Production of a lead screw

 

 

Rolled Vs. Whirled!

The manufacturer of a lead screw explained briefly and concisely. 

How does the production of lead screws actually work?  What are the processes and what is the difference between thread rolling and thread whirling manufacturing processes?

Let’s make a comparison between two manufacturing methods: thread rolling and thread whirling.

Thread rolling manufacturing process

Thread rolling manufacturing process is part of the manufacturing process of shaping according to DIN 8580. In contrast to thread whirling, it works absolutely without cutting.

The manufacturing process of thread rolling is very easy. A workpiece is placed centrally between two tools with the profile. They rotate simultaneously and the tread is rolled into the surface of the raw material by cold forming. The thread profile has been transferred to the workpiece by the compressive stress and rotation. This is how the thread is created.

Here is an example:

Production of lead screw (Thread rolling manufacturing process)

Benefits: For high volume and mass production, this method is faster and more cost-effective than thread whirling, because the requirement of the material is lower. Additionally, cold forming achieves a hardening of the surface and higher strength. The pitch angle, the high surface quality of the rolled thread and the low coefficient of friction of the plastics result in high efficiency and long service life of the lead screw drive.

Our lead screws can be designed online with just a few steps and be able to download the CAD including production drawing without any charges. Users do not require any CAD software knowledge to handle CAD programs. In addition to the configuration tool, igus® also offers a wide range of products in its online shop.

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Thread whirling production

Now, we are going to take a look at the second manufacturing option. As mentioned above, thread whirling is a machining production process. This method dedicates to the production of the male thread.

Unlike thread rolling, the manufacturing process of whirling requires only one tool. The ring-shaped tool is clamped around the appropriate workpiece and rotates very slowly while the whirling tool rotates outside at very high speed. The thread is produced by inward-facing cutting bits.

Take a look at the illustration for better understanding.

                           Production of lead screw (Thread whirling manufacturing process)

The Benefits: This process is ideal for very precise thread production that requires a particularly high surface quality. i.e. the surface is rougher and edges sharper compared to thread rolling. Its flexibility makes it suitable for a wide range of thread geometries. The process is usually used for materials that are not or least suitable for thread rolling.

Conclusion: lead screw production

Both manufacturing processes have their special specifications. igus® uses thread rolling as a standard process because it saves cost, and better surface finish, and longer service life. Thread whirling is more suitable for small quantities and very precise threads with narrow tolerances. It also depends individually on the required specifications and application used.

 

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