Micro Screws Got You Down? Let's Talk Thread Rolling!

Contents hide

1 Micro Screws Got You Down? Let's Talk Thread Rolling!

For 30 years, I've been immersed in the world of mechanical engineering, specifically in the fastener industry. And if there's one thing I've learned, it's that even the smallest components can make the biggest difference. Today, I want to dive deep into a fascinating area: micro-thread rolling for micro screws.

Are you dealing with the intricate world of electronics, medical devices, or precision instruments? Then you're likely very familiar with micro screws. These tiny fasteners are crucial, but manufacturing them with consistent, high-quality threads can be a real headache. Believe me, I've seen countless production lines struggle with this challenge.

So, what's the solution? In my experience, thread rolling is the answer, and specifically, machines designed for micro-threading. Let's explore why, and how this technology can revolutionize your micro screw production.

Why Choose Thread Rolling for Micro Screws? Isn't Machining Easier?

You might be thinking, "Why not just machine the threads? It's a common process." And yes, machining is an option. But when we talk about micro screws – those delicate components with diameters often under 2mm – machining has some serious drawbacks.

From my years in the field, I've seen firsthand the problems with machining micro screw threads:

Material Waste: Machining is a subtractive process. You're cutting away material, which is wasteful, especially when dealing with precision metals. With thread rolling, it's a chipless forming process, meaning virtually no material is lost. This becomes crucial when you're working with expensive materials or aiming for cost-effective production.
Weakened Screws: Cutting threads interrupts the grain flow of the metal, making the screw weaker, particularly at the thread root – the most critical stress point. Thread rolling, on the other hand, improves the material's strength. The cold forming process work-hardens the material and realigns the grain flow, following the thread profile. This results in threads that are significantly stronger and more fatigue-resistant. In applications where reliability is paramount (think medical devices!), this strength advantage is non-negotiable.
Slower Production: Machining, especially for intricate micro threads, is a relatively slow process. If you need high volumes of micro screws, machining can quickly become a bottleneck. Thread rolling is significantly faster. Dedicated micro-thread rolling machines can churn out hundreds of parts per minute, dramatically increasing your production rate.
Tool Wear and Breakage: Tiny cutting tools used for micro-machining are incredibly fragile and prone to wear and breakage. This leads to frequent tool changes, downtime, and increased costs. Thread rolling dies are much more robust and last significantly longer, reducing tooling costs and downtime.

Simply put, for micro screws, thread rolling isn't just an alternative – it's a superior method in terms of strength, efficiency, material usage, and cost-effectiveness.

What Kind of Micro-Thread Rolling Machines Are We Talking About? Let's Look at Some Examples.

Over the years, I've worked with various thread rolling equipment, and I've seen some impressive advancements in micro-thread rolling technology. Let's take a look at a few examples of machines specifically designed for this delicate task. These machines are built to handle diameters from as small as 0.6mm up to around 2.6mm, and lengths from under 1mm to about 25mm. They are true marvels of precision engineering!

The AR-001FC: Entry-Level Powerhouse for Micro Threads

If you're just starting with micro-thread rolling or need a reliable, compact machine for smaller batches, the AR-001FC is a great option. From my experience, this type of machine is incredibly user-friendly and efficient. It uses a flat feeding system, which is straightforward to set up and operate.

Here's a quick rundown of its key specs:

Model	Max. Blank Diameter, mm	Max. Blank Length, mm	Output capacity, pcs/min	Feeding Type
AR-001FC	0.8 - 2.0	0.8 - 10	100 - 150	Flat

As you can see, it handles diameters from 0.8mm to 2.0mm and lengths up to 10mm. With a production rate of 100-150 pieces per minute, it's a significant step up from machining for volume production. The "Flat" feeding type means the blanks are fed linearly into the rolling dies. This is a simple and effective method for smaller micro screws.

And just to give you an idea of the kind of tiny components these machines produce, take a look at these micro screw samples:

Incredible, right? These are the screws that hold together our smartphones, medical instruments, and countless other essential devices.

The RG-00L2: Precision and Operator-Friendly Design

For even greater precision and ease of use, the RG-00L2 series machines are a fantastic choice. These are designed for slightly smaller micro screws, ranging from M0.6 to M1.7 in diameter and lengths from 0.7mm to 6mm.

What I particularly appreciate about machines like the RG-00L2 is their focus on operator experience. Let's face it, in any manufacturing setting, skilled operators are crucial. These machines incorporate features that make them easier to set up, adjust, and troubleshoot, even for less experienced personnel.

One clever design element is the 45-degree angled pusher. This angled pusher smoothly guides the micro screw blanks into the rolling dies. This is particularly beneficial for screws with large heads and thin shanks, which can be tricky to feed consistently.

Another standout feature is the digitized gap adjustment. Instead of relying on feel or guesswork, the RG-00L2 provides a visual, digital display of the gap between the thread rolling dies. This makes precise adjustments much simpler and faster, reducing setup time and ensuring consistent thread quality. In my book, anything that simplifies setup and reduces downtime is a huge win.

The vibratory feeder on these machines is also intelligently designed. It has a modular structure, allowing you to adapt it to different workpiece shapes. Furthermore, it automatically regulates the number of blanks on the vibrating plate, ensuring a stable and consistent feeding process, even for complex thread forms.

And let's not forget about safety and cleanliness. The RG-00L2 comes with a sealed casing. This not only protects the internal mechanisms from oil mist and dust, but also enhances operator safety and reduces noise levels in the workshop. A clean and safe working environment is always a priority in my book.

