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Thread forming: Producing threads without chip removal
Thread production involves a variety of methods, and tapping is just one of them. While it's often the preferred choice, other techniques like milling, turning, rolling, and thread forming are also available. In this post, we’ll explore the thread forming method in depth, helping you understand its advantages, limitations, and how it compares to traditional cutting processes.
What is Thread Forming?
Thread forming is a chipless method of thread creation, meaning no material is removed during the process. Instead, the thread is formed by displacing the material through pressure, which results in a denser, stronger thread structure. This technique is commonly referred to as cold forming because it occurs below the material’s recrystallization temperature, preserving the integrity of the metal fibers.
How Does It Differ from Cutting Threads?
Thread forming taps differ significantly from conventional screw taps. Unlike cutting tools, they don’t have sharp edges or flutes for chip removal. Instead, they feature a polygonal shape with a forming cone that presses the thread into the workpiece. The absence of cutting edges means no chips are produced, but it also requires careful lubrication due to high friction.
One of the most noticeable differences is the thread itself. Formed threads often show small hollows at the tips, known as “claws.†More importantly, the material fibers remain intact, leading to improved mechanical properties and higher tensile strength compared to cut threads.
Advantages of Thread Forming
Thread forming offers several benefits. First, it produces threads with excellent surface quality and increased pull-out strength. Second, it allows for deeper threads than traditional tapping methods. Third, since no chips are generated, there’s no risk of chip clogging or damage to the workpiece.
Applications and Limitations
Not all materials are suitable for thread forming. The process works best with highly formable metals such as aluminum, titanium, stainless steel, and some nickel-based alloys. However, it's not ideal for hard or brittle materials. Additionally, the pitch size is limited—typically up to 3–4 mm depending on the material. If you need a larger pitch, another method may be more appropriate.
Key Considerations
When using thread forming, it’s essential to select the correct core hole diameter. This is calculated differently than in thread cutting. Proper lubrication is also critical, as the high friction can lead to excessive heat. Oil grooves or internal lubricant systems can help maintain performance and tool life.
Pros and Cons
The main advantages of thread forming include no chip generation, better surface finish, and longer tap life. However, it has limitations in terms of material compatibility and requires specialized equipment. High-quality lubricants and precise machining are also necessary for success.
If you're looking for thread forming taps or compatible cutting oils, check out the online shop of tap manufacturer BAER. Our team is here to help if you have any questions or need further assistance. Explore our range today!