REQUIRED CAPACITY FOR THE MACHINE
Please calcaulate out the necessary precessing power with inputting the thread parameters in following formula.
|N = 0.174 x 10-6 x C x T x D x N Kw|
|C=1 Triangular Screw (M, Unified, and WIT )|
|C=2 Trapezoidal Screw (Tr, Acme, etc.) or R-shape Screw|
|T=Tension (N/mm²), P=Pitch, D=Diameter, N=Revolution of Material|
Thread Rolling Process is the fast and economical way due to its capability for high speed revolution Parameters below are just the bench mark, and arranged by users. But "Revolution" can never be slower than 20m/min
"Revolution" can be increased if the pitch is fine, and contractively , can be decreased if its rough. Please use following formulas to calculate out the revolution speed according to the variation of the thread.
|ROLLING SPEED v=m/min
ROLLING TIME t=sec
d = Preprocessed Diameter = Pitch Diameter (mm) p = Pitch (mm) L = Thread Length (mm)
|Recommended conditions of Revolution||
FIGURE OF PREPROCESSING
The material must be preprocessed to the "Pitch Diameter (d2)". And the right size of "Pitch Diameter" will be fixed after the trial processing because of the difference coming from each material's specification. The tolerance of preprocessed diameter must be with in ± 0.02 mm.
FIGURE OF APPROACHING SIDE EDGE
The starting point of rolling (approaching side edge) must be chamfered with the inclination form 10 to 20 degree. And the Diameter of the edge must be slightly smaller tha "Minor Diameter (d3) " of the thread. As the chamfer's invlination is getting lower, the duration of roll is getting longer due to the reduction of stress against roll.
Normally, recessing is not necssary for the part of thread-end. In case of need , the preprocessed diameter of recessing point should be smaller from 1 to 5mm, and the edge should be chamfered same as the starting point.
TOOL LIFE OF ROLL
Several thousand meters of thread can be processed with standard roll as far as installed and operated in accordance with manual perfecrly.
Relative high revolution (30m/min or higher) will brings good effec to the duration of rolls.
The duration of the rolls is depending not on on the figure of the thread, but also on the thoroughness of coolant and the specification of material - Elongation, Elasticity, etc.
DESIRABLE SHAPE OF THREAD
As indicated by the photo below, the top of thread should not be complete into a sharp edge, but remain slightly incomplete, this incomplete top shape affects to thedutation significantly.
Normally, it must not be a problem because the top of the thread has no funcion for the screw.
LUBRICATION AND COOLING
Please be sure to use the "Coolant" or "Lubrication oil" to extend the duration of rolls, and also be sure to wash away the chips and dusts before rolling, which is glued to the work-piece from preprocess.
The general fluid, for instance solubie type oil thin down 10-20 times - better with additive, can be used for Thread Rolling process. The cutting oil of low-viscosity can also be used for Thread Rolling.
In andy case, The duration of rolls can be extenede substantially with adding additive agent.
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