Thread rolling systems

Rolling attachments, re-defined

Boehlerit is extending its product portfolio and has found a competent partner for advice on and application of profile and thread rolling
heads as well as the design of customer-specific, purpose-built models of axial and tangential rolling systems in Adam Rollsysteme GmbH.

In the aerospace industry, for instance, machining is considered an undesirable processing method due to the associated destruction of
the milling fibres. With rolling, the desired profile is pressed into the material beyond the stress-strain limit.

The Adam axial and tangential rolling systems by Boehlerit offer not just the shortest cycle times, long tool life, perfect surface qualities
and outstanding precision, but are also highly economical as they reduce the amount of material used. The Adam axial rolling systems
cover a working range of 1.4 to 100 mm and are primarily used on turning and milling centres to process threads and profiles.
The tangential rolling systems, on the other hand, are ideal for manufacturing extremely short threads, threads with very short runouts,
knurls and smaller gears. The working range lies at 1.6 to 42 mm, with a roll width of 15.5 to 31 mm.

With every Adam tangential rolling system, Boehlerit supplies customised rolling head holders for fitting the rolling head to the tooling
machine. With these rolling systems, the Kapfenberg-based company offers a wide range of tool solutions that will suit most application
scenarios.

BOEHLERIT Kapfenberg in Styria/Austria

Technical changes or misprints excepted.

2
Adam axial rolling systems

The broad working range of the individual rolling head types is made possible by the simple and fast exchange process for the rolls.
As a next step, other cold forming processes such as smoothing, milling and beading can also be performed. The axial rolling heads may
be used in stationary or rotating applications. The axial rolling head is locked by radial turning of the locking handle or by means of an
optional, automated locking mechanism. The rolling head opens by stopping the infeed and the rolls release the workpiece. Depending on
the design, the axial rolling head is equipped with 2, 3 or in some cases even 6 thread rolls, which are used on a set-by-set basis.
The axial rolling systems may be used for short and long threads.

High-precision thread rolls:

The thread rolls are adapted to the profile to be manufactured in terms of diameter, shape and flank lead and constitute the forming tool.
Different shaft variations are available for different machines.

Right-hand as well as left-hand threads may be produced just as easily as regular threads, fine threads, pipe threads, trapezoidal threads
and special threads.

Benefits:

■ Broad working ranges

■ Rotating and stationary for use on machining centres, turning lathes, automatic rotary indexing machines and special-purpose machines
■ Machining of parts with long threads
■ Self-opening by means of infeed stop for touch-free return travel
■ Reproducible manufacturing results

A wide roller programme is available. The dimensional accuracy of the rolled threads is guaranteed for materials of up to a maximum tensi-
le strength of 1400 N/mm².
Stationary thread rolling head:

The Adam thread rolling head in a stationary design was developed for use with rotating workpieces.
The opening of the thread end may be performed by means of an infeed stop of the machine or by limiting the infeed with an internal stop.

The closing process may be performed either manually or with suitable locking devices for automated locking.

Rotating thread rolling head:

The Adam thread rolling head in a rotating design was developed for use with stationary workpieces. The rotating axial rolling heads follow
the same principle as the stationary models. Just like the stationary model, the rotating axial rolling head remains locked and continues to
machine your thread until either the machine infeed is stopped or the workpiece reaches the pre-set internal stop. This process also pulls
the rotary axial rolling head out of its coupling stage, thereby opening it. The thread rolls will turn away from the surface of the workpiece
over their eccentric cams. The backwards movement of the rolling head to detach it from the workpiece is controlled by the tooling machi-
ne.
To prepare the axial rolling head for the next rolling process, the rotating version must also be locked. Again, this may be done effectively
and comfortably using automatic locking devices. Their function is controlled by the tooling machine and activated by pressurised air or
cooling agent.

3
 Adam axial rolling systems [Link]

Adam axial rolling systems may be used on all standard tooling machines, for instance on CNC machining centres, manual tooling machines
and in straightforward applications such as stationary drilling machines and boring mills. Set-up on your tooling machine is quick, easy and
flexible for all applications.

