This has been an objective of
mankind since the invention of the ship.
The statement has grown to reflect shelter conditions in virtually any
With the advent of Covid-19 the
importance of a “Safe Port” has become a global objective. As a
supplier to both big and small businesses our commitment is to continue
“business as usual” within the circumstances surrounding us. Our
supply from Italian manufacturers is limited due to the situation in their
country. Please keep our Italian friends
in your thoughts and prayers.
However, most our suppliers are
maintaining operations and many of our customers and suppliers are considered
“Essential Businesses” and will continue in operation. These Many parts of our country are still
operating and require the same technical resources they were accustomed to
during normal times.
We have added protection to our
staff by initiating a “work from home policy,” limiting office
staffing to handle shipping and answer phones.
Fortunately, this digital age makes it possible for us to practice
social distancing within physical office and warehouse spaces and allow our
home bound staff have the resources needed to serve you as usual.
Our team is available to answer
your phone calls and emails. We are
eager to support you, process your orders and supply technical assistance
whenever needed. Contact us with your individual needs, we’re here to help!.
Fette thread rolling tools have versatility and can be
applied to rolling other forms besides external threads. Knurling and swaging
applications are easily done on axial, tangential and radial tools with great
success. Axial heads are especially successful at rolling straight form, left
hand helical, right hand helical and diamond knurl patterns.
The displacement of material forming the knurl pattern
exhibits no sharpness in the formed knurl. This is especially important
when handling knurled instruments wearing delicate gloves. Very fine to very
course patterns are achievable and tooling set up is extremely easy. The
application of rolling speeds, like threading, makes cycle times extremely
short. This makes the tool application very cost effective.
Swaging is also easily adaptable and the axial approach to
swaging yields consistent product quality hard to achieve with a side approach
swaging tool. Distortion is nonexistent and swage roll life is extremely high.
Symmetrical and step style swage forms can be accomplished. Form coining of
nose radiuses is also done frequently. The tools are not limited to straight
If your current tool selection includes thread rolling heads you may not have known that they have applications beyond male threads. Contact us with your Knurling and Swaging applications. We can identify your current tooling and determine if it’s applicable. We can also quote a new application with all the necessary tooling.
All cut taps are not manufactured on equal footing. Most European and Japanese taps are produced from powdered metal blanks. This allows for improved performance of the cutting edge due to the irregular grain structure of the tool. Coatings are also “state of the art” and have a large impact on performance. An example of unique design is the LMT V-Magic Tap. The coating consists of a TICN multi-layer coating on the threads with a steam oxide coating in the gullet. It is designed to improve chip removal performance in materials that produce long erratic chip flow. The steam oxide coating has a greater coefficient of friction than the TICN and forces the curling chip to pack more densely as it flows away from the tap. This aids in controlling the chip flow and form improving the overall performance of the tap.
Roll threading a journal requires turning the diameter
before rolling. Roll threading implies that part volume is a key. In any
high-volume production application, the parts require turning to prep for
threading. The blazing speed of roll threading can be mirrored with equal
speeds in turning the blank. Utilizing a multi fluted indexable hollow mill
with 3 or more carbide turning inserts can triple or quadruple turning speeds
always utilizing a single pass process. Nothing is faster or more accurate.
Most always, the time saved in turning, more than pays for
the tooling costs. It always yields dramatic production cost savings as well as
equally dramatic production increases. Not all hollow mills are created equal.
Some indeed work better than others and our years of thread rolling experience
have given us an edge in identifying the right tool for your application.
Sample us with your component requirements and challenge us to identify the
ideal tool for your application.
Through the publication of previous blogs, we have discussed
in some depth the critical advantages offered by rolling as opposed to cutting
threads in most metals. The tooling design has changed little over several
decades. Using the tools successfully required some self-taught practices that
could be derived from the published instruction furnished with the tool. We
know, only too well, that often the publications were read after the fact when
failure was the initial result. The versatility of the tool required some
set-up knowledge that was not broadly covered in the instructions or was
misunderstood. While the tool was initially used broadly on multi spindle screw
machines and set up was conducted by trained experienced set up people, the
transition to single spindle CNC applications often lacked the trained set up
Recognizing the changing work place applications, more
recently, the tool design has been altered to make it a more user-friendly
tool. Previously, the tool had to be manipulated to use it effectively through
its entire range of thread sizes. Distinguishing the changing market place
applications encouraged the German designers to “modernize” the set-up
capability of the tool.
