PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Threads and Thread Cutting

Unit 55
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Objectives
Recognize and state the purposes of six common thread forms Set up a lathe to cut inch external Unified threads Set up an inch lathe to cut metric threads Set up a lathe and cut internal threads Set up a lathe and cut external Acme threads

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Threads
Used for hundreds of years for holding parts together, making adjustments, and transmitting power and motion Art of producing threads continually improved Massed-produced by taps, dies, thread rolling, thread milling, and grinding

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Threads
Thread
Helical ridge of uniform section formed on inside or outside of cylinder or cone

Used for several purposes:

Fasten devices such as screws, bolts, studs, and nuts Provide accurate measurement, as in micrometer Transmit motion Increase force

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Thread Terminology
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Thread Terminology
Screw thread
Helical ridge of uniform section formed on inside or outside of cylinder or cone

External thread
Cut on external surface or cone

Internal thread
Produced on inside of cylinder or cone

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Major diameter
Largest diameter of external or internal thread

Minor diameter
Smallest diameter of external or internal thread

Pitch diameter
Diameter of imaginary cylinder that passes through thread at point where groove and thread widths are equal Equal to major diameter minus single depth of thread Tolerance and allowances given at pitch diameter line

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Number of threads per inch

Number of crests or roots per inch of threaded section (Does not apply to metric threads)

Pitch
Distance from point on one thread to corresponding point on next thread, measured parallel to axis Expressed in millimeters for metric threads

Lead
Distance screw thread advances axially in one revolution (single-start thread, lead = pitch)

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Root
Bottom surface joining sides of two adjacent threads External thread on minor diameter Internal thread on major diameter

Crest
Top surface joining two sides of thread External thread on major diameter Internal thread on minor diameter

Flank
Thread surface that connects crest with root

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Depth of thread
Distance between crest and root measured perpendicular to axis

Angle of thread
Included angle between sides of thread measured in axial plane

Helix angle
Angle that thread makes with plane perpendicular to thread axis

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Right-hand thread
Helical ridge of uniform cross section onto which nut is threaded in clockwise direction When cut on lathe, toolbit advanced from right to left

Left-hand thread
Helical ridge of uniform cross section onto which nut is threaded in counterclockwise direction When cut on lathe, toolbit advanced from left to right
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Thread Forms
April, 1975 ISO came to an agreement covering standard metric thread profile
Specifies sizes and pitches for various threads in new ISO Metric Thread Standard Has 25 thread sizes, range in diameter from 1.6 to 100 mm Identified by letter M, nominal diameter, and pitch M 5 X 0.8

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Table 55.1 ISO metric pitch and diameter combinations

Nominal Diameter (mm)
1.6

Thread Pitch (mm)

0.35

Nominal Diameter (mm)

20

Thread Pitch (mm)

2.5

2
2.5 3

0.4
0.45 0.5

24
30 36

3
3.5 4

3.5
4 5

0.6

42

4.5
5 5.5

0.7 48taken Portion of table 0.8 from textbook 56

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ISO Metric Thread

60 included angle, crest = 0.125 times pitch
D (depth of thread) is 0.6143 times pitch Root is 1/4th of pitch, Flat on root (FR) wider than crest (FC)

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ISO Metric Thread

D (external) 0.54127 x P FC .125 x P FR .250 x P

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American National Standard Thread

Divided into four main series, all having same shape and proportions
National Coarse (NC) National Fine (NF) National Special (NS) National Pipe (NPT)

Has 60 angle with root and crest truncated to 1/8th the pitch Used in fabrication, machine construction

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American National Standard Thread

.6134 D .6134 x P or N .125 F .125 x P or N

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British Standard Whitwork (BSW) Thread

Application is same as for American National form thread
.6403 D .6403 x P or N .1373 R .1373 x P or N

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Unified Thread
Developed by U.S., Britain, and Canada for standardized thread system Combination of British Standard Whitworth and American National Standard Thread

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.6134 N .5413 D (internal thread) .5413 x P or N .125 F (external thread) .125 x P or N .250 F (internal thread) .250 x P or N D (external thread) .6134 x P or

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American National Acme Thread

Replacing square thread in many cases Used for feed screws, jacks, and vises
D = minimum .500P = maximum .500P + 0.010 F = .3707P C = .3707P - .0052 (for maximum depth)

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Brown & Sharpe Worm Thread

Used to mesh worm gears and transmit motion between two shafts at right angles to each other but not in same plane
D = .6866P
F = .335P C = .310P

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Square Thread
Being replaced by Acme thread because of difficulty in cutting it D = .500P Often found on vises F = .500P and jack screws C = .500P + .002

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International Metric thread

Standardized thread used in Europe
D = 0.7035P (maximum) = 0.6855P (minimum) F = 0.125P R = 0.0633P (maximum) = 0.054P (minimum)

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Thread Fits and Classifications

Fit
Relationship between two mating parts Determined by amount of clearance or interference when they are assembled

Nominal size
Designation used to identify size of part

Actual size
Measured size of thread or part Basic size: size from which tolerances are set

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Allowance
Permissible difference between largest external thread and smallest internal thread Difference produces tightest fit acceptable for any given classification
The allowance for a 1 in.8 UNC Class 2A and 2B fit is: Minimum pitch diameter of the internal thread (2B) = .9188 in. Maximum pitch diameter of the external thread (2A) = .9168 in. Allowance = .002 in.

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Tolerance
Variation permitted in part size May be expressed as plus, minus, or both Total tolerance is sum of plus and minus tolerances In Unified and National systems, tolerance is plus on external threads and minus on internal threads
The tolerance for a 1 in.8 UNC Class 2A thread is: Maximum pitch diameter of the external thread (2A) = .9168 in. Minimum pitch diameter of the external thread (2A) = .9100 in. Tolerance = .0068 in.

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Limits
Maximum and minimum dimensions of part
The limits for a 1 in.8 UNC Class 2A thread are:
Maximum pitch diameter of the external thread (2A) = .9168 in.. Minimum pitch diameter of the external thread (2A) = .9100 in.

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ISO Metric Tolerances and Allowances

ISO metric screw thread tolerance system provides for allowances and tolerances defined by tolerance grades, tolerance positions, and tolerance classes Tolerance grades specified numerically
Medium tolerance indicated by number 6, number below 6 indicates finer tolerance and number above 6 indicates greater tolerance Tolerance for thread at pitch line and major diameter may be shown on drawing using the following symbols:

External threads: e indicates large allowance g indicates small allowance h indicates no allowance

Internal threads: G indicates small allowance H indicates no allowance

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Tolerance Example:
An external metric thread may be designated as follows: Nominal Metric Size Pitch M 6 X 0.75

Pitch Dia. Tolerance 5g

Outside Dia. Tolerance 6g

The thread fit between mating parts is indicated by internal thread designation followed by the external thread tolerance: M 20 X 2 - 6H/5g 6g

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Symbols Used to Indicate Allowance

For external threads:
e indicates a large allowance g indicates a small allowance h indicates no allowance

For internal threads:

G indicates a small allowance H indicates no allowance

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Three Categories of Unified Thread Fits

External threads classified as 1A, 2A, and 3A and internal threads as 1B, 2B, 3B Classes 1A and 1B
Threads for work that must be assembled Loosest fit

Classes 2A and 2B
Used for most commercial fasteners Medium or free fit

Classes 3A and 3B
Used where more accurate fit and lead required No allowance provided

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Thread Calculations: Example 1

To cut a correct thread on a lathe, it is necessary first to make calculations so thread will have the proper dimensions. Calculate pitch, depth, minor diameter, and width of flat for a 10 UNC thread. D = single depth of thread P = pitch

Minor dia Major dia - ( D D) .75 - (.061 .061) .628 in.

1 1 P .100 in. tpi 10 P 1 1 Width of flat x D .61343 x P 8 8 10 .61343 x .100 .061in. .0125 in.

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Thread Calculations: Example 2

What are the pitch, depth, minor diameter, width of crest and width of root for an M 6.3 X 1 thread?
P = pitch = 1 mm D = 0.54127 x 1 = 0.54 mm

Width of root 0.25 x P 0.25 x 1 0.25 mm

Minor dia Major dia - ( D D) 6.3 - (.54 .54) 5.22 mm Width of crest 0.125 x P 0.125 x 1 0.125 mm

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Procedure to Set the QuickChange Gearbox for Threading

1. Check drawing for thread pitch required 2. From chart on quick-change gearbox, find whole number that represents pitch in threads per inch or in millimeters 3. With lathe stopped, engage tumbler lever in hole, which is in line with the pitch 4. Set top lever in proper position as indicated on chart

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5. Engage sliding gear in or out as required 6. Turn lathe spindle by hand to ensure that lead screw revolves 7. Recheck lever settings to avoid errors

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Thread-Chasing dial
Lathe spindle and lead screw must be in same relative position for each cut
Thread-chasing dial attached to carriage for this purpose

Dial has eight divisions

Even threads use any division Odd threads either numbered or unnumbered: not both
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Thread Cutting
Produces a helical ridge of uniform section on workpiece Performed by taking successive cuts with threading toolbit of same shape as thread form required Work may be held between centers or in chuck

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Procedure to Set Up a Lathe for Threading (60 Thread)

1. Set lathe speed to speed used for turning 2. Set quick-change gearbox for required pitch in threads per inch or in millimeters 3. Engage lead screw 4. Secure 60 threading toolbit and check angle using thread center gage 5. Set compound rest at 29 to right; set to left for left-hand thread

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6. Set cutting tool to height of lathe center point 7. Mount work between centers
Make sure lathe dog is tight on work If work mounted in chuck, it must be held tightly

8. Set toolbit at right angles to work, using thread center gage 9. Arrange apron controls to allow split-nut lever to be engaged

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Thread-Cutting Operation
Procedure to cut a 60 thread 1. Check major diameter of work for size 2. Start lathe and chamfer end of workpiece with side of threading tool to just below minor diameter of thread 3. Mark length to be threaded by cutting light groove at this point with threading tool while lathe revolving

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4. Move carriage until point of threading tool near right-hand end of work

5. Turn crossfeed handle until threading tool close to diameter, but stop when handle is at 3 o'clock position
6. Hold crossfeed handle in this position and set graduated collar to zero

7. Turn compound rest handle until threading tool lightly marks work

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8. Move carriage to right until toolbit clears end of work

9. Feed compound rest clockwise about .003 in.

10. Engage split-nut lever on correct line of thread-chasing dial and take trial cut along length to be threaded 11. At end of cut, turn crossfeed handle counterclockwise to move toolbit away from work and disengage split-nut lever

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12. Stop lathe and check number of tpi with thread pitch gage, rule, or center gage

13. After each cut, turn carriage handwheel to bring toolbit to start of thread and return crossfeed handle to zero
14. Set depth of all threading cuts with compound rest handle
See Table 55.2 and Table 55.3

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When tool is fed in at 29, most of the cutting is done by the leading edge of toolbit.

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Table 55.3: Depth setting for cutting 60 ISO metric threads

Compound Rest Setting Pitch (mm)
(mm) 0.35 0 0.19 30 0.21 29 0.21

0.4
0.45 0.5

0.21
0.24 0.27

0.25
0.28 0.31

0.24
0.27 0.31

0.6

0.32 0.37 0.37 table taken 0.7 Portion of0.37 0.43 0.43 from textbook 0.8 0.43 0.5 0.49

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Table 55.2 Depth settings for cutting 60 national form threads*

Compound Rest Setting
tpi 24 20 18 16 14 0 .027 .036 30 .031 29 .0308

.0325 .0375 .037 .0417 .041 .0405 .0468 .046 .0465 .0537 .0525

13 Portion .050 of.0577 .057 table taken from textbook 11 .059 .068 .0674

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15. Apply cutting fluid and take successive cuts until top (crest) and bottom (root) of thread are same width 16. Remove burrs from top of thread with file 17. Check thread with master nut and take further cuts

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Six Ways to Check Threads

Depends on accuracy required:
1. Master nut or screw 2. Thread micrometer 3. Three wires 4. Thread roll or snap gage 5. Thread ring or plug gage 6. Optical comparator

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To Reset a Threading Tool

Must reset when need to remove partly threaded work from lathe, tool removed for regrinding, or work slips under lathe dog Procedure 1. Set up lathe and work for thread cutting 2. Start lathe, toolbit clear of work, engage split-nut lever on correct line 3. Allow carriage to travel until toolbit opposite any portion of unfinished thread

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4. Stop lathe, leaving split-nut lever engaged 5. Feed toolbit into thread groove using only compound rest and crossfeed handles until right-hand edge of toolbit touches rear side of thread 6. Set crossfeed graduated collar to zero 7. Back out threading tool using crossfeed handle, disengage split-nut lever, and move carriage until toolbit clears start of thread

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8. Set crossfeed handle back to zero and take trial cut without setting compound rest

9. Set depth of cut using compound rest handle and finish thread to required depth

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To Convert an Inch-Designed Lathe to Metric Threading

Metric threads may be cut on standard quickchange gear lathe by using a pair of change gears having 50 and 127 teeth respectively. Lead screw has inch dimensions so necessary to convert pitch in millimeters to centimeters and then into threads per inch
1 in. = 2.54 cm which gives ration 1:2.54

1 50 50 teeth x 2.54 50 127 teeth

(spindle or drive gear) (lead screw)

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Procedure to Cut a 2-mm Metric Thread on Standard Quick-Change Gear Lathe

1. Mount the 127-tooth gear on lead screw 2. Mount the 50-tooth gear on spindle 3. Convert the 2-mm pitch to threads per centimeter: 10 mm 1 cm

10 P 5 thread/cm 2 4. Set quick-change gearbox to 5 tpi

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5. Set up lathe for thread cutting 6. Take light trial cut 7. Reverse spindle rotation until cutting tool has just cleared start of threaded section 8. Check thread with metric screw pitch gage 9. Cut thread to required depth Note: Never disengage the split nut until the thread has been cut to depth.

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Procedure to Cut a Left-Hand Thread (60)

Basically same as for right-hand threads, with few exceptions: 1. Set lathe speed and quick-change gearbox for pitch of thread to be cut 2. Engage feed-direction lever so that lead screw will revolve in opposite direction to that for right-hand thread

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3. Set compound rest to 29 to the LEFT 4. Set up left-hand threading tool and square it with work 5. Cut groove at left end of section to be threaded
Gives cutting tool starting point

6. Proceed to cut thread to same dimensions as for right-hand thread

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Cutting a Thread on a Tapered Section

Use same setup as for regular thread cutting Most important that threading tool be set at 90 to axis of work
Do NOT set it square with tapered surface

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Common Methods of Measuring Threads

1. 2. 3. 4. 5. 6. Thread ring gage Thread plug gage Thread snap gage Screw thread micrometer Optical comparator Three-wire method

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Three-Wire Method of Measuring Threads

Recommended by Bureau of Standards and National Screw thread Commission Three wires of equal diameter placed in thread, two on one side and one on other side
Wire used should be hardened and lapped to three times accuracy of thread to be inspected

Standard micrometer used to measure distance over wires (M) Different sizes and pitches of threads require different sizes of wires

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The Three-Wire Method of Measuring 60 Threads

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To Calculate the Measurement over the Wires

M = measurement over the wires D = major diameter of the thread G = diameter of the wire size used N = number of tpi Any of the following formulas can be used to calculate G:
1.010 or 1.010P N .57735 Best - size wire or .57735P N .505 Smallest wire or .505P N Largest wi re

where

1.5155 M D 3G N

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Multiple Threads
Used when necessary to obtain increase in lead and deep, coarse thread cannot be cut May be double, triple or quadruple, depending on number of starts around periphery of work Pitch: distance from point on one thread to corresponding point on next thread Lead: distance nut advances lengthwise in one complete revolution
Single-start: pitch and lead equal Double-start: lead twice the pitch Triple-start: lead three times pitch

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Single Thread

Double Thread

Triple Thread
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Multiple Threads May be Cut on a Lathe

1. Using accurately slotted driveplate or faceplate 2. Disengaging intermediate gear of end gear train and rotating spindle desired amount 3. Using thread-chasing dial
Only for double-start threads with odd-number lead

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Procedure to Cut an 8-tpi Double Thread

1. Set up lathe and cutting tool as for cutting single-start thread 2. Set quick-change gearbox to 4 tpi 3. Cut first thread to half depth required for 4 tpi 4. Leave crossfeed handle set to depth of thread and not reading on compound rest graduated collar 5. Withdraw threading tool from work using compound rest handle

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6. Revolve work exactly turn

Remove work from lathe with lathe dog attached Replace work in lathe with tail of dog in slot exactly opposite one used for first thread

7. Reset crossfeed handle to same position as when cutting first thread 8. Cut second thread, feeding compound rest handle until graduated collar at same setting as for first thread

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Thread-Chasing Dial Method of Cutting Multiple Threads

Double-start threads with odd-numbered lead may be cut using thread-chasing dial 1. Take one cut on thread by engaging split nut at numbered line on chasing dial 2. Without changing depth of cut, take another cut at unnumbered line on chasing dial (second thread will be exactly in middle of first thread) 3. Continue cutting thread to depth, taking two passes for every depth-of-cut setting

