5 Things to Know Before Buying Hydraulic Threading Machine

What are hydraulic tools?

Hydraulic tools organically combine the hydraulic system with ordinary tools into a whole. Convert powerful hydraulic power into reciprocating linear motion, rotational motion, cycloidal motion and other mechanical motions. A complete hydraulic tool system consists of five parts, namely power components, actuating components, control components, auxiliary components and hydraulic oil.

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What tools are hydraulic tools?

1. Hydraulic wrench

Hydraulic torque wrench generally refers to a bolt-tightening tool that can output and set torque. It is a high-pressure hydraulic tool and is widely used in equipment maintenance and installation in many heavy and chemical industries. There are two types of hydraulic torque wrenches: drive shaft and hollow type.

2. Hydraulic wrench/tensioner/jack pump

Hydraulic wrench/tensioner/jack pumps include three types of pumps, namely wrench pumps, tensioning pumps and jack pumps. Their main function is to provide power for hydraulic wrenches, bolt tensioners, and hydraulic jacks. Each type of pump has subtle differences compared to other pumps, but their working principles are the same.

3. Hydraulic jacks

Hydraulic jack refers to a jack that uses a plunger or hydraulic cylinder as a rigid lifting member. It has the characteristics of compact structure, stable operation, large supporting force and self-locking. Hydraulic jacks have a strong support capacity, and heavy-duty hydraulic jacks have a support capacity of more than 100t.

4. Hydraulic bolt tensioner

The bolt hydraulic tensioner uses a hydraulic boost pump (ultra-high pressure hydraulic pump) to provide hydraulic power.

The tensile force is determined based on the tensile strength, yield coefficient and elongation of the material, and the tensile force generated by the ultra-high pressure oil pump is used to elongate the applied bolt in its elastic deformation zone.

The diameter of the bolt is slightly deformed, making the nut easy to loosen. In addition, it can also be used as a device for applying axial force to the hydraulic interference connection for top-pressure installation.

The biggest advantage of the tensioner is that multiple bolts can be tightened and disassembled at a fixed value at the same time with uniform force. It is a safe, efficient and fast tool and the best way to tighten and disassemble bolts of various specifications. It is used in the petrochemical industry, nuclear power, wind power, hydropower, thermal power, shipbuilding, railway, aerospace, mining, heavy machinery and other fields. According to different working conditions, application conditions and user requirements, special tensioners can be designed.

5. Hydraulic flange separator

Flange separator is a device for separating large industrial machines. It is divided into an integrated hydraulic flange separator and a split flange separator. Mainly used for pipeline maintenance, pipeline construction, testing and flange replacement, maintenance of gaskets, pressure vessels, cylinder head opening, power plants, bearing disassembly, oil and gas drilling, motor rotor disassembly, offshore platforms, jacking work, shipbuilding, industrial equipment, horizontal movement of workpieces and other industries.

6. Hydraulic nut splitter

Hydraulic nut splitters are used when the nuts on industrial equipment are exposed to the open air, high temperature, or corrosive environment, and are corroded and seized, and the threads are damaged due to collision.

Where the nut needs to be removed, it is usually very difficult to remove the rusted nut. The usual method is to use gas welding to cut off the nut and bolt together.

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However, in some special working environments, electric welding is sometimes strictly prohibited, such as underground coal mines, pulverized coal bins of thermal power plants, oil pipes and high-pressure and high-temperature pipelines, etc., making it even more difficult to replace nuts and bolts.

7. Hydraulic puller

The hydraulic puller moves forward directly with the hydraulic starting rod, so the push rod itself does not rotate. The hook seat can directly adjust the distance forward and backward along with the thread. During operation, as long as the handle swings back and forth slightly, the hydraulic starting rod moves forward, the hook correspondingly retreats, and the pulled object is pulled out.

The hydraulic puller is easy to operate and labor-saving. The three-claw type and the two-claw type can be replaced according to the needs of on-site work. You can freely rotate and press the puller to move away from the center point of the piston, and quickly touch the center point of the workpiece being pulled. Optional pumps are available.

8. Other

In addition to the above common hydraulic tools, there are many other hydraulic tools. Such as hydraulic splitting machines, hydraulic presses, hydraulic punching machines, hydraulic pipe bender, hydraulic nut crushers, hydraulic clamps, hydraulic cutters, etc.

Advantages of hydraulic tools

1. Mineral oil is generally used as the working medium. The relative moving surfaces can be self-lubricated and have a long service life.
2. Light weight, small size, small movement inertia and fast response speed.
3. Various components of hydraulic transmission can be arranged conveniently and flexibly according to needs.
4. Overload protection can be automatically realized.
5. It is easy to operate and control and can achieve a wide range of step-less speed regulation (speed regulation range up to :1).
6. It is easy to achieve linear motion.
7. It is easy to realize the automation of the machine. When electro-hydraulic joint control is adopted, not only a higher degree of automatic control process can be achieved, but also remote control can be achieved.