The quality of the manufactured threads as well as the tool life of Adam rolling systems and their thread and profile rolls are the most impor-
tant arguments in our favour when compared to cutting tools. These advantages result in extremely short set-up and downtimes as well as in
fast cycle times during the production process of your threads and profiles. Adam rolling systems also come with the option of cost-effective
locking mechanisms, which further reduce cycle times and make for an even faster and more comfortable set-up.

Shank design Flange design

Typ A: Stationary use (e. g. „A 12“) Stationary and rotating use

Typ AG: Stationary and rotating use (e. g. „A 12 G“),
for left-hand threads: additional „L“
(e. g. „A 12 L“)

Shank design Flange design

Overview of axial rolling systems – types and sizes

Rolling head system - size Working range D - shaft D - housing

Diameter - Standard Diameter - Standard
from mm to mm mm Zoll mm Zoll
A0 2,6 5,5 20 3/4“ 50 1,9680
A 001 2,6 4,0 20, 16 3/4“ 40 1,5748
A 01 3,5 6,0 20, 16 3/4“ 40 1,5748
A1 6,0 11,0 20, 16 3/4“ 64 2,5196
A 12 n 6,0 12,0 20, 16 3/4“ 64 2,5196
esig
A 1223 kd 5,0 8,0 20, 16 3/4“ 56 2,2047
an
A2 Sh 8,0 16,0 25 1“ 88 3,4645
A 23 8,0 22,0 25 1“ 88 3,4645
A 233400 16,0 36,0 30, 25 1“, 1.1/4“ 96 3,7795
A3 12,0 22,0 30 1.1/2“, 1.1/4“ 117 4,6063
A 34 12,0 30,0 30 1.1/2“, 1.1/4“ 117 4,6063
Rolling head system - size Working range D - Flange D - Flange
Durchmesser - Standard Durchmesser - Standard
from mm to mm mm Zoll mm Zoll
A 4-1 14 30 140 5,5118 165 6,4960
A 45-1 ign 16 42 140 5,5118 165 6,4960
A 5-1 d es 18 39 200 7,8740 200 7,8740
nge
A 56-1 Fla 22 52 200 7,8740 200 7,8740
A 6b-1 30 45 200 7,8740 255 10,0393

4
Adam tangential rolling systems

Adam tangential rolling systems will increase your efficiency in thread and profile production on CNC machining centres, CNC
turning machines and on all manual cross-slide machines.

The main advantage of our tangential thread rolling systems is the option to roll threads as well as profiles within a workpiece,
between shoulders and varying diameters and whilst rolling shortest threads and run-ons.
Combine these advantages with ultrashort cycle times, and the capacity of your machine tools will be increased dramatically.

Our tangential rolling systems move laterally across the workpiece and are fitted with two thread rolls. These are used on a set-
by-set basis. A release mechanism is not required. The length of the thread results from the width of the rolling head.

Adam rolling systems tangential system

TR 20, e.g. with 2-part holder for fitting on a
cross-slide machine

Overview of Adam tangential rolling systems – types and sizes

Rolling head system - size Working range Width of roll, Length of rolling head,
max. min.
from mm to mm mm Zoll mm Zoll
TR10 2 14 15,5 0,6102 104 4,09 44
TR20 2 30 21,5 0,8464 131 5,1574
TR30 2 42 31,0 1,2204 168 6,614

Every Adam tangential rolling system comes with an individually adjustable tangential rolling head holder,
which is used for fitting and fixing the thread rolling head to your tooling machine.

5
 Adam thread and profile rolls [Link]

Designs/versions
Roll sets for thread rolling systems by different manufacturers,
for instance LMT-FETTE, WAGNER, WINTER, REED, etc.

Roll sets for all standard thread and profile rolling machines

Tangential rolls Axial rolls

Thread rolls and dies

We also supply matching thread and pro¬file rolls for our Adam rolling
systems. All of our thread and profile rolls are designed and manufactured
according to the latest technologies and findings and tailor-made for your
individual application.

Adam thread rolls and dies are made on state-of-the-art CNC grinding
centres. Our roll production has been ISO 9001-certified since 1993.
For our thread rolls and dies, we use a wide range of high-performance
materials from Western European manufacturers, always in line with
individual requirements. All heat and surface treatments are performed in
state-of-the-art vacuum and protective gas furnaces and to a reproducible
quality standard.

Our entire manufacturing process is based on many years‘ experience Dies

with using these rolls for rolling systems and rolling machines.
For this reason, Adam rolls have a long tool life that in turn reduces the
set-up and downtimes of your tooling machines and make the use of
Adam rolling systems particularly efficient.

We are also happy to supply you with thread and profile rolls from other
manufacturers that perfectly match these roll systems. Adam thread rolls
and dies are suitable for infeed our throughfeed applications. We supply
the right rolls for threads and profiles in all shapes and sizes that fit all
standard die machines, in the same outstanding quality as our rolls for
rolling systems.

Each set of Adam dies is customised to suit your specific application

and requirements. For Adam dies, we also supply high-precision plunge
rolls with radius-runout (RRO) in a variety of formats. Adam thread rolls
and dies are used in aerospace and automotive engineering, in racing
and of course in tool and machine construction.

6
Rolling systems

Adam rolling systems use material sparingly - there is no costly waste in the form of chips. Adam rolling systems allow for the high-precision
production of nearly all thread sizes and types as well as for special applications such as flanging, radii, knurling and gearing. The workpiece
surfaces obtain a press-polished surface quality. Adam rolling systems may be used universally, thereby increasing productivity. They are
used in a wide range of industries, such as the automotive industry, the supply industry and in machine construction. Adam rolling systems
may also be used efficiently in smaller batch sizes.

Service/maintenance and repair

Our service includes the analysis of the condition of your rolling system and the compilation of a cost estimate. You will be invoiced only for
the required spare parts and the return delivery – labour is included in the free service package.
We are also happy to service most rolling systems from other manufacturers that are still in use at your facility.

Technical data:
Adam thread rolling heads are suitable for the machining of all materials with cold-forming properties.
The required strain of the material depends on the forming size.

Workpiece preparation:

The starting diameter must be prepared with narrow tolerances (for the pre-machining diameter,
please see the tables from page 8 to 11).
A chamfer with an angle of approximately 10 - 30° is required.

Tensile strength:

During cold-forming, the tensile strength of the material will increase. The fibre orientation is not disturbed, resulting in a higher static and
dynamic tensile strength.

Rolling speed:

The rolling speed ranges from 20m/min to 80m/min (in exceptional cases, up to 100m/min). The thread is produced in a single run (for
guiding values on rolling speeds, please see the table on pages 12 and 13.)

Surface quality of the thread flank:

The surface quality of the thread flank is very high as the flank is burnished. This also results in a low corrosion tendency.

7
 Metric ISO common threads [Link]

Thread limit dimensions and lead angle for bolt threads see DIN 13 part 20

60°

d d = Bolt major-Ø
d2 = Bolt pitch-Ø
d2 d3 = Bolt minor-Ø

d3 Lead-∢ β to nominal diameter d2

Tolerance field
(mm)

Thread- Lead
Nomi-
pitch
4h 6g 6e ∢
nal
d d2 d3 d d2 d3 d d2 d3 β
Ø P max. min. max. min. max. max. min. max. min. max. max. min. max. min. max. Deg., min.

Example of a bolt thread designation (tolerance centre): M 16 - 6g

Example of a bolt left-hand thread designation (tolerance centre): M 16 - 6g-LH

8
Metrisches ISO-Feingewinde

Metric ISO common threads

Thread limit dimensions and lead angle for bolt threads see DIN 13

60°

d d = Bolt major-Ø
d2 = Bolt-pitch-Ø
d2 d3 = Bolzen minor-Ø

d3 Lead-∢ β to nominal diameter d2

Tolerance field
(mm)

Thread- Lead
Nomi- 4h 6g 6e
nal- pitch d d2 d3 d d2 d3 d d2 d3 β
Ø P max. min. max. min. max. max. min. max. min. max. max. min. max. min. max. Deg., min.

Example of a bolt thread designation (tolerance centre): M 16 - 6g

Example of a bolt left-hand thread designation (tolerance centre): M 16 - 6g-LH

9
 Metric ISO fine threads

Metric ISO fine threads [Link]

Tolerance field
(mm)

Thread- Lead
Nomi- 4h 6g 6e
nal pitch d d d β
d2 d3 d2 d3 d2 d3
Ø P max. min. max. min. max. max. min. max. min. max. max. min. max. min. max. Deg., min.

Example of a bolt thread designation (tolerance centre): M 16 - 6g

Example of a bolt left-hand thread designation (tolerance centre): M 16 - 6g-LH

10
Metrisches ISO-Feingewinde
Metric ISO fine threads

Tolerance field
(mm)

Thread Lead
Nomi- 4h 6g 6e
nal pitch d d2 d3 d d2 d3 d d2 d3 β
Ø P max. min. max. min. max. max. min. max. min. max. max. min. max. min. max. Deg., min.

Example of a bolt thread designation (tolerance centre): M 16 - 6g

Example of a bolt left-hand thread designation (tolerance centre): M 16 - 6g-LH

11
 Rolling speeds [Link]

Rolling speed ft./min.

Blank diameter 20 25 30 35 40 50 60 70 80 90 100
Component rotating at r.p.m.
1 6400 8000 9600 11150 12750 16000 19200 22300 25500 29000 32000
2 3200 4000 4800 5600 6400 8000 9600 11200 12800 14400 16000
3 2150 2700 3200 3750 4250 5350 6400 7500 8500 9600 10650
4 1600 2000 2400 2800 3200 4000 4800 5600 6400 7200 8000
5 1300 1600 1950 2250 2600 3250 3900 4500 5150 5800 6420
6 1100 1330 1600 1875 2150 2700 3200 3750 4300 4800 5350
7 950 1150 1400 1600 1850 2300 2750 3200 3650 4120 4600
8 800 1000 1200 1400 1600 2000 2400 2800 3200 3600 4000
9 720 900 1100 1250 1450 1800 2150 2500 2850 3200 3550
10 640 800 1000 1200 1300 1600 1950 2250 2600 2900 3200
12 540 700 800 950 1100 1350 1600 1900 2150 2430 2700
14 450 600 700 800 950 1150 1400 1600 1850 2100 2300
15 430 550 650 750 875 1100 1300 1500 1720 1950 2150
16 410 510 600 700 800 1000 1200 1400 1600 1800 2000
18 369 450 540 630 720 910 1100 1270 1445 1600 1800
20 320 400 485 560 640 800 800 1130 1300 1450 1620
22 300 375 450 520 600 740 900 1050 1200 1320 1470
24 270 350 420 470 540 675 800 950 1100 1200 1350
25 260 330 400 460 520 640 775 900 1050 1170 1300
26 250 315 390 450 510 630 750 870 1000 1125 1250
28 230 300 350 415 470 590 700 800 920 1030 1150
30 220 270 340 380 435 540 640 760 875 970 1090
32 210 260 320 364 425 530 615 720 800 910 1000
34 190 240 295 340 385 480 570 665 760 855 950
35 185 230 280 330 375 465 550 640 740 835 935
36 180 225 270 315 360 450 540 630 710 800 900
38 170 210 260 300 340 430 510 590 680 760 850
40 160 200 240 285 325 410 485 560 640 720 800
45 145 180 215 255 290 365 435 510 580 650 715
50 130 160 195 225 260 325 390 450 520 590 650
55 120 150 175 205 235 295 350 410 470 530 590
60 110 135 160 190 215 270 325 375 435 490 540
65 100 125 130 175 200 255 305 350 400 450 500
70 95 115 140 160 185 230 275 325 370 420 465
75 90 110 130 150 175 215 260 310 350 390 435
80 85 105 125 145 160 205 250 290 330 370 410
85 80 100 115 135 155 190 230 265 310 340 380
90 75 90 110 125 145 180 215 255 290 325 365
100 70 85 100 115 130 160 195 225 260 300 325

12
Rolling speeds

In general, the following applies:

■ Cone threads may be produced with a higher rolling speed than trapezoidal threads.

■ In case of a higher strain σ, the rolling speed is higher than for materials with a smaller strain σ.

■ Materials with a higher tensile strength must be rolled with a lower rolling speed.

■ For cone threads, we recommend 20 - 80 m/min as a guideline. For trapezoidal and similar threads,
we recommend approx. 15 - 30 m/min.

Rolling speed formula: Rotational speed formula:

d2 . π . n 1000 . V
V= [m/min] n= [min-1]
1000 d .π
2

Sample calculation: M 10 x 1,5 (6 g) Sample calculation: M 10 x 1,5 (6 g)

Starting -Ø (flank -Ø) d2 = 8,99 mm Starting-Ø (flank-Ø) d2 = 8,99 mm
Workpiece speed n = 1800 U/min Rolling speed V = 51 m/min

8,99 . π . 1800 1000 . 51

V= [m/min] n= [min-1]
1000 8,99 . π

V = 50,84 m/min n = 1805,76 min-1

13
 Material rolling properties [Link]

Generally speaking, materials starting from a minimum strain of approx. 5% and a tensile strength of up to approx. 1400 N/mm² may be
formed.

Table values

Please refer to the information in the table below for each individual case.
The values listed in the table are guide values only and may vary depending on the rolling head type, the material quality and the machine
conditions.
If you require technical support, please contact your Boehlerit customer service representative.

Materials Material Material Tensile Hardness Strain Rolling Rolling speed

DIN code strength Brinell σ min. 5 % properties m/min.
N/mm² (HB)
Ferrous metals
General ST 37 1.0120 500 150 28 lll 40 - 80
structural
ST 50 1.0531 500 - 600 150 - 190 22 lll 30 - 60
steels
ST 60 1.0540 500 - 600 190 - 250 15 lll 20 - 50
CK 45 1.1191 650 - 850 200 - 250 15 lll 20 - 50
Case harde- C 15 E 1.1141 500 150 16 lll 40 - 70
ning steel
16 MNCr 5 1.7131 500 - 850 150 - 200 10 ll 30 - 50
Nitriding 34 CrAl 6 1.8504 1000 290 14 ll 20 - 50
steels
31 CrMo V 9 1.8519 1000 - 1300 290 - 380 11 ll 20 - 40
Free cutting 9 S 20 1.0711 360 160 25 lll 30 - 60
steels
9 S Mn Pb 28 1.0718 380 170 23 lll 30 - 60
35 S 20 1.0726 500 600 190 18 lll 30 - 60
Heat treatable C 35 1.0501 700 200 18 lll 40 - 70
steels
CK 60 1.1221 700 - 900 200 - 260 14 ll 30 - 60
42 CrMo 4 1.7225 900 - 1200 260 - 350 11 ll 20 - 50
30 CrMo V 9 1.7707 1200 - 1400 350 - 400 9 l 20 - 40
34 CrNiMo 6 1.6582 1000 - 1400 350 9 l 20 - 40
Tempered 50 CrV 4 1.8159 900 - 1000 250 10 l 20 - 40
steels

