THREAD CUTTING,

TAPPING AND
BROACHING
Nainik Shah - 171040075
Ajinkya Shah - 171040076
Ameya Iyer - 171040089
THREAD CUTTING
Definition

■ Thread cutting on the lathe is a process that produces a helical

ridge of uniform section on the work-piece. Threads are used as
fasteners, to transmit power and for adjustment. The subject of
thread manufacture has assumed a great significance because of
the ever increasing demand for high precision devices.
Uses

Screw Threads are used:

1) To hold parts together. They act as fasteners. Ex. V- threads
2) To transmit motion and power. Ex. Square, ACME threads
Nomenclature
■ Major (nominal) diameter – This is the largest diameter of a screw
thread, touching the crests on an external thread or the roots of an
internal thread.
■ Minor (core) diameter – This is the smallest diameter of a screw
thread, touching the roots or core of an external thread (root or core
diameter) or the crests of an internal thread.
■ Pitch diameter – This is the diameter of an imaginary cylinder, passing
through the threads at the points where the thread width is equal to the
space between the threads.
■ Pitch – It is the distance measured parallel to the axis, between
corresponding points on adjacent screw threads.
■ Lead – It is the distance a screw advances axially in one turn.
■ Flank – Flank is the straight portion of the surface, on either side
of the screw thread.
■ Crest – It is the peak edge of a screw thread, that connects the
adjacent flanks at the top.
■ Root – It is the bottom edge of the thread that connects the
adjacent flanks at the bottom.
■ Thread angle – This is the angle included between the flanks of
the thread, measured in an axial plane.
Methods of manufacture

Threads are manufactured by the following processes

■ Casting
■ Thread Chasing
■ Thread Rolling
■ Die thread and tapping
■ Thread Milling
■ Thread Grinding
Casting

■ The accuracy and finish of threads made by casting will depend

upon the method of casting.
■ Threads made by sand casting are rough and not used much,
except in vises and rough machinery.
■ Threads made by die casting and permanent mould casting are
very accurate and of high finish. Due to the inherent drawbacks of
casting method, this has a limited field of application.
Thread Chasing

The method of cutting threads with a single point tool on a central

lathe and with a multipoint tool on a turret lathe, is called thread
chasing.
1) Thread cutting on a central lathe: The first step is to get an
accurately shaped and mounted tool. The second step is to
establish a specific relationship between the longitudinal
movement of the tool parallel to the axis of rotation.
To start cutting a thread, the tool is fed inward until it first scratches
the surface of the job. The graduated dial on the cross-slide is
noted or set to zero. The split nut is then engaged and the tool
moves over the desired job length. At the end of tool-travel, it is
quickly withdrawn by means of cross slide. The split nut is
disengaged and the carriage return to the starting portion, for the
next cut. These cuts are continued till the thread reaches the
desired depth.
2) Thread chasing on turret lathe:
• The main drawback of cutting threads on a central lathe
is that the operation cannot be done at higher cutting
speeds, since the permissible speed is limited by the
quickness with which the operator can withdraw the
cutting tool from the job at the end of the cut.
• This drawback is overcome in turret lathe, where thread
chasing attachment is used to cut the thread.
• The attachment has no thread dial, which enables the
operation of the machine to be done even by a semi-
skilled worker.
• From the head stock of the machine, power is given to a
short lead screw, known as the leader, by means of
change gears.
• The feed nut and the tool slide are carried on a shaft,
which can be engaged or disengaged to the leader by
means of a hand lever.
Thread Rolling

Thread rolling is a cold working process in which a blank

of diameter approximately equal to the pitch diameter of
the required thread, is rolled between hardened steel
rolling dies having the negative contour of the thread to
be produced.
There are three types of thread rolling machines:
1) Reciprocating, flat die machines
2) Cylindrical die machines
3) Rotary planetary machines, having a rotary die and one or more
stationary concave die segment.
Advantages of thread rolling:
1) It is the fastest method of producing a thread, with a production
rate of more than 2000 pieces per minute.
2) Being a chip-less forming process, there is a lot of material saving
3) During thread rolling, the material is strained plastically and is work
hardened, and is, therefore stronger against both tension and
fatigue, especially the latter.
4) The grain fibres remain continuous and follow the contour of the
threaded surface. Due to this, the threads are less easily sheared
off than the machined threads.
5) The surface of rolled thread is harder than a cut thread, hence
wear resistance increases.
6) Surface finish is better as controlled by the rolls
7) Dimensional accuracy is better, as very little wear occurs on the
rolls as it would on a cutting tool
Die Threading and Tapping