Disadvantages of hydraulic tools

1. It is prone to leakage. The oil pressure of the hydraulic system is high, and the hydraulic oil can easily leak through seals or gaps, causing the consumption of hydraulic media and causing environmental pollution.
2. Low transmission efficiency: During the energy transmission process of hydraulic transmission, there are often more energy losses (pressure loss and flow loss, etc.), which makes the transmission efficiency low.
3. Inaccurate transmission ratio: Due to factors such as the compressibility of the transmission medium, leakage, and elastic deformation of the pipeline, the hydraulic system cannot strictly guarantee fixed-ratio transmission.
4. Sensitive to temperature. The viscosity of oil changes with temperature. Changes in viscosity cause changes in flow, leakage and resistance, which can easily lead to unstable movement of the working mechanism.
5. High manufacturing costs. To reduce leakage, hydraulic components require higher manufacturing precision, thus increasing manufacturing costs.

At Last

Different types of thread rolling machines are available in the market. These machines have different capabilities and prices. Demand for thread rolling machines has been increasing over the years, which is why many manufacturers are striving to meet the demand. The availability of many brands of thread rolling machines makes it hard to find the perfect thread rolling machines. 

This article will discuss the different types of thread rolling machines available and how to select a suitable machine. Additionally, it will talk about the market share of the thread rolling machines market and the machines’ process. 

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Table of Contents
Overview of thread rolling machines market
Thread rolling process
Types of thread rolling machines
Guide to selecting suitable thread rolling machines
Summary

Overview of thread rolling machines market 

The global thread rolling equipment market is segmented based on the type of machines, by industry of application, and by region. Over the next five years, the market is expected to rise considerably due to the increased inclusion of technological innovations on the machines by key players in the market. Some of these manufacturers are Tsugami China, Nakamura Jico Co. Ltd., and Tobest. 

Based on an OEC report in , the global thread rolling machines market was valued at USD 93.4 million. This represented a 21.6% drop from the USD 119 million value in . This drop in market value was due to the reduced adoption of thread rolling machines across the globe. However, the demand for these machines is expected to grow as a result of a variety of applications like automotive, electronics, and medical. 

In , the top exporters of thread rolling machines were Italy at USD 18.1 million, Taiwan at USD 17.4 million, Japan at USD 16.4 million, China at USD 11.8 million, and Germany at USD 9.86 million. The top importers were China with a value of USD 14.4 million, the U.S. at USD 10.8 million, India at USD 6.01 million, Thailand at USD 5.91 million, and South Korea at USD 3.52 million. 

Thread rolling process

Generally, thread rolling is a metal forging process where a machined blank is pressed between rotating dies. The blank’s thread profile is ground into the dies. As the blank is penetrated by the dies, the metal flows into the die cavities. This results in a thread profile into the workpiece. A cut thread interrupts the part’s grain structure while cold working a rolled part strengthens it. To obtain an appropriate outer diameter (0.375 inches), blanks should be machined or ground into a specific pitch diameter in advance of thread rolling. 

The common thread processes include:

– Thru-feed: thread rolling of parts with long thread lengths that exceed the dies’ width.

– Infeed: parts thread rolling where the thread length is shorter than the dies’ width.

– Infeed/thru-feed: a two-step thread rolling for long thread lengths in which partially or incompletely formed threads are reduced. 

Types of thread rolling machines

1. Flat die thread rolling machine

A flat die thread rolling machine has four main parts which include a conductor bar, pusher arm, and two flat dies where one is fixed and the other is moved backward and forward by a crank-type mechanism. The flat dies come with a thread profile machined into them and another thread profile inclined by the pitch of the thread they can create. 

The blanks to be threaded are held by the conductor bar, which ensures they are kept in the right orientation. Also, the conductor bar is inclined in a position that when it engages with the blanks, gravity pulls them down towards the pusher arm. The pusher arm forces the blanks into a void between the moving and stationary flat dies. A thread is created when the moving die moves forward and the blanks roll due to the frictional forces of the process. 

2. 2-die cylindrical thread rolling machine

A 2-die cylindrical thread rolling machine has three variations which include infeed, thru-feed, and a combination of infeed & thru-feed. Infeed machines have two parallel dies that rotate in the same direction and at the same speed. One die is fixed while the other has lateral movements. The rolling process depends on friction to rotate the blank. In this case, the lateral movement is adjusted to set the thread pitch and diameter. 

Long threaded sections like lead screws and studding are created by the thru-feed process. Notably, large threads require more than one pass to produce complete threads. There are combination machines that can allow for both infeed and thru-feed thread rolling processes.

3. 3-die cylindrical thread rolling machine

A 3-die cylindrical thread rolling machine comes in three variations. Two of the three dies are fixed while the third moves vertically or laterally based on the layout of the machine. The 3-die cylindrical thread rolling machine is selectively suited for long threaded items like lead screws. 

4. Planetary thread rolling machine

A planetary thread rolling machine has the blanks fed into the dies like in a flat die thread rolling machine. The machine has two dies where the circular die rotates and the curved die is fixed. Some planetary thread rolling machines contain multiple curved segment dies mounted around the circular die. This feature ensures high production rates. 

Guide to selecting suitable thread rolling machines

1. Cost

Cost includes the initial purchasing price, the cost of accessories, and the equipment maintenance costs. On average, thread rolling machines are available at prices of about USD 5,000. The material being threaded and the demand of the production line determines the kind of thread rolling machine to be purchased. Buyers should consider their budget when investing in efficient thread rolling equipment. Furthermore, they should generally ensure a no scrap, lower tool cost, and lower labor formula to significantly reduce the costs. 

2. Precision 

The final quality of the rolled thread is dependent on the precision of the thread rolling machine. Apart from material choice, accuracy is determined by the preparation process of the blanks to be threaded. Conventionally, thread rolling displaