The threaded rolling machine is a vital piece of equipment in the manufacturing sector, particularly in the production of high-strength fasteners. However, to maximize its lifespan and efficiency, it is crucial to avoid common operational errors that could lead to premature wear and tear. Here, we outline the key mistakes that can significantly impact the longevity of your threaded rolling machine.

1. Poor Machine Precision and Vibration Issues

One of the most significant factors influencing the lifespan of a threaded rolling machine is its precision. When the machine operates with poor accuracy and excessive vibration, it not only affects the quality of the threaded products but also puts undue stress on the internal components. Regular maintenance and calibration are essential to ensure optimal precision and reduce vibrations.

2. Misalignment of Rolling Dies

Another common error is improper alignment of the rolling dies. If the dies are not positioned correctly, the workpieces may experience axial displacement during the rolling process. This misalignment causes the threads to endure both shear and compressive stresses, leading to accelerated wear on the threaded rolling machine. Ensuring proper alignment before each job can help avoid this critical mistake.

3. Inconsistent Workpiece Dimensions and Surface Cleaning

A further factor affecting the lifespan of threaded rolling machines is the inconsistency in the dimensions of the workpiece materials. Variations in size can lead to improper engagement with the rolling dies. Moreover, if the workpieces are not adequately cleaned and contain residual contaminants such as grinding dust, oxidation, or dirt, this can hinder the rolling process, ultimately deteriorating the machine more quickly than anticipated.

4. Uneven Hardness of Rolled Workpieces

The hardness of the rolled workpieces is another crucial element that influences the functioning of threaded rolling machines. For instance, bolts graded 8.8 should exhibit a hardness of 27-30HRC, while those graded 10.9 should fall between 35-37HRC. Mixing untempered high-hardness (50-55HRC) quenched materials with tempered sections due to poor management can result in blade chipping. Regular checks on hardness levels help maintain uniformity and protect the machine’s components.

5. Lack of Lubrication During Rolling

Failing to incorporate proper lubrication during the rolling process leads to dry friction, resulting in a dramatic rise in the temperature of the thread tips. If this temperature exceeds the tempering threshold of the rolling dies, the threads may undergo excessive tempering and softening, causing issues such as tooth collapse or pilling failures. Therefore, consistent application of suitable lubricants is vital to safeguard the threaded rolling machine.

6. Residual Magnetism Issues

Lastly, it is essential to ensure that the rolling wheels are adequately demagnetized before leaving the factory. Any residual magnetism can attract fine iron particles during operation, which can accelerate the wear of the threaded rolling machine. Implementing a robust demagnetization process before use can prevent these magnetic issues, prolonging the machine’s operational life.

Understanding and addressing these common mistakes can significantly extend the lifespan of your threaded rolling machine. Regular maintenance, proper operation, and attention to material characteristics can enhance productivity and reduce costs associated with premature equipment failure. By focusing on precision, alignment, cleanliness, hardness, lubrication, and demagnetization, manufacturers can leverage their threaded rolling machines to their fullest potential.

By implementing these best practices, you can ensure your threaded rolling machine serves efficiently for years to come.