Diameters
CJWinter | www.cjwinter.com
11. Chamfer Angle
o A 30° chamfer will give an
approximate 45° angle after
rolling.
o When rolling harder
materials a lower chamfer
angle [25-28°] is preferred
so thread roll life is not
compromised.
Recommended Angle: 30° from the axis of the part
CJWinter | www.cjwinter.com
12. Shoulder/Stock Clearance
o Premature wear and damage will occur to the roll if the
roll contacts the shoulder.
o Stock clearance is also an important consideration
especially when hex stock is used.
Maintain a minimum distance of 1.25 to 1.5 X pitch,
depending on shoulder configuration
CJWinter | www.cjwinter.com
13. Thread Length vs. Roll Length
o Roll work face needs to
be calculated for each
part to make sure proper
clearances are used.
o We offer this as a free
service to our customers
to make sure that the
thread roll process and
tooling life are optimized.
o Rule of thumb =
Roll WF = (2.5 x Pitch)
+ Thread Length
CJWinter | www.cjwinter.com
14. Techniques:
CJWinter | www.cjwinter.com
• In-feed/(plunge)-helical die with radial material displacement
• Skewed Roll Axis-Annular Die (No Helix)
• Skewed Roll Axis-Helical Die
Thread Rolls and Associated
Forming Techniques
15. Comparison of Roll and Helix Orientation
CJWinter | www.cjwinter.com
Thread Rolls and Associated Forming Techniques
FOR ALL CASES:
Helix on Part = Skew angle of Roll Axes + Die Helix Angle
A) Plunge / Infeed Roll
Feed Rate = zero [part does not move]
B) Helical Slow Feed Roll
Feed Rate < part helix angle
C) Annular Groove Roll
Feed Rate = part helix angle
D) Helical Fast Feed Roll
Feed Rate > part helix angle
Orderedbyincreasingfeedrate
Green- Rolled Part
16. CJWinter | www.cjwinter.com
Thread Roll Tapers
Wide range of taper options to accommodate any application
Single Taper
Double Taper
Continuous Minor Tapered Minor
Roll Roll
O.D. Taper Length can be
varied for either Continuous
Minor or Tapered Minor Rolls.
Roll
24. CJWinter | www.cjwinter.com
• Used to Prevent thread
Damage/ Cross-Threading
• Better Screw alignment/ Ease
of Assembly
• CJWinter is a worldwide
licensed supplier of
MAThread & MATpoint thread
dies
Image From:
https://www.assemblymag.com/articles/91865-
whats-new-with-screws
Tooth Forms
Special
25. Special
(Metric Electrical Thread)
CJWinter | www.cjwinter.com
• Used in Thin walled/Low
thread depth Applications
• Electrical Fittings/Conduit
Connections
Image From: https://www.tme.eu/html/EN/lapp-kabel-metal-cable-glands-
with-long-pg-threads/ramka_17312_EN_pelny.html
Tooth Forms
27. CJWinter | www.cjwinter.com
Commonly Used to increase to
surface area/ increase fluid
movement for greater efficiency
in heat exchanger components
Image From: http://www.globalsources.com/gsol/I/Copper-
tube/p/sm/1133828772.htm#1133828772
Tooth Forms
Special
29. CJWinter | www.cjwinter.com
Commonly Used to increase to
surface area/ increase fluid
movement for greater efficiency
in heat exchanger components
Image From: http://www.globalsources.com/gsol/I/Copper-
tube/p/sm/1133828772.htm#113382877200
Tooth Forms
Special
31. Correct Tooling – Rolls
o Styles
o Material/Coating Options
Considerations:
CJWinter | www.cjwinter.com
32. Correct Tooling – Rolls
o Different styles depend on part orientation to the collet
o Some rolls are reversible; others are not
o In the configurations shown, the thread roll style required will be
affected by roll/part orientation
o Send your part print to CJWinter to ensure correct style is calculated
Styles
CJWinter | www.cjwinter.com
33. Correct Tooling – Rolls
Options
Heat Treating Special Materials Coatings
Toughness vs.
Hardness
Toughness implies
longer roll life.
Hardness has its own
special applications.
Different substrate
materials can
improve roll life
depending on
application.
Improves die life and
increases lubricity
when rolling. Slightly
more costly, but cost
is outweighed by the
increase in roll life.
