Processes, Types, and advantages of Thread Rolling

Thread Rolling: Types, Processes and Advantages

Introduction

This guide contains everything you need to know about thread rolling and screw machine products.

You will learn about topics such as:

What is thread rolling?
Thread rolling processes
Advantages and disadvantages of thread rolling
Common defects
Types of thread rolling machines
And much more��

Chapter 1: What is Thread Rolling?

Thread rolling is a threading process that involves deforming metal stock by pressing it between dies to produce external threads on the surface. This technique can also generate internal threads via a procedure known as thread forming. Unlike conventional threading methods like thread cutting, thread rolling is a non-subtractive approach, meaning it doesn't involve removing metal from the stock. Rolled threaded fasteners offer benefits such as enhanced thread strength, accurate final measurements, superior surface finish, and reduced friction coefficients.

Screw machine products include threaded machine items such as bolts, nuts, and screws. These threaded components can be grouped based on their purpose. Bolts, nuts, and screws serve as structural elements or fasteners. Threaded fasteners may also be integrated into parts, creating threaded fittings.

Threaded fasteners are utilized to establish non-permanent connections, allowing for components to be mechanically loosened or disassembled. On the other hand, power screws and lead screws function as mechanical devices or drives, serving as mechanisms to regulate movement and transmit force to other machine parts, thus playing an essential role in mechanical systems.

Screw Thread Forms

Screw threads can be classified according to their shapes.

V-Thread: These threads are triangle-shaped and typically form an angle of 60° with flanks. Crests and roots are usually sharp, though sometimes slightly flattened due to fabrication limitations.
American National Thread: Previously referred to as the United States Standard Screw Thread, this thread type standardizes a V-thread version with specified dimensions for crest and root flatness. It replaced the basic V-thread for general purposes.
British Whitworth Thread: This thread type was the UK equivalent of the American National Thread.
Unified Thread: The Unified Thread form succeeded the American National Thread, merging thread standards from the US, Canada, and the UK for interchangeable parts. It retains a V-shape with rounded or flat crests and roots, offering series like Unified Fine (UNF), Unified Coarse (UNC), Unified Extra Fine (UNEF), and Unified Special (UNS).
Metric Thread: This thread form transitioned threading standards to the metric system under ISO, phasing out the UTS thread form in favor of metric dimensions.
Square Thread: Designed for power transmission, square threads are ideal for mechanisms due to perpendicular load-bearing faces. However, they are impractical due to manufacturing constraints.
Acme Thread: An adaptation of the square thread, the Acme thread has a trapezoidal shape with a narrower root than crest. It is easier to machine and stronger than the square thread.
Buttress Thread: This thread features one perpendicular flank or slightly angled with the axis, while the other flank forms a 45° angle, designed to handle high loads in one direction.
Knuckle Thread: Characterized by highly rounded crests and roots with a flank angle of 30°, this design allows debris to move aside, ensuring smooth thread meshing.

Chapter 2: What is an overview of threading processes?

Thread generation processes are fundamental to manufacturing, machine shops, and the production of precision fasteners, screws, and bolts. Understanding threading processes is critical for industries that rely on high-strength, accurately dimensioned threaded components. Thread production is typically classified into three main categories—subtractive, deformative (also called deformation), and additive—each distinguished by how threads are created or formed on metal, plastic, or composite workpieces. These various techniques form the backbone of industrial fastener manufacturing, and each process has unique advantages based on application, thread profile, and product requirements.