Die threading is the method of cutting external threads on cylindrical

or tapered surfaces by the use of solid or self opening dies.
1) Solid dies: A solid die consists of a hardened, threaded nut with
several longitudinal grooves cut away and shaped to provide
cutting edges to the remaining portions of the thread. To facilitate
their use from either end, entry chamfers are provided at both
ends.
To cut threads, the die is screwed on the bar upon which the
threads are to be cut. To move the die along the bar, it is held in
‘stock’. To cut a smoother thread and to prolong the life of the die,
a suitable lubricant is used.
2) Self-opening die heads: The major drawback of solid-type dies that
they must be unscrewed from the work-piece by reversing the
machine spindle, to disengage the die from the work. This
drawback is overcome by using self-opening die heads. When the
required length of thread is cut, the dies open automatically. At the
end of the turret slide travel, the front portion of the die head
continues to move forward by a small amount, until the chasers in
the die-head are moved radially outwards in the body, under the
action of a scroll or cam.
Taps are the tools for cutting internal threads. A tap is similar to a
threaded bolt, with one to four flutes cut parallel to its axis. The
flutes perform three functions:
1) Provide cutting edges
2) Conduct the cutting fluid to the cutting regions
3) Act as channels to carry away the chips formed by the cutting
action.
Types of Taps:

1) Solid taps: These are made up of a single piece. The shank of the
tap is kept plain and the end is squared.
2) Collapsing taps: For better results, a tap should not be backed off
the thread it has just produced because, during backing off it may
catch tiny chips which can do damage to the product. So, for
good finish and to speed up operations, collapsing taps are used,
which collapse inward automatically when the thread is
completed. This makes it possible to withdraw the tap from the
hole without reversing the machine spindle.
Thread Milling

In thread milling, the threads are cut by a revolving form milling cutter conforming to
the shape of the thread to be produced. Characteristics of thread milling are:
1) This is a fast thread cutting method for producing threads usually of too large a
diameter for die heads.
2) The threads produced are more accurate than those produced by dies, but less
accurate than those produced by grinding.
3) Thread running upto a shoulder on the workpiece can be cut without any
difficulty.
4) Worms and lead screws which are too large to be cut with a single point tool can
be milled.
5) This method is desirable when the pitch of the thread is too coarse to be cut with
a die.
6) The method is more efficient than cutting threads on a lathe, especially when the
job is long or when large amounts of metal are to be removed.
Thread Grinding

• Thread grinding is used to produce very accurate threads.

• The principle of thread grinding is similar to thread milling.
• The grinding wheels can be single ribbed or multi ribbed. In case of single
ribbed wheel, the wheel turns against the rotation of the job.
• In addition to this, a relative axial motion between the wheel and the job is
provided with the help of a precision lead screw.
• The wheel is tilted at an angle equal to the helix angle of the thread. This
method is known as ‘Traverse Thread Grinding’.
• A multi-ribbed wheel is used to cut the entire threads in one revolution of the
work.
• The wheel is fed into the work to the required depth and moves axially a
distance equal to the pitch of the thread while the work revolves through one
revolution.
• The cutter is set parallel to the axis of the job. This method is known as ‘Plunge
Cut Grinding’.
Methods of measurement

To find out the accuracy of a screw thread, it is necessary to measure the following:
1) Major Diameter
2) Minor Diameter
3) Effective or Pitch Diameter
4) Pitch
5) Thread angle or Form
■ Major Diameter:
1) The major diameter of a screw or the minor diameter of a nut can be checked by
a plain snap and plug gauges respectively
2) They can also be measured with micrometers and vernier callipers.
■ Minor Diameter:
1) Minor diameter of a screw can be measured with a screw thread micrometer
calliper.
2) To check the minor diameter of a screw, two V-shaped inserts are used, so that
their sharp apexes contact the roots of the screw threads.
■ Pitch Diameter:
1) One of the most accurate methods for checking the pitch diameter is the ‘three-
wire method’.
2) The method consists of placing three small diameter cylinders in the thread
grooves at opposite sides of a screw and measuring the distance W over the
outer surfaces of the wires with an ordinary micrometer calliper having flat
measuring faces.
From the figure, M= Diameter over the wires
E= Effective Diameter (to be found)
d= Diameter of wires, h= height of wire centres above the pitch line, r= radius of
wire, H= depth of thread, D= Major Diameter of the thread
Two Wire Method

1) Wires of exactly known diameters are chosen, such that they

contact thee flanks at their straight portions.
2) The screw thread is mounted between the centres, the wires
are placed in the grooves and the reading M is taken.
3) Thus, the effective diameter E=T+P, where T=M-2d and P is
the value which depends upon the diameter of the wire, pitch
and angle of the screw thread.
TAPPING
What is tapping?

■ Tapping is the process of cutting a thread inside a hole so that a

cap screw or bolt can be threaded into the hole.
What are taps?

■ Tap is a chip producing threading tool with multiple cutting teeth.

■ Tapping can be done by hand or machines such as:
1. Drilling machines
2. Lathes
3. Automatic screw machines
4. Vertical CNC milling machines
Tap types
■ A set of standard hand taps is made of a taper, plug and
bottoming tapers
1. Taper for starting threads
2. Plug tap for continuing thread after taper tap has cut into
hole
3. Bottoming for continuing threads to bottom of a blind
hole
Tap drills

■ The drill used to make the hole prior to tapping is called a tap drill
■ Theoretically, it should be equal in diameter to the minor diameter
of the screw that will be fitted into the tapped hole
Tap wrenches

■ Two types of tap wrenches are available

■ The selection of tap wrench depends on tap size.
■ A T-handle tap wrench is used with all small taps while Handle tap wrench is
used with large taps.
Care in tapping

■ Use the correct size tap drill

■ Use a sharp tap and apply sufficient quantities if cutting fluids.
■ Start the taper tap square with the work.
■ Do not force the tap to cut
■ Avoid running a tap to the bottom of a blind hole and continuing to apply
pressure.
■ Remove burrs on a tapped hole with smooth file.
Tap nomenclature
BROACHING
What is broaching?

■ Broaching is a method of removing metal by pushing or pulling a cutting tool

called a broach which cuts in fixed path.
■ Broaching is generally limited to removal of about 6mm of stock or less.
Broaching

■ The tool may be pulled or pushed through the surfaces to be finished

■ Surfaces finished by broaching may be flat or contoured and may be either
internal or external.
History of broaching

■ The term broaching may have derived from an ancient Roman word braces,
which meant an object having projecting teeth.
■ The operation dates back to 1850’s, the tools were the called ‘drifts’.
What is a broach?

■ A broach is a multiple-edge cutting tool that has successively higher cutting

edges along the length of the tool.
Types of broaches:

Broaches are classified in various ways according to:

1. Type of operation: internal or external
2. Method of operation: push or pull
3. Type of construction: solid, built-up, inserted tooth, progressive cut, rotor cut,
double jump, or overlapping tooth
4. Function: surface, keyway, round hole, splint, spiral, burnishing, etc.
1. According to type of operation

Internal broaching (hole broaching) External broaching (surface broaching)

Used to enlarge and finish various contours Used for machining flat surfaces. Competes
in through holes performed by casting , with milling, planning, shaping, and similar
forging, rolling, drilling, punching, etc. operations.
2. According to method of operation

Push Broach Pull Broach

Subjected to compressive force during Subjected to tensile force during operation

operation
Essentially shorter in length Made as long as possible
Generally used for external broaching More widely used for internal broaching
3. According to type of construction

■ When a broach is made in one piece, it is called a solid broach.