CJWinter | www.cjwinter.com
34. Relationship of Roll to Blank
Rolls are designed to
incorporate the maximum
number of starts allowed to fit
in attachment.
o More starts = Higher RPM
allowed
o More starts = Longer roll
life
Depending on the roll design,
the roll WF should always
overhang the part by at least
2-2.5 threads
CJWinter | www.cjwinter.com
35. CJWinter | www.cjwinter.com
• We manufacture both Helical and
Annular machine dies in various styles
for your thread rolling machine, including
Through-Feed, Double-Taper, Speed-Up,
Plunge, and Slow-Up.
• CJWinter also offers overhung die
holders and double support die holders
for both straight threads and taper pipe
threads.
Correct Tooling –
Cylindrical / Machine Dies
CJWinter manufactures the premier line of machine
dies and tooling.
36. CJWinter | www.cjwinter.com
• D2 - Moderate toughness and intermediate
wear resistance. Supplied on dies for machine
screw threads.
• DC53 - General-purpose cold work die offering
twice the toughness of D2 with superior wear
resistance and higher fatigue strength.
Die Materials – Air Hardening
Correct Tooling –
Cylindrical / Machine Dies
37. CJWinter | www.cjwinter.com
Die Materials – High Speed
• M2 - High-speed steel with excellent
toughness and wear resistance. Optimal for
cold work dies.
• M42 - Super high-speed tool steel designed
for machining high-strength and pre-hardened
steels and nonferrous alloys. Ideal for
aerospace and oil and gas industries.
Correct Tooling –
Cylindrical / Machine Dies
38. CJWinter | www.cjwinter.com
Die Materials – Options
• High performance coatings are also available
for the different materials used
• Other materials available upon request.
Contact us for details.
Correct Tooling –
Cylindrical / Machine Dies
39. Edge Finishing >> KEY for
performance and improved life
o Standard 30°, 45°, 60°
Chamfer angles
o A 30° chamfer will give an
approximate 45° angle after
rolling
Recommended Angle: 30° from the axis of the part
CJWinter | www.cjwinter.com
40. Edge Finishing – KEY for
performance and improved life
o When rolling harder materials a
lower chamfer angle [25-28°] is
preferred so thread roll life is
not compromised
o Custom R3
Radius Root Runout Chamfer
o Special chamfers and edge
finishes may be specified with
order
Recommended Angle: 30° from the axis of the part
CJWinter | www.cjwinter.com
41. • Escofier
• Izpe
• Landis
• Nissei
• ORT Italia
CJWinter | www.cjwinter.com
CJWinter manufactures thread rolls to fit attachments from
all major manufacturers, some of which are listed below:
Correct Tooling –
Cylindrical / Machine Dies
• Regg
• Reed
• Tesker
• Tsugami
• Seny
44. Correct Tooling – Attachments
o Radial Pinch
o Axial End Rolling
o Tangential Attachments
o Axial Rotary Transfer
o Applications
Considerations:
CJWinter | www.cjwinter.com
45. Correct Tooling – Attachments
o Attachment advances rapidly over part in an open position and then rolls
penetrate into work piece radially.
o Pitch diameter adjustments on the fly are possible without any tooling
and without the removal of the attachment.
o Only one dwell cam is required to roll the entire thread rolling range.
o Penetration (Roll Feed) Rate is quickly adjusted via an air control valve.
o Equalized thread rolling pressure virtually eliminates spindle wear and
part deflection.
Radial Pinch
CJWinter 160SA - Pneumatic Attachment
CJWinter | www.cjwinter.com
46. Correct Tooling – Attachments
o Attachment traverses
axially from tail stock /
end, working spindles into
workpiece centerline
o Allows forming of parts
that are longer than the
roll width if required.
Axial End Rolling
CJWinter 189,190, & 191 Series End Rolling Attachments [ER Series]
CJWinter | www.cjwinter.com
47. Correct Tooling – Attachments
o Attachment approaches
part radially and straddles
work piece to produce
threads.
o The fixed distance
between the rolls is set to
the minor diameter of work
piece. Some models
require manual adjustment
of pitch diameter while
others are controlled by a
pitch adjusting knob.
Tangential
CJWinter NC-41 Tangential Attachment
Detroit Attachment
CJWinter | www.cjwinter.com
48. Correct Tooling – Attachments
o Tangential attachments
are designed to roll
threads at a controlled
feed rate. Typically,
different cams are
required to modify feed
rate — this can be costly
and time consuming.
o The side pressure
produced by the pushing
tangential action can
cause the part being tolled
to deflect and accelerated
spindle wear.
Tangential
160 Tangential Attachment
CJWinter | www.cjwinter.com
49. Correct Tooling – Attachments
o The attachment advances
over the part in an open
position and then the rolls
penetrate into the work
piece radially.
o Attachment can also be
used to produce threads
behind the shoulder.
o The part thread length is
less than the rolling
length.
Axial Rotary Transfer
CJWinter 234-SAAxial Attachment
CJWinter | www.cjwinter.com
52. Speeds & Feeds
o Thread rolling tends to be the fastest operation
o Faster is usually better
o Rule of thumb:
o Part RPM: ~ 300 RPM per start of roll
o Typically does not constrain the cycle time
* See Appendix for handy Speed & Feed calculations
CJWinter | www.cjwinter.com
53. Material Selection & Properties
Design Considerations
Correct Tooling
Speeds & Feeds
Accurate Gaging
Common Issues & Troubleshooting
CJWinter | www.cjwinter.com
54. Accurate Gaging
o Go / No-Go Ring gages
o Micrometers / Pitch
micrometers
o Tri Roll [Johnson Gage]
o Functional Segments
o Pitch Diameter Rolls
o Pipe Threads
o 6 Step
o 1L, 2L Ring Gages
Types
“To yield useful repeatable data, it is critical to align inspection methods to part geometry
based on customer requirements, part geometry, and GD&T”
CJWinter | www.cjwinter.com
55. Gaging
o Machine part blank diameter to ~ Max Pitch Diameter -.002
o Roll the thread until the pitch diameter is within specification – between
Pitch Diameter max & min
o Adjust the blank diameter until the Major diameter is within specification -
between Major diameter max & min
Rolling a Straight Thread
CJWinter | www.cjwinter.com
56. Gaging
o Blank diameter – use micrometers and/or comparator
o Pitch diameter – use pitch micrometers and/or over pins
o Major diameter – use micrometers and/or comparator
Measuring features on a Straight Thread
Micrometers Pitch Micrometers Comparator or Shadowgraph
CJWinter | www.cjwinter.com
57. Gaging
o Machine part blank diameter to specifications outlined in chart
o Included angle of blank is 1°47’.
o Verify blank diameter at location Y [column “Y” and “B.D.@Y”]
o Roll the thread until the pitch diameter gages within the L1 & L2 gage
specifications.
o Adjust the blank diameter, until the Major diameter gages within 6 – Step gage
specifications - if required
Rolling on a Tapered Pipe Thread
CJWinter | www.cjwinter.com
58. Gaging
o Blank diameter – Use
micrometers and/or
comparator
o Pitch diameter
o Use L1 gage to verify pitch
E1 location
o Use L2 gage to verify pitch
E2 location
o Major diameter – Use 6-
Step to verify major
diameter
Measuring features on a Tapered Pipe Thread
CJWinter | www.cjwinter.com
59. Gaging
o NPT L1 rings inspect the
functional size or hand tight
engagement of pipe threads,
Parts are acceptable when
they generally acceptable
when they come flush to end
of ring +/- one turn.
o NPTF L1: Same as NPT;
thread tolerances are more
closely controlled, requiring
an L2 thick ring gage as well
as the L1 ring.
Measuring features on a Tapered Pipe Thread
CJWinter | www.cjwinter.com
60. Gaging
o NPTF L2 ring inspects the
wrench engagement threads
and is to be used in conjunction
or relationship with the NPTF
L1. Thread tolerances are more
closely controlled requiring an
L2 thick ring gage as well as the
L1 ring.
o NPTF 6 step ring gages are
used to check external threaded
parts. NPTF 6 gages check the
crest truncation or profile of the
external threads and are used
in conjunction or relationship
with the L1 L2 ring gages.
Measuring features on a Tapered Pipe Thread
CJWinter | www.cjwinter.com
61. Material Selection & Properties
Design Considerations
Correct Tooling
Speeds & Feeds
Accurate Gaging
Common Issues & Troubleshooting
CJWinter | www.cjwinter.com
63. Top 10 Common Issues
1. Slivers/Flakes in Threads
2. Incorrect Pitch/Lead
3. Mismatched Helix Angle
4. Different Rolling Conditions
5. Hollow Work, Closed Hole,
or Out of Round Conditions
6. Thread Filled out in Center,
but Not End
7. Poor Finish
8. Poor Thread Form
9. Crests Not Filled Out
10. Scuffed Crests
CJWinter | www.cjwinter.com
64. Common Issue #1: Slivers/Flakes in Threads
o Are rolls in match?