Rolling properties:

lll Good rolling properties

ll Can be rolled

l Limited rolling properties

14
Material rolling properties

Materials Material Material Tensile Hardness Strain Rolling Rolling speed

DIN code strength Brinell σ min. 5 % properties m/min.
N/mm² (HB)
Ferrous steels
Tool steels X 210 Cr 12 1.2080 800 230 ll 30 - 50
X 130 W 5 1.2453 800 - 1000 230 - 290 9 ll 20 - 40
115 CrV 3 1.2210 600 - 700 220 10 ll 30 - 50
High speed S 6-5-2
1.3343 850 - 900 240 - 300 l 20 - 40
steels (DM 05)
S 6-5-2-5
1.3243 850 - 900 240 - 300 l 20 - 40
(E Mo 5 Co5)
Stainless X 10 Cr 13 1.4006 550 - 650 200 - 250 18 ll 30 - 50
steels
X 22 CrNi 17 1.4057 800 - 900 250 - 320 12 ll 30 - 50
X 12 CrMoS 17 1.4104 500 - 800 200 - 250 20 ll 30 - 50
X 5 CrNi 1810 1.4301 500 - 700 200 - 250 50 lll 35 - 55
X 10 CrNiS 189 1.4305 500 - 700 200 - 250 50 lll 35 - 55
X5CrNiMo 17122 1.4401 500 - 700 200 - 250 30 ll 30 - 50
X6CrNiMoTi 17122 1.4571 500 - 700 200 - 250 40 ll 30 - 50
Cast steels GS 38 1.0416 500 150 20 lll 40 - 60
GS 36 Mn 5 1.5067 500 - 600 150 - 200 17 lll 40 - 60
GS 50 CrMo 4 1.7228 650 200 11 ll 30 - 50
Malleable cast GTS 45 450 - 500 150 - 200 6 ll 30 - 60
iron
GTS 65 600 - 700 210 - 250 6 ll 30 - 60
Cast iron GGG 40 0.7040 400 - 500 140 - 180 27 - 15 lll 30 - 60
GGG 50 0.7050 500 - 600 180 - 210 12 ll 30 - 50
GGG 60 0.7060 600 - 750 210 - 250 8 ll 30-50
High
NiCr 20 Co 19 Nimonic 263 540 - 700 160 - 200 ll 30 - 50
temperature
steels
NiCr 17 Mo 17 Hasteloy 700 - 900 200 - 260
ll 20 - 40
FeW
Nickel alloys Inconell 600 900 - 1100 260 - 330 l 20 - 40

Non-ferrous metals
Copper C-CU (F 20) 2.0120 ca. 200 40 - 65 ca. 30 lll 40 - 100
E-Cu (F 25) 2.0060 250 65 - 90 ca. 8 lll 40 - 80
Copper alloys MS 63 (F 30) 2.0320.10 300 ca. 70 40 lll 40 - 80
(Brass)
MS 60 Pb (F 41) 2.0370.26 400 ca. 100 15 ll 40 - 70
MS 60 Pb (F 35) 2.0372.10 340 ca. 90 35 lll 40 - 70
MS 58 F 44 2.0380.26 430 ca. 125 19 ll 40 - 70
M 58 F 44 2.0401.10 430 ca. 125 19 ll 40 - 70
Zinc alloys ZnCu 1 3.3525 180 - 200 40 - 60 15-4 lll 40 - 70
Aluminium AlMg 2 3.2315 150 - 210 40 - 60 15-4 lll 40 - 70
alloys
AlMgSi 1 3.4355 200 - 320 60 - 95 14-9 ll 40 - 70
AlZnMg 3 3.1355 400 - 450 105 - 125 10-5 l 30 - 50
AlCuMg 2 3.4365 450 115 9 ll 30 - 50
AlZnMgCu 1,5 3.7035 530 - 540 140 7 ll 30 - 50
Titanium Ti 99,7 3.7124 290 - 550 85 - 160 ca. 22 lll 30 - 60
alloys
TiCu 2,5 3.7115 550 - 750 160 - 220 ca. 20 lll 30 - 60
TiAl 15 Sn 2 3.7164.7 750 - 950 220 - 280 ca. 10 ll 30 - 60
TiAl 7 Mo 1030 - 1100 ll 20 - 40

15
BOEHLERIT GmbH & Co. KG
Werk VI-Strasse 100
8605 Kapfenberg
Österreich/Austria
Telefon +43 3862 300 - 0
Telefax +43 3862 300 - 793
info@[Link]
[Link]

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