Subtractive processes, often referred to as cutting processes in the context of precision machining, are among the most widely used methods. Machinists, toolmakers, and fabrication engineers carefully select these processes based on thread type (internal vs. external), required material strength, thread finish, and production volume. Below is a comprehensive summary of common thread generation methods:

Tapping: Tapping is a thread machining process for producing internal threads, commonly found in nuts and tapped holes. This is achieved using a tap, a cylindrical or conical cutting tool typically made from high-speed steel or carbide. The tap has multiple cutting edges that mirror the external thread form. During thread tapping, the tap is rotated and progressively advanced axially into the pre-drilled hole or bore of the metal stock, cutting the internal thread as it goes. This method is frequently used for thread manufacturing in mass production environments, especially for machined parts requiring high accuracy.
Die Threading: This process is used to produce external screw threads, such as those on bolts, studs, and threaded rods. Its method of applying force and cutting action is similar to tapping, but a die is used to cut external threads onto the metal stock, with multiple cutting points forming the helical thread pattern. Dies are available in solid, self-opening, and adjustable varieties to suit different production requirements. Thread dies provide reliable results for low- to medium-volume production and are ideal for repairs or creating custom threads outside of automated machinery.
Single-point Cutting: Single-point cutting is performed on a lathe or CNC turning center, where the workpiece is securely held and rotated. The cutting tool, precisely mounted on the carriage and fed linearly by a lead screw, traces the helical path to form the thread. This process is suitable for both internal and external threads and is well-suited for creating custom, variable-pitch threads or unique profiles. While single-point threading is slower than tapping or die-threading, its flexibility and ability to cut large or specialized threads make it valuable for prototyping and low-volume, precision applications.
Chasing: This process uses a tool called a thread chaser, which is an assembly of several single-point cutting tools arranged in succession. The thread chaser is typically mounted on the lathe’s carriage, gradually indexed to cut the thread accurately along the workpiece length. Thread chasing is commonly used for large-diameter threads and for restoring worn or damaged threads where precision is critical.
Milling: In thread milling, single or multiple rotary cutting tools are used to machine threads into a workpiece. Unlike tapping or die-threading, thread milling involves the rotation of both the cutting tool and the workpiece along their respective axes, allowing for the creation of both internal and external threads, including tapered and multi-start forms. Thread milling provides exceptional flexibility and is preferred in CNC production for quick changeover, high accuracy, and the ability to run on difficult-to-machine materials such as stainless steel or high-strength alloys.
Grinding: Instead of traditional cutting, thread grinding employs abrasive wheels or discs to remove material and achieve a fine surface finish and precise thread dimensions. This process is often used in conjunction with other threading methods and is commonly reserved for hard materials, finishing, or high-precision threaded components such as lead screws, ballscrews, and high-tolerance fasteners. Thread grinding is essential in the manufacturing of aerospace, medical, and instrumentation threads, where tight dimensional tolerances and smooth surface finishes are mandatory.

Deformation (deformative) processes generate threads by displacing and reshaping the metal workpiece without any removal of material. Common deformation threading processes include rolling and casting:
Rolling: Thread rolling is an external threading process that plastically deforms the workpiece by passing it through precision-ground roller dies. These dies have the inverse of the desired thread form and, through pressure and friction, reshape the surface to form threads with improved surface finish and increased strength due to work hardening. Thread rolling is widely used in automotive, construction, and high-volume fastener manufacturing for its efficiency, accuracy, and the enhanced fatigue resistance it imparts to threads. The process is considerably faster than thread cutting and produces no waste material.
Casting: Thread casting involves pouring or injecting molten metal into a precision die or mold that contains the negative shape of the desired threaded part. While casting is efficient for producing net-shape parts in high volume, it generally requires secondary machining—such as tapping or thread chasing—to achieve accurate threads, particularly for small or fine thread profiles. Among the most common uses of casting in thread manufacturing are for large fittings or coarse threads found in pipe fittings and valves.

Finally, additive manufacturing processes, also referred to as 3D printing, are innovative methods for thread production by precisely depositing material layer by layer. These processes are increasingly applied for prototyping and for manufacturing both plastic and metal parts, especially when complex or custom thread geometries are needed. Currently, additive threading is often combined with secondary finishing operations—such as grinding or lapping—to meet industry tolerances.