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Square Threads
Found in vise screws, jacks, and other devices where maximum power transmission required Square threading tool looks like short cuttingoff tool Both sides of square threading tool must be ground at angle to conform to helix angle of thread
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Square Threading Tool

Helix angle of thread (angle of square threading tool) depends on two factors:
Changes for each different lead on given diameter (greater lead, greater angle) Changes for each different diameter of thread for given lead (larger diameter, smaller angle)

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To Calculate the Helix Angles of the Leading and Following Sides of a Square Thread
lead of thread Tan leading angle circumfere nce of minor diameter lead of thread Tan following angle circumfere nce of major diameter

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Clearance
Square toolbit must be provided with approximately 1 clearance on each side
Makes it thinner at bottom

For leading side of tool

Add 1 to calculated helix angle

On following side
Subtract 1 from calculated angle
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Procedure to Cut Square thread

1. Grind threading tool to proper leading and following angles
Width of tool should be ~.002 in. wider than thread groove

2. Align lathe centers and mount work 3. Set quick-change gearbox for required number of tpi 4. Set compound rest at 30 to right, which will provide side movement if necessary to reset cutting tool

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5. Set threading tool square with work and center 6. Cut right-hand end of work to minor diameter for approximately .060 in. long 7. If work permits, cut recess at end of thread to minor diameter .500 8. Calculate single depth of thread
N

9. Start lathe and just touch tool to work diameter 10. Set crossfeed graduated collar to zero

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11. Set .003 in. depth of cut with crossfeed screw and take trial cut 12. Check thread with thread pitch gage 13. Apply cutting fluid and cut thread to depth, moving crossfeed in from .002 to .010 in. for each cut
Depth of cut will depend on thread size and nature of workpiece

Note: Since thread sides are square, all cuts must be set using crossfeed screw

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Acme Thread
Gradually replacing square thread because stronger and easier to cut with taps and dies Used extensively for lead screws because 29 angle formed by its sides allows split nut to be engaged during thread cutting Provided with .010-in. clearance for both crest and root on all sizes of threads

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Procedure to Cut an Acme Thread

1. Grind toolbit to fit end of Acme thread gage
2. Grind point of tool flat until it fits into slots of gage
Indicates number of threads per inch to be cut
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3. Set quick-change gearbox to required number of threads per inch 4. Set compound rest 14 to right 5. Set Acme threading tool on center and square it with work using gage 6. At right-hand end of work, cut section .060 in. long to minor diameter 7. Cut thread to proper depth by feeding cutting tool, using compound rest

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Measuring Acme Threads One Wire Method

Single wire or pin of correct diameter placed in thread groove and measured with micrometer Thread correct size when micrometer reading over wire is same as major diameter of thread and wire is tight in the thread
Diameter of wire to be used can be calculated as follows: Wire diameter = .4872 x pitch
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Internal Threads
Cutting threads in a hole
Operation performed on work held in chuck or collet or mounted on faceplate Threading tool similar to boring toolbit except shape ground to form of thread to be cut

Procedure 1. Calculate tap drill size of thread

1 Tap drill size major diameter N

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2. Mount work to be threaded in chuck or collet or faceplate 3. Drill hole approximately 116 in. smaller than tap drill size in workpiece 4. Mount boring tool in lathe and bore hole to tap drill size 5. Recess start of hole to major diameter of thread for .060-in. length 6. If thread does not go through workpiece, a recess should be cut at end of thread to major diameter; recess should be wide enough to allow threading tool to run out and permit time to disengage split-nut lever

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The compound rest is set at 29 to the left for cutting right-hand internal threads.
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7. Set compound rest at 29 to left, to right for left-hand threads 8. Mount threading toolbit into boring bar and set it to center 9. Square threading tool with thread center gage 10. Place mark on boring bar, measuring from threading tool, to indicate length of hole to be threaded 11. Start lathe and turn crossfeed handle out until threading tool just scratches internal diameter

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7. Set crossfeed graduated collar to zero 8. Set .003-in. depth of cut by feeding compound rest out and take trial cut 9. At end of each cut on internal thread, disengage split-nut lever and feed crossfeed handle in to clear thread 10. Clear threading tool from hole and check pitch of thread 11. Return crossfeed handle back to zero and set depth of cut by turning compound rest out desired amount 12. Cut thread to depth; check fit with a screw or threaded plug gage