David C. Willens is the Director of Research and Development at Kinefac Corporation, Worcester, Mass. He has a Ph.D. in mechanical engineering from Worcester Polytechnic Institute and is co-author of the chapter on the Rolling Process in the 2015 McGraw Hill Manufacturing Engineering Handbook. He has been involved in the design of thread and form rolling machinery, dies, and processes for over 18 years.
Why use the rolling process to produce high accuracy lead screws, actuator screws, and other power transmission components rather than traditional cutting processes such as turning, grinding, milling, whirling, or hobbing? Rolling processes and cutting processes both produce a precise form on the workpiece. But if the form geometry, tolerances, and material selection allow, rolling is the process to beat. Speed, surface finish, fatigue strength, precision, dimensional stability, and material savings are some of the primary advantages realized when the rolling process is applied.
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