The newest inception of the tried and true thread rolling
attachment has been upgraded to the newly designed EVO style. The EVO tool
utilizes a setting adjustment that can function through the entire range of the
tool. This eliminates the need to disassemble and reconfigure the tool to
accommodate the smallest to largest possible thread that can be run by the
tool. The tool has two distinct gauge readings that can be mounted to provide
easy viewing of the set point. The closing handle can be rotated 360 degrees to
allow for virtually any location to create the closing of the head after each
operation. These basic but vital changes have made the tool much more user
friendly. While the basic differences between the older original design and the
newer EVO design don’t impact the usefulness of older tools, the new EVO design
changes can be a reason to migrate to the new design. The EVO design also
utilizes solid carbide bushings between the spindle and roll negating the need
for roller bearings. This too helps to reduce changeover time and is a secure
method to lengthen service time between spindle replacement.
Global tooling sources are a common resource for virtually
every country within our planet. North America, Europe, Asia, Scandinavia and
Japan presently supply the bulk of the world’s requirements for metal working
tools. The speed and efficiency of world travel has opened the world as a
market place for technology no matter where the source. This advantage to
manufacturing has only been achieved within the past few decades. Prior to the
advent of speedier international travel, technology evolved but was localized.
The twentieth century is notable for warfare and advances in
technology. We learned following Germany’s defeat in World War Two that they
were within weeks of deploying their version of the Atomic Bomb. Certainly,
this would have a devastating impact on Great Britain or the United States or
both. Jet aircraft, rocketry, carbide cutting tools and thread rolling technology
were a few of the revolutionary products developed for warfare by Germany. As
victors, the Allied countries were the future beneficiaries of Germany’s
strategic technologies. Today as our ally, Germany continues to develop tools
and products that help manufacture products more efficiently and more cost
Metalworking has been advanced with thread rolling
technology that improves cost and performance of any threaded product. Carbide
has been improved with new coating technologies and grades that have virtually
eliminated the use of high-speed steels in manufacturing. As an example, Fette
introduced a coated carbide insert for machining Aluminum that can achieve
operating speeds to 10,000 SFM. Coated carbide nib taps that can outlast their
steel counterpart by a 10 to 1 ratio. High speed milling spindles that start
at 50,000 rpm. The revolution in development of metalworking tools is most
visible at any tooling show throughout the world. Today’s manufacturer must
research and deploy the best tool for a job or face being pushed aside by the
competition. Among our strengths is external and internal threading. We can
help improve your product performance and cost employing the tooling
strategies just discussed. Simply contact us and challenge us to help you
achieve the cost and performance benefits we’ve outlined.
Rolling screw threads in metal is the most cost and quality
effective method of producing threaded parts. Three basic thread production
technologies exist throughout the metal working world. Axial tools produce one
thread with each revolution and have no length limitation other than the
potential stroke length of the machine the tool is mounted on. The
tool design utilizes a roll that requires a soft lead to start the metal
deformation leading to a finished thread form. Depending on the roll lead the
part will exhibit 1.5 or more unfinished thread forms at the end of the part.
The harshness or softening of the lead has a direct impact on overall roll
life. Despite the unfinished thread characteristic, it is possible to gauge to
a shoulder using an undercut behind the thread body to clear away the
unfinished thread portion.
Fette thread rolls are designed with different lead
designations labeled .6K, 1K, 2K and 3K.
0.6K lead roll leaves 1.5 unfinished threads.
1k lead leaves 2 unfinished threads.
2K lead leaves 3 unfinished threads
3K lead leaves 4 unfinished threads.
Both 1K and 2K lead rolls are considered standard and priced
accordingly. A .6K and 3K lead roll set are considered “special” and
are premium priced.
Is there any advantage to running lengthy leads? OF
COURSE! A 2K lead can add 20% to roll life in many materials. A 3K lead
is frequently used in the oil patch industry and the additional unfinished
threads have no impact on the performance of sucker rods as an example. Cost
and availability of rolls often become the driving factor in tool selection as
well as part design. Applying the best roll selection can impact on overall
cost per thread but part design is frequently the driving force behind roll
When thread design commands very short threads or little to
no relief, axial thread rolling is not the best option even though axial
rolling is always the lowest cost tooling option.