Resynchronize
o Is the centerline of rolls
parallel with work
centerline?
Check slide for alignment
o Is cross slide adapter worn
or loose?
Check slide gib and
springs; tighten adapter if
used
o Are rolls overfilled?
Reduce blank diameter
o Is roll diameter correct?
o Is material adaptable to cold
working?
Check with material supplier/
customer
Change material if possible
o Does blank have a rough finish?
Regrind tooling
o Is stock seamy?
Not suitable for thread rolling
o Do rolls slip on work?
Feed rate is too slow; increase
penetration rate
CJWinter | www.cjwinter.com
65. Common Issue #2: Incorrect Pitch/Lead
1. Measure in a comparator
o Measure over as many full threads as
possible
o
𝑁𝑢𝑚𝑏𝑒𝑟 𝑎𝑏𝑜𝑣𝑒
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡ℎ𝑟𝑒𝑎𝑑𝑠 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑
= 𝑃𝑖𝑡𝑐ℎ
2. Use Rolls Modified Lead (ML)
o Used when thread is rolled on the part,
and pitch has increased, causing a
gaging problem
o Measure pitch/lead, then adjust
pitch/lead to compensate part’s stretch
3. Order new rolls
o For ML rolls, it is best to send sample
parts that have been rolled to confirm
pitch/lead error. Your manufacturer can
then design rolls to correct ML error
and product a part that gages properly
CJWinter | www.cjwinter.com
66. Common Issue #3: Mismatched Helix Angle
What happens when the roll contacts the blank?
• “Screw jacking” – If kept on part for too long,
attachments/rolls get pulled into collet.
Optimize rolling time. Enter and exit as fast as
possible. Allow thread to form properly and fully,
then remove. The longer the roll remains in contact
with the part, the greater the chance of problems
developing.
CJWinter | www.cjwinter.com
67. Mismatched Helix Angle (cont.)
1. Roll OD first touches blank diameter.
The roll helix angle is larger than the helix
at the blank diameter.
Roll pushes away from the collet.
2. Roll OD is halfway between blank
diameter and minor diameter.
The helix on the part and roll will match
and track perfectly.
3. Roll OD is at minor diameter of part.
The roll helix angle is smaller than the part.
Roll pulls threads toward the collet (screw jacking).
CJWinter | www.cjwinter.com
68. Common Issue #4: Different Rolling Conditions
Forgings
o Grain flow is a concern when rolling
these parts. The grain structure material
is not consistent within a section of
material.
Work Hardening
o Occurs on different materials when
tooling (form/shave) dulls
o Increase the penetration rate when
rolling the thread
CJWinter | www.cjwinter.com
69. Common Issue #5: Hollow Work, Closed Hole, or
Out of Round Conditions
o Is wall thickness sufficient?
Drill later in cycle
o Is mandrel supported?
o Is feed rate too high?
Slow down penetration rate
Threads
per Inch
Blank Diameters in Inches
Up to ½ ½ to 1 1 to 2 2 to 3 3 to 4 4 to 5
32 0.040 –
0.050
0.050 –
0.063
0.070 –
0.088
0.095 –
0.119
0.110 –
0.138
0.130 –
0.163
24 0.055 –
0.069
0.070 –
0.088
0.095 –
0.119
0.120 –
0.150
0.150 –
0.188
0.175 –
0.219
20 0.065 –
0.081
0.080 –
0.100
0.115 –
0.144
0.145 –
0.181
0.180 –
0.225
0.210 –
0.263
18 0.070 –
0.088
0.090 –
0.113
0.130 –
0.163
0.160 –
0.200
0.195 –
0.244
0.230 –
0.288
16 0.080 –
0.100
0.100 –
0.125
0.140 –
0.175
0.180 –
0.225
0.220 –
0.313
0.265 –
0.331
14 0.095 –
0.119
0.115 –
0.144
0.165 –
0.206
0.210 –
0.263
0.250 –
0.313
0.300 –
0.375
12 0.110 –
0.138
0.135 –
0.169
0.190 –
0.238
0.240 –
0.300
0.300 –
0.375
0.350 –
0.438
10 .. 0.160 -
0.200
0.230 –
0.288
0.290 –
0.363
0.360 –
0.450
0.420 –
0.525
8 .. .. 0.285 –
0.356
0.360 –
0.450
0.450 –
0.563
0.530 –
0.633
CJWinter | www.cjwinter.com
70. Common Issue #6: Thread Filled out in
Center, but Not End
o Does blank maintain diameter
throughout?