■ Broaches are sometimes built up of several sections, and sometimes made up
of a series of teeth inserted in a block of steel.
■ Progressive cut broaches have teeth, a part of which are of same height along
the broach but have different widths.
Construction of Pull Broach
Broach elements
Broach elements
Ordinary cut broaches for machining previously drilled or bored holes consist of
the following elements:
1. Pull end: It permits engagement of the broach with the broaching machine
through the use of puller head.
2. Front pilot: It centres the broach in the hole before the teeth begin to cut.
3. Roughing and semi finishing teeth: They remove most of the stock in the
hole.
4. Rear pilot and follower rest: They support the broach after the last tooth
leaves the hole.
5. Land: The top portion of a tooth is called land and in most cases ground to
give a slight clearance
Broach elements
6. Back off or clearance angle: This corresponds to the relief angle of single point
cutting tool.
7. Rake or hook angle or face angle: This corresponds to rake angle on a lathe tool.
8. Pitch: the linear distance from the cutting edge of one tooth to the corresponding
edge on the next tooth is called the pitch t.
Broach material

■ Most broaches are made from 18-4-1 tungsten chromium vanadium steelground
after hardening.
■ Carbide broaches are used extensively in the broaching of cast iron in the
automotive field.
Broaching Methods

Broaching according to method of operation, may be classified as follows:

■ Pull Broaching
■ Push Broaching
■ Surface Broaching
■ Continuous Broaching
Pull Broaching Push Broaching
■ The work is held stationary and ■ The work is held stationary and
broach is pulled through work the broach is pushed through
work
■ Broaches are usually long and
held in a special head ■ Hand and hydraulic arbor presses
are popular for push broaching
■ Pull broaching is used mostly for
internal broaching but it can do ■ This method is mostly used for
surface broaching sliding holes and cutting keyways
Surface Broaching Continuous Broaching
■ Either the work or the broaching ■ The work is moved continuously
tool moves across the other and the broach is held stationary
■ This method has rapidly become ■ The path of movement my be
an important means of surface either straight horizontal or
finishing circular
■ Many irregular and intricate ■ This method is suitable for
shapes can be broached by this broaching a number of similar
works at a time
Broaching machines

■ Broaching machines consist of a work holding fixture, a broaching tool, a

drive mechanism and a suitable supporting frame.
■ Although the component parts are few, several variations in design are possible
■ There are two principle types of machines: horizontal and vertical.
■ In addition to these standard types, there are special and continuously
operated machines.
1. Horizontal broaching machine

■ Nearly all horizontal machines are pull type.

■ They are capable of both internal and external surfaces.
■ In operation, either the workpiece is kept stationary and broach is fed past or
broach is kept stationary and workpiece is fed past
■ They have the disadvantage of taking more space than the vertical broaching
machines.
1. Horizontal Broaching machines

■ They are used primarily for broaching keyways, splines, slots, round holes, and
other internal shapes or contours
2. Vertical broaching machines
■ This type of machines are available for both pull or push type
■ In this machine, we can mount more than one broach
■ Vertical machines are employed in multiple operations, since they
are convenient to pass work from one machine to another and
they are more likely to be found doing surface operations.
■ They require an operator platform or a pit.
3. Surface broaching machines

■ They have their broaching tools attached

to a ram or rams forced in a straight path
along guideways past the workpiece.
■ On some machined, the ram moves
horizontally, on others, vertically.
■ When two rams are used, the machine is
called a duplex broach.
4. Continuous broaching machine

■ In this, the work-piece is loaded on the table which rotates continuously.

■ During the operation, the broach is stationary.
Broaching fixtures

Fixtures are most important in broaching operations. They are used particularly for
two reasons:
1. Because of the high pressures used and because of the manner in which
cutting is done.
2. Broaching being essentially a mass production operation, fixtures speed up the
operation and help to keep it accurate.
Broaching fixtures

Broaching fixtures perform one of the following functions:

1. Move the work into and out of cutting position.
2. Hold the work rigidly so that it will not deflect.
3. Guide the broach in relation to the work.
4. Locate the work in correct position.
5. Index or feed the work between cuts.
Advantages of broaching

■ Rate of production is very high.

■ Little skill is required to perform broaching operation.
■ High accuracy and a high class of surface finish are possible.
■ Both roughing and finishing cuts are completed inone pass of the tool.
■ The process can be used for internal or external surface finishing.
■ Any form that can be reproduced on a broaching can be machined.
■ Cutting fluid may be readily applied where it is most effective.
Limitations of broaching

■ High tool cost.

■ Very large work-pieces cannot be broached.
■ The surface to be broached cannot have an obstruction.
■ Broaching cannot be used for the removal of a large amount of stock.
■ Parts to be broached must be capable of being rigidly supported and must be
able to withstand the forces that set up during cutting.
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