The creation of screw threads
began several centuries ago, as a cutting technology. It was first used in wood
applications and as cutting materials improved, metal applications. With the
advent of more powerful machinery, rolling threads on various metals became
possible. The ductility of most metals lead to the discovery and development of
thread rolling technology. Each technology had benefits that were strongly
influential in their direct application.
Cut threads require lower
horsepower to be successful and could be used in materials with little or no
ductility. Most threads up to 2″ diameter are easily rolled on most manual
and CNC machines, both horizontal and vertical. Mechanical requirements are
easily calculated. A one-inch length of a cut thread can be completed in many
materials in 10 seconds. Difficult materials require more passes and more cycle
time. Rolled threads can be completed at a rate of 1 inch per second of cycle
time. Difficult materials pose little if any additional cycle time
requirements. Cut threads create sharp, bright finishes and are without
question prettier than rolled threads.
Rolled threads produce
radiused root and crest of the thread and exhibit at least a 40% increase in
tensile strength over a cut thread. Rolling a thread redistributes the grain of
the material while its cut thread cousin cuts across the grain. Cut threads
will always win a beauty contest over rolled threads but will lose in overall
quality comparison in all roll-able materials. In many of the more difficult
materials to cut, rolling can increase tensile strength by as much as 300%. Cut
threads in corrosive materials will always corrode at a more rapid rate than a
rolled thread with burnished flanks. Many applications that specify rolled
threads only are taking advantage of tensile improvement and corrosion
Roll cost as a ratio of parts
produced versus insert cost per parts produced, rolling will always win the
overall tool cost comparison. All thread classes can be cut or rolled. If your
part cost can be improved by shorter cycle time and improved tensile strength,
thread rolling may be your single opportunity to garner bid work in a job shop
atmosphere. Challenge us to help you find the best cost and quality to improve
your winning bid ratio.
Our shared victories with our allies in two world wars made
us recipients of several technological discoveries. Following the end of WW2,
jet propulsion and rocketry were only two of many technologies to migrate to
America along with many of the scientists and engineers who developed them for
Rolling of external threads in metal became one of the
technologies we garnered from Germany. National Acme Machine Company in
Cleveland Ohio developed a joint venture with the Willhelm Fette Co. in Germany
to market and use thread rolling attachments in their multi spindle production
machines. James Abbott from NAMCO became the US point man for the joint
venture. As time moved forward, NAMCO was acquired by the Cleveland Twist Drill
Co and they made an internal decision to copy and produce the thread rolling
tools being imported from Europe. This led to the development of Fette America and
the product from Germany imported to the American market. Jim Abbott became
their technology manager for their American market place.
Since the disillusion of the joint venture, the American
made product changed ownership several times but did not evolve. The German
product on the other hand continued to evolve with many strategic changes
implemented to allow the device to be used on modern CNC equipment as well as
multi spindle machines. The product continues to evolve today and Turning
Concepts (TC) has taken an active role in the evolvement. TC has developed an
attachment for axial thread rolling heads that permits a roll on roll off
strategy taking advantage of the canned cycle programs of the typical CNC
machine. Patent applications are processing while implementation is in
progress. Rolling heads are being preset and shipped with specific
instruction that typically allow installation with first piece acceptance. We
at TC prefer to lead with a technology we understand and can apply with
confidence. Let us help by sharing our experience and implement a solution to
your manufacturing demands.
There used to be an old saying “You can lead a horse to
water, but you can’t make him drink.” For too many years this saying could
easily apply to thread rolling technology. For too many potential users it
seemed too complicated, too difficult to understand. It was thought the tooling
required could only be applied to multi spindle screw machines. The reality is
it can be relatively simple to apply and even more appropriate to install on
modern CNC equipment.
We have been involved in the application and development of thread rolling attachments for more than 50 years. Application knowledge and service have been the core strength of our organization servicing North America’s thread rolling users. We indeed cover North America and despite our location in the Eastern Time Zone, we service customers in the Central, Mountain and Pacific time zones as their workdays unfold. Our application engineers routinely monitor their phones daily. Accepting calls from end users throughout North America as their time dictates. Precise knowledge and dedicated service make our organization the “go to” people for thread rolling technology. Certainly, we want to sell thread rolling products but more importantly we want to support your threading applications. Knowing your threading history and machine applications give us confidence in your repeat business and provide you with the confidence to expand your application. Contact us, we’re eager to provide you with contact names and phone numbers of our people that can be your mobile guide.