Here's a closer look at some key features of the RG-00L2:

Stable Micro Feeding: Orbital and linear vibratory feed eliminates jamming.
Efficient Feed Adjustment: 45-degree pusher simplifies setup.
Defect Detection: Monitors for thread defects.
Adjustable Vibrating Disc: Adapts to different product shapes.
Visual Information Display: Digital gap display for easy adjustment.
Stable Oil Pressure: One-way non-return oil circuit.
Comprehensive Safety Features: Emergency stops, safety door microswitch, signal lamps, etc.

Here are the specifications for the RG-00L2:

Model	Wire Diameter, mm	Shank Length, mm	Output capacity, pcs/min	Feeding Type
RG-00L2	M0.6 - M1.7	0.7 - 6	80 - 250	Flat

Notice the increased production speed, up to 250 pieces per minute! That's serious throughput for such tiny, precision components.

Want to see it in action? Check out this video:

Video of the operation of the micro-thread rolling machine

Резьбонакатный станок для накатки резьбы на микровинты серии RG-00L2 - YouTube

TAIWAN METIZ ALLIANCE

901 subscribers

Резьбонакатный станок для накатки резьбы на микровинты серии RG-00L2

TAIWAN METIZ ALLIANCE

Watch later

Copy link

Info

Shopping

Tap to unmute

If playback doesn't begin shortly, try restarting your device.

RG-00L3: Similar Performance, Streamlined Design

The RG-00L3 is essentially a very similar machine to the RG-00L2, offering the same performance and specifications. It might have slight variations in design or specific components, but in terms of functionality and output, they are largely comparable. This is common in the industry – manufacturers often offer slightly different models to cater to specific customer preferences or minor variations in production needs.

Model	Wire Diameter, mm	Shank Length, mm	Output capacity, pcs/min	Feeding Type
RG-00L3	M0.6 - M1.7	0.7 - 6	80 - 250	Flat

RG-05N2 & RG-05N3: Handling Slightly Larger Micro Screws with Slanted Feeding

For slightly larger micro screws, in the M1.4 to M2.6 diameter range and lengths up to 25mm, the RG-05N2 and RG-05N3 models come into play. These machines utilize a slanted feeding system.

Why slanted feeding? For slightly larger and sometimes longer micro screws, a slanted feed can provide more controlled and stable feeding into the rolling dies. It helps to orient the parts correctly and prevent jamming, especially for screws with larger heads or more complex shapes.

Like the RG-00L2, the RG-05N2 also features a sealed casing for cleanliness and noise reduction. It also incorporates a vibratory feeder designed for stable feeding of various profiles. Instead of a single pusher, these machines use two pushers at a 45-degree angle to further enhance feeding stability, especially for those screws with larger heads and smaller shanks.

An interesting optional feature for the RG-05N2 is a product detection device. This can automatically detect thread rolling defects and separate out any scrap parts, ensuring only high-quality screws make it to the next stage of production. In high-volume manufacturing, automated quality control like this is invaluable.

Here are the specs for the RG-05N2 and RG-05N3 (which are again, very similar):

Model	Wire Diameter, mm	Shank Length, mm	Output capacity, pcs/min	Feeding Type
RG-05N2	M1.4 - 2.6	2 - 25	80 - 250	Slanted
RG-05N3	M1.4 - 2.6	2 - 25	80 - 250	Slanted

And here's a video showcasing the RG-05N2 in operation:

Video of the operation of the micro-thread rolling equipment

Резьбонакатный станок для микровинтов RG-05N2 - YouTube

TAIWAN METIZ ALLIANCE

901 subscribers

Резьбонакатный станок для микровинтов RG-05N2

TAIWAN METIZ ALLIANCE

Watch later

Copy link

Info

Shopping

Tap to unmute

If playback doesn't begin shortly, try restarting your device.

Integrating with Cold Forming: The Complete Micro Screw Production Line

For maximum efficiency, micro-thread rolling machines like these are often integrated with cold forming equipment. Cold forming is used to create the initial shape of the screw blank, including the head. By combining cold forming and thread rolling in a production line, you can achieve a fully automated, high-speed process for manufacturing micro screws from raw wire to finished, threaded parts. This integrated approach is the gold standard for high-volume micro screw production.

What Else is Out There? Exploring Similar Micro Thread Rolling Technologies.

While the machines we've discussed are excellent examples, the world of micro thread rolling is constantly evolving. There are other manufacturers and technologies worth exploring. In my experience, when looking at similar equipment, consider these factors:

Servo-Driven Systems: Many advanced micro thread rolling machines now use servo motors for greater precision and control over the rolling process. Servo drives allow for finer adjustments of rolling pressure and speed, leading to even higher thread quality and reduced scrap rates.
CNC Integration: Some manufacturers offer CNC-controlled micro thread rolling machines. CNC integration allows for more complex thread profiles and greater flexibility in handling different screw designs. It also facilitates easier setup and changeover between different screw types.
In-Process Monitoring: Beyond defect detection, some systems incorporate sophisticated in-process monitoring. Sensors continuously monitor rolling force, vibration, and other parameters to detect subtle variations and ensure consistent thread quality in real-time. This level of process control is becoming increasingly important for demanding applications.
Automation and Robotics: The trend is towards greater automation. Look for machines that can be easily integrated with robotic loading and unloading systems, as well as automated feeding and sorting mechanisms. Full automation minimizes manual handling, increases throughput, and improves overall production efficiency.

In conclusion, if you're serious about manufacturing high-quality micro screws efficiently and cost-effectively, micro-thread rolling is the way to go. The machines I've highlighted are just a starting point. By understanding the technology and exploring the latest advancements, you can make informed decisions about your production line and ensure you're equipped to meet the growing demand for these essential miniature fasteners. It's a fascinating field, and after 30 years, I'm still excited to see where it goes next!

Micro Screws Got You Down? Let’s Talk Thread Rolling!