Key additive threading techniques include stereolithography, selective laser sintering (SLS), and fused filament fabrication (FFF):
Stereolithography (SLA): One of the most widely used 3D printing processes for producing plastic parts, stereolithography involves a vat of photo-reactive liquid resin, which is selectively cured and solidified by a focused ultraviolet light or laser. SLA-printed threads are ideal for rapid prototyping and low-volume manufacturing, especially for precision plastic threaded components.
Selective Laser Sintering (SLS): This process utilizes a high-powered laser beam to sinter powdered materials—plastic, nylon, or various metals—layer by layer, fusing them into a solid structure. While plastics remain the most common material, growth in sintered metal threads is enabling the on-demand production of custom metal parts with complex or internal thread geometries that are not easily machined by traditional methods.
Fused Filament Fabrication (FFF/FDM): In this economical and accessible method, a continuous filament of thermoplastic or composite material is heated, melted, and extruded through a nozzle to build the part layer by layer. FFF is commonly used for developing prototypes with functional threads or for manufacturing replacement components in low-stress applications.

How to Select a Threading Method: Choosing the optimal thread generation process depends on several factors, including material type (such as carbon steel, alloy, aluminum, brass, or plastic), required thread geometry (standard, metric, acme, or custom thread profiles), production volume, cost considerations, and the mechanical properties required of the finished thread. For example, thread rolling is preferred for mass production of high-strength bolts, while thread grinding is chosen for aerospace or medical applications where extreme accuracy and surface finish are critical. CNC threading, incorporating both single-point and thread milling techniques, brings flexibility, efficiency, and repeatability to modern manufacturing environments.

For engineers, purchasing agents, or machinists seeking to specify or source threaded components, understanding the advantages of each technique ensures optimal performance, longevity, and cost-effectiveness. Partnering with a trusted threaded fastener manufacturer or precision thread supplier is crucial for applications with tight tolerances, custom designs, or specialized requirements.

Leading Manufacturers and Suppliers

Chapter 3: What are the advantages and disadvantages of thread rolling?

Using a rolled screw machine product comes with both advantages and disadvantages. The primary advantage of thread rolling is that it produces stronger surfaces and offers high dimensional accuracy. However, because this process relies on metal deformation, it is generally limited to soft metals and involves higher tooling costs.

Listed below are the benefits of using rolled screws and bolts:

High thread strength: Thread rolling is usually done in relatively low temperatures making it a cold working process. Cold working is known to produce parts with higher strengths without the need for secondary heat treatment. This makes rolling suitable for threading materials that do not respond to heat treatment. Rolled threads are 10 to 20 percent stronger than cut or ground threads.
Good surface finishes: Thread rolling inherently imparts smooth and burnished threads without the need for secondary polishing processes. The high compressive forces that deform the metal remove any unevenness on the surface of the thread. Rolled surfaces have a surface roughness of approximately 8 to 24 microinches Ra while cut threads typically have 64 to 125 microinches Ra. Rolled threads are also free of tears, chatter marks, cutting marks, and burrs.
Precision threading: Since the dies used in thread rolling are mirror images of the threads to be generated and there is no material being removed from the stock, the process can produce parts with high precision and accuracy over long runs. This is true provided that the dies are accurate and made with sufficient hardness.
Lower coefficient of friction: Good surface finish leads to a lower coefficient of friction. A lower coefficient of friction provides more uniform and consistent tightening of nuts and bolts or better power transmission for lead screws.
Lower production lead times: Thread rolling is generally faster than thread cutting. Rolling speeds depend on the type of material, thread profile, size and capacity of the machine, and method of feeding the metal stock. For reciprocating dies, thread rolling can produce 30 to 40 parts per minute with stock diameters ranging from 5/8 to 1 1/8. For cylindrical dies, 10 to 30 parts per minute for sizes ranging from 1 to 1 ½ inch.
Lower cost brought by the efficient use of material: Since thread rolling is a deformative process, no amount of material is removed throughout the process. This leads to better energy utilization since there is no need to collect and recycle wasted materials.

Below are the disadvantages of thread rolling. It can be seen that these mostly affect the manufacturer rather than the end-user. Ultimately, these contribute to the product cost making rolled threaded products, in some cases, more expensive than products produced from other processes.
Not practical for hard materials: Thread rolling is mostly done on malleable metals. Even though it is possible, thread rolling is not done for metals above 40 Rockwell C. Beyond this hardness level, thread grinding is more practical. Rolling hard materials significantly decreases tool life.
More expensive tooling: Dies used for rolling must be hard and precise. Any deformity of the die will result in poor dimensional accuracy of the threads. Because of the required hardness, precisely fabricating the dies are difficult.
Stock diameter must be precise: There must be the right amount of material that will flow to be displaced and raised above the original surface. The diameter of the stock must be calculated and verified by trial especially when producing accurate threads. To get the right diameter, the stock may require a preliminary turning process.

Chapter 4: What factors should be considered in thread rolling?

As with any machining process, several factors must be considered to ensure optimal operating conditions and product quality. Below are some of the key variables that impact thread rolling.

Material Requirements: A known disadvantage of thread rolling is its incompatibility with hard materials. The materials to be rolled must have a hardness not greater than HRC 40. Materials that can be rolled are low-carbon steels, mild steels, stainless steels, copper alloys, and often, aluminum. Moreover, the material must have the right degree of ductility. The recommended range is 12 to 20% elongation factor.
Stock Diameter: The correct stock diameter is almost the same as the pitch diameter of the screw or bolts. Usually, the space or cavity between the threads and below the pitch line is the same as the volume of the thread above the pitch line. Some adjustments for tolerances may be needed to attain the desired crest formation, especially if secondary processes such as coating, or plating are needed to be done.
Chamfer Angle: Chamfer is the tapered conical surface at the start of a thread. Before rolling, the edge at one end of the stock must be machined to have a chamfer. A correct chamfer angle must be set to properly shape the thread at the end. The recommended chamfer angle is 30° for most cases.
Feeding: There are three basic techniques for feeding the stock into the dies: radial infeed, tangential feed, and through feed. In radial infeed, the dies move radially towards the axis of the stock. For tangential feed, the pitch of the stock approaches the rollers from its side making square, tangential contact. Lastly, through feed involves a cylindrical die that mates against the stock causing it to move axially.
Thread Rolling Speeds: Thread rolling speeds depend on the mechanical and power limitations of the machine, the thread diameter, and the material and hardness of the metal stock. Rolling speeds can range from 30 to 100 m/min. Low rolling speeds are required for hard materials while high speeds are for soft and ductile materials.
Coolant and Lubricant: Coolants or cutting fluids are extensively used in thread cutting, but these are also necessary for thread rolling. Deforming the metal also generates heat which can compromise both the dies and stock. Moreover, coolants can act also as lubricants to reduce the friction between the dies and stock.

Chapter 5: What are the common defects in thread rolling?

Although the thread rolling process provides higher precision compared to other methods, defects can still occur due to upsets and irregularities in the operation. Common issues include out-of-tolerance stock dimensions, worn or misaligned rollers, and improper stock feeding. The following are the most frequent defects observed in thread rolling.

Truncated Thread Crest: This defect is described by a non-fully formed crest or an excessively truncated crest. One reason could be an undersized stock where there is insufficient material to flow and create the crests. This is fixed by gradually increasing the size of the stock. If the pitch diameter is oversized, then the more probable root cause is a loose threading head which is solved by sizing-in. If not, then the defect is possibly caused by too much hardness of the material. Thus, it is then necessary to change into a softer material.
Flaking: Flaking or slivers causes unusual roughness on the surface of the threads. This is usually caused by the incompatibility of the material for rolling. The root causes can be excessive lead and sulfur content, inconsistent grain structure, and sometimes cold working before rolling. If the material being used already has a good rollability, then other possible causes can be mismatched rollers or dies, rough roller surface, overfilling, or slow rolling speeds.
Drunken Threads: This defect is seen as wavy or uneven thread crests. This is a result of mismatched dies, misaligned feeding of the stock, or poor die construction. The best solution is to check the condition of the rolls and their bushings.
Curved Pitch Line: This is viewed as the tapering of the threads towards the ends of the threaded segments of the bolt or screw. The curvature can be concave or convex. Its root causes are inconsistent stock diameter, misaligned stock relative to the roller, wearing of rollers, or too much deformation of the material causing it to flow towards the end of the stock.
Out-of-tolerance Helix Angle: This can be a result of a variety of causes such as unsynchronized rollers, imperfect rollers, incorrect feeding of the stock, or screw jacking. This can be solved by correctly timing and aligning the rollers, proper stock feeding, and optimizing the rolling speed.
Poor Finish: Poor finish is a result of factors such as worn-out dies, high material hardness, oversized stock diameter, or presence of contaminants in the coolant supply.
Cupped End: A cupped end appears as a concave-end caused by forcing the metal to flow over an insufficient chamfer. This is more evident on softer metals. The defect is solved by properly chamfering the stock, usually about 30°.

Chapter 6: What are the types of thread rolling machines?

Thread rolling is a straightforward process that begins with cutting a metal bar to length and forging it to create the bolt or screw head. Next, the bar is machined to achieve the correct stock diameter and a chamfer on one end. The prepared stock is then fed into the threading machine, where it passes through dies to shape the thread. After the thread is rolled, the stock undergoes secondary processes such as plating, anodizing, and coating.

This process summary applies to all types of thread rolling. However, thread rolling machines differ based on the type of die used. They can be categorized into flat-die, planetary, or cylindrical-die types.

Flat-die Type: This type of thread rolling machine consists of two rectangular dies where one is stationary while the other is reciprocating. The reciprocating die moves parallel to the stationary die. The surface of the dies contains ridges representing the profile of the thread to be produced. These ridges are inclined at an angle equal to the helix angle of the thread. The distance between the crests of the dies is equal to the minor diameter of the thread.

The threads are formed typically in one passage only. The length of the die allows the stock to be rolled around six to eight times. The stock is inserted on one end, either manually or automatically. The dies roll the stock tangentially which carries it up to the opposite end by friction.
Segment or Planetary Type: A planetary type operates by rolling the stock through one stationary and one moving surface. However, this machine uses rotating motion instead of translation. This type involves stationary curved dies and a central rotating die. One or more stationary dies can be matched with a single rotating die. A stationary die rolls one stock at a time.

Similar to the flat-die type, the planetary machine has a finite rolling surface that forms the thread through one passage. The stock is inserted on one end of the curved die. The rotating die then rotates a full arc of the curved die revolving the stock until ejected on the opposite end.
Cylindrical-die Type: Cylindrical dies or rollers are regarded as dies with infinite work surfaces. These machines usually operate through the combination of radial and through feeding. Unlike the flat-die and planetary types, the cylindrical-die type deforms the metal through multiple passes as it rolls. Cylindrical-die type machines can be further divided into two major categories: two-die and three-die machines.
1. Two-die: This type of threading machine has two parallel rollers wherein one or both can move radially to accept and penetrate the stock. The stock is positioned with a slight offset from the plane of the centerline of the dies to prevent it from rising out. A smooth roller support or rest bar is located in the middle to hold the stock as it is being threaded.
2. Three-die: This machine has three rollers positioned 120° from each other. Typically, all rollers can move radially wherein the position of the stock is maintained at the center during penetration. Compared with two-die machines, three-die types have better force balance but are more difficult and complex to adjust.

Conclusion

Thread rolling is a type of threading process which involves deforming a metal stock by rolling it through dies to form external threads along its surface. Internal threads can be formed using the same principle, specifically termed thread forming.
The processes of generating threads are generally classified into three methods: subtractive, deformative, and additive. These differ on how the thread is shaped or formed.
The main advantage of thread rolling is the stronger surface and dimensional accuracy of the product. However, the process is limited to soft metals and requires more expensive tooling.
There are different types of thread rolling machines that vary according to the type of die used. Thread rolling machines can be a flat-die, planetary, or cylindrical-die type.