Check blank for taper or shave tool not
reaching center
o Is roll center line parallel with work
center line?
Check slide for alignment
o Is thread long enough?
Generate concave blank, .0002 - .0003
o Is thread too long?
Generate convex blank, .0002 - .0003
CJWinter | www.cjwinter.com
71. Common Issue #7: Poor Finish
o Are rolls overfilled?
Check if blank diameter is oversized
o Are rolls synchronized?
Resynchronize thread rolls
o Has material accumulated in threads?
If material cannot be removed, replace rolls
o Is material ductile enough for cold working?
Change material if possible
o Are there chips from other operations?
Ensure a good jet of clean oil is reaching rolling position
o Are rolls worn or broken?
Replace rolls
CJWinter | www.cjwinter.com
72. Common Issue #8: Poor Thread Form
o Is work bending during rolling?
Support part during rolling
o Does rolls’ timing match?
Resynchronize rolls
o Are there too many work revolutions?
Increase roll penetration
Most coming thread rolling issues are due to rolling too slow
o Is centerline of rolls parallel with center line?
Check slide for alignment
Check attachment/mounting hardware
CJWinter | www.cjwinter.com
73. Common Issue #9: Crests Not Filled Out
o Is blank too small?
Increase blank diameter
o Is thread on roll too deep?
Replace with rolls of correct depth
*Note: Special truncated rolls are available if burnish crest or round crest
are required on your part
*Many users do not consider crests a serious problem, and allow thread
forms to be produced with crests not completely filled out — avoiding
roll overload and prolonging roll life.
CJWinter | www.cjwinter.com
74. Common Issue #10: Scuffed Crests
o Is the attachment retracting too slowly?
Increase speed of roll retraction
o Are rolls and gear train binding?
Check gear train, remove any foreign matter
o Is the rolling set off the center line of work?
Reset slide with gage
o Are materials accumulating in threads?
Check coolant flowing on rolling position and make sure a good jet of
clean oil is flushing and lubricating this position properly.
CJWinter | www.cjwinter.com
75. NEW Products in Thread Rolling
Precision Involute Knurls and Splines
CJWinter | www.cjwinter.com
76. NEW Products in Thread Rolling
192-ES: Precision Involute Knurls and Splines
• Overall dimensions for the
standard tool are illustrated to
the right.
• Capacity of the tool includes
most parts in the following
ranges:
CJWinter | www.cjwinter.com
77. NEW Developments in Thread Rolling
On Non-leaded Brass (ECO
BRASS). We have been able
to roll threads with 16 TPI
[1.5] or finer with good
success.
A process for coarser threads
is still under-development.
CJWinter | www.cjwinter.com
Lead-Free Brass
• 1/8 – 27 run on a 1” ACME
• 4th and 6th position
Photo A
78. NEW Developments in Thread Rolling
We used our radial pneumatic
attachment – The CJWinter pneumatic
attachment will allow for very fast and
precise adjustment of both the
penetration rate and pitch diameter. We
have learned that this is critical for
rolling no lead brass.
The radial approach allows
displacement of material in more even /
balanced material flow versus using a
tangential attachment. Radial method
seems to work better for no lead
applications.
The Pneumatic attachment allows for
the independent setting of the
penetration rate - independent of cam.
CJWinter | www.cjwinter.com
Lead-Free Brass
• 3/8 – 18 run on a 1” ACME
• 4th and 6th position
Photo B
79. NEW Developments in Thread Rolling
Standard Thread Rolls should work fine.
If you have to have a full thread and
experience flaking on the top of the
thread, try using thread rolls designed
for burnishing crests.
Good cutting oil can also make a big
difference. You need a good mineral
base oil with extreme pressure
additives. A good mineral base oil
with extreme pressure additives is
what has worked for us.
CJWinter | www.cjwinter.com
Lead-Free Brass
• 7/16 – 20 run on a 1” ACME
• 4th and 6th position
Photo C
80. NEW Developments in Thread Rolling
You need to have a good blank
before thread rolling.
Due to the 3:1 ratio between the
blank diameter and the major
diameter, you need less than
0.0005” repeatability on your
blank diameter.
CJWinter | www.cjwinter.com
Lead-Free Brass
• 1/4 – 28 run on a Davenport
• 3rd position
Photo D
81. Acknowledgements
Thanks to the Chase team for
their hard work and feedback
on these developments:
• Tommie Clair
• Thaddeus Scranton
• Thomas Christie
CJWinter | www.cjwinter.com
82. About CJWinter
o Thread Rolling Attachments
o PNEUMATIC
o END ROLLING
o CNC
o TANGENTIAL
o MATCH TAPER
o OUTBOARD
o Thread Rolls for any attachment
o Cold Root Rolling
o Machine Dies
o Specialty Dies
o Tools Holders & Slides
Learn more at www.cjwinter.com
CJWinter | www.cjwinter.com
83. • CJWinter has proven that speedy delivery, flawless quality and
competitive prices can all be delivered simultaneously for our machine
dies.
• Our team of dedicated engineers focuses on solving every customer’s
thread rolling and machine die challenges. Our specialty is providing
superior products in the industries shortest lead time.
CJWinter | www.cjwinter.com
Better Tools, Faster Turnaround
84. • Half a century of leading-edge service to the machining
industry
• Individual attention
• Superior service
• Flexibility
• Meticulous attention to detail
• Innovation and quality
• Intensive hands-on training and experience
• We understand what you need, and are able to customize
jobs to meet your exact specifications.
CJWinter | www.cjwinter.com
From CJ Winter, you get:
86. Questions?
Visit us at www.cjwinter.com
Contact:
Lib Pietrantoni
Director of Global Sales, ME
lpietrantoni@brinkmanproducts.com
Paul Allart
Product Engineer
allart@brinkmanproducts.com
CJWinter | www.cjwinter.com
90. Common Issue #11: Hollow Work in
Tapered Threads
o Is wall thickness uneven or insufficient?
Drill later in cycle
o Is mandrel offering enough support where needed?
Check mandrel for size with hole
o Is high feed rate causing rapid penetration?
Slow penetration rate
o Does taper of rolls compensate for tendency of work to taper?
Use correct rolls for job
CJWinter | www.cjwinter.com
91. Common Issue #12: Drunken Threads
o Do rolls match?
Resynchronize rolls
o Is roll centerline set off from centerline of work?
Check slide for alignment
o Are rolls inaccurate?
Replace rolls
o Is work bending during rolling?
Support part during rolling operation or slow penetration rate
Check centerline of rolls to part
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92. Common Issue #13: Split Thread Axially
o Is stock seamy?
Change stock
o Are there marks from shave tool or hollow mill?
Regrind tooling
o Is tubing material welded?
Use seamless tubing material
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93. Common Issue #14: Off-size Threads
Are any of the following oversized?
o Blanks
Reduce blank diameter
o Pitch diameter
If major diameter is correct size, oversize the blanks
If major diameter is undersize, increase roll penetration
o Major diameter
If pitch diameter is correct size, reduce blank diameter
If pitch diameter and major diameter are both undersize, increase
the blank diameter.
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94. Common Issue #15: Undersize Threads
Are any of the following undersized?
o Blanks
Increase blank diameter
o Pitch diameter
If major diameter is oversize, reduce roll penetration
If major diameter is correct size, increase blank diameter
o Major diameter
Increase blank diameter
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95. Common Issue #16: Off-of-Round Threads
o Is blank out of round?
Shave tool is not reaching center, or not cleaning up rough form diameter
o Is roll centerline set off from centerline of work?
Check slide for alignment
o Is feed rate too high?
Reduce penetration rate
o Are there insufficient work revolutions?
Reduce penetration rate
o Is material ductile enough for cold working?
Change material, check with supplier
o Is the attachment off the centerline of work?
Reset the cross slide with gage
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96. Common Issue #17: Tapered Threads
o If pitch diameter is straight, major diameter is tapered and not
filled out on small end:
Straighten blank
o If pitch diameter and major diameter are both tapered in the
same way:
Straighten blank
Taper adjust roll pins
o If pitch diameter and major diameter are tapered in opposite
directions and thread is not filled out on end:
Support part during rolling. Part deflecting out of contact with center of
rolls
CJWinter | www.cjwinter.com
97. Common Issue #18: Thread with Expanded Lead
o For expanded lead in rolls:
Use correct rolls (Modified Lead)
o For extruding material on short length of blank:
Use longer blank; remove excess in another position
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98. Other Thread Rolling Problems
Get answers on CJWinter.com’s
troubleshooting guide
CJWinter | www.cjwinter.com