INDUSTRIAL FASTENERS INSTITUTE

6363 Oak Tree Boulevard • Independence, Ohio 44131 USA, www.indfast.org

Dramatically Extend Roll Die Life and Improve Thread

Quality Using Improved Set-up Procedure
Pressure is constantly on fastener manufacturers to lower prices while improving quality. Roll thread dies are
usually the source of the largest tooling costs in most screw and bolt making operations. The cause of most customer
complaints is associated with thread quality. These two facts make the threading operation a good place to look for
both savings and quality improvements. Better roll die set-up can contribute to both tool savings and better, more
consistent thread quality.

“Thread differential analysis” is the procedure of using variable thread gages to measure a thread’s pitch
diameter and functional diameter and then comparing the size of the two measurements. The purpose of the com-
parison is to determine the magnitude of the cumulative effect of the deviations in the individual thread elements.
This procedure provides the machine operator an objective means of determining thread die match during the setup
of the threading process. The closer these two measurements are to each other the better is the match between the
two rolling dies. This analytical procedure is far superior to an operator working on a die set-up until the thread enters
the GO ring, does not enter the NOGO ring, and he subjectively decides that the thread crests appear to be “sharp
enough”.

Manufacturers should make it a standard setup requirement that the process will not be turned on until the
difference between the measurement of the thread’s pitch diameter and its functional diameter is less than 40% of the
thread’s total pitch diameter tolerance, or .0010 inches which ever is less. What is accomplished by working on the
set-up until these two measurements are very close to each other is the reduction of the thread’s lead error.

This procedure provides the operator with an empirical means of determining perfect or near perfect die
match. The closer the measurements of pitch diameter and functional diameter are on a given thread, the closer the
dies are to perfect match. The more perfect the die match, the lower the pressure on the die plate faces. The lower
die face pressure, the longer the dies will last and the longer the threader’s ram will go without adjustment or replace-
ment. Longer thread die life and machine life result in substantial operation saving over time.

A manufacturer can usually recover the cost of variable thread gaging within one year as a result of the
savings realized in thread rolling dies alone. It is reasonable to expect roll die savings between 20% and 35% by
using differential analysis when setting up roll threaders. The amount of savings associated with the use of differen-
tial analysis during threader set-up is directly related to the hardness of the screw or bolt blanks being rolled. The
greatest savings will be realized by those rolling hardened blanks such as ASTM A193 B7 bolts and studs, and those
thread rolling 300 series stainless steel screws and bolts.

Before turning the threading operation on for full production the major diameter, pitch diameter, and func-
tional diameter must all be within specification. It is also a good practice to make sure the thread will enter a GO gage
freely. If the set-up procedure described in this article is followed so that the pitch diameter and functional diameter
are within .0010 inches of each other, but those measurements are not near the middle of the pitch diameter toler-
ance the size of the blank diameter should be altered for future jobs so that relationship can be achieved.

Fastener users worldwide are demanding more consistent quality and continue to pressure manufacturers
for lower prices. Fastener manufacturers must continually improve their operations and their methods to meet these
demands. Using differential analysis in roll threading set-up will help manufacturers provide more consistent thread
quality while saving tooling costs by greatly extending roll die life.

IFI
Technical Bulletin ® Dramatically Extend Roll Die Life IFI
Page 1 of 2
Published and issued by the and Improve Thread Quality
Industrial Fasteners Institute Issued: March, 1999
of Independence, OH Using Improved Set-up Procedure
All standards and specifications are advisory only. Their use by anyone is entirely voluntary. Reliance thereon for any purpose by anyone is at the sole risk of that person or the
user of the product, and the IFI is not responsible for any loss, claim, or damage arising therefrom. In formulating and approving standards and specifications, the IFI has not
investigated and will not investigate patents which may apply to the subject matter. Prospective users of the standards and specifications are responsible for advising themselves
of and protecting themselves against any patent infringement liability which may arise out of such use. © INDUSTRIAL FASTENERS INSTITUTE 2008
 INDUSTRIAL FASTENERS INSTITUTE
6363 Oak Tree Boulevard • Independence, Ohio 44131 USA, www.indfast.org

Disclaimer: All information provided in this document and/or presentation is based on data the Industrial Fasteners
Institute believes to be reliable and accurate. Such information is intended for use by persons at their own discretion
and risk. The information here in is based on industry standards and recognized practices. The Industrial Fasteners
Institute and the representatives providing this material assume no responsibility for the content.

IFI
Technical Bulletin ® Dramatically Extend Roll Die Life IFI
Page 2 of 2
Published and issued by the and Improve Thread Quality
Industrial Fasteners Institute Issued: March, 1999
of Independence, OH Using Improved Set-up Procedure
All standards and specifications are advisory only. Their use by anyone is entirely voluntary. Reliance thereon for any purpose by anyone is at the sole risk of that person or the
user of the product, and the IFI is not responsible for any loss, claim, or damage arising therefrom. In formulating and approving standards and specifications, the IFI has not
investigated and will not investigate patents which may apply to the subject matter. Prospective users of the standards and specifications are responsible for advising themselves
of and protecting themselves against any patent infringement liability which may arise out of such use. © INDUSTRIAL FASTENERS INSTITUTE 2008