What is Roll-On Roll-Off™ Thread Rolling System?

Technology is constantly evolving. The Ford model T eventually evolved in to the F40 and beyond. Thread rolling likewise is a constantly evolving technology. The tools themselves have become more user friendly and the rolls have improved in performance over a wider range of materials.

New strategies have evolved to reclose a thread rolling head following its popped open stature. Indexing the tool and striking its closing handle on a fixed obstruction was a widely used method. An air cylinder mounted as an actuator was another method. Cleverly configured tension spring devices also had merit. All these methods required limited investment and could exhibit modest failure occurrences.  More recently, a closing device attached to the tool and activated with high pressure coolant seemed to address the earlier issues. While it could only be affective on machines with the required coolant pressure, it too was susceptible to mechanical failure.

Lights out manufacturing can’t tolerate intermittent failure. In a goal to find a constant method to achieve lights out production on virtually every machine configuration, we developed a patent pending device to keep the head closed and utilize a Roll-On Roll-Off™off strategy. The desired result has had remarkable success. While nearly matching the cycle times prevalent with the older strategies the lack of moving parts has impacted on the physical life of the tool itself. Rotating the spindles during normal pop open operations generate wear on both the spindle and face plate. This resultant wear begins to exhibit itself as taper in the thread form. The new device allows for tool float and keeps the head closed negating wear on spindles and face plates.

Closing strategies and closing device cost are no longer a consideration. Closing failures are no longer a consideration in a “lights out” run time strategies.

Device development was internal to Turning Concepts, LLC. We are presently the single source for the patent pending tool attachment. Do you have an application that could benefit from our development?  Contact us directly for information on availability and cost.

Want To Improve Tool Life Dramatically?

It started with the wheel and later led to the telephone and electricity. Invention and discovery continue to change the face of our world as we know it. Thread rolling developed in the early twentieth century and has mostly remained constant since its invention. While difficult materials can be rolled, the life of the rolls themselves are limited when compared to mild steels. Nitriding was one means of improving roll life and reducing part cost but also had marginal benefit. Recently a new method has emerged that has shown the ability to improve tool life dramatically. It requires secondary processing of the basic thread roll that adds time to delivery as well as an increase in roll cost by 50% to 70% above the cost of the manufactured roll but the results can be staggering.

We presently have a customer running 17-4PH Stainless Steel that is achieving a 1000% increase in basic roll life. The cost benefit is dramatic, the downside for us is a 10-fold reduction in roll sales to this customer. We pride ourselves on our attention to technology and the goal of being the most valued supplier our customers do business with.

The new technology to improve wear resistance on thread rolls can probably be used on any part that sees friction wear as a failure mode. We can offset our thread roll sales loss by employing the technology into other tools not presently strong in our sales forecasts. Parts that fail due to friction, gears, wear plates, hobs, mold and die plates as well as a multitude of other components could well be strong candidates for improvement. Is friction a contributor to your tooling cost?  Contact us, we would like to offer a solution and allow you to speak with our end users that are on the cusp of dramatic change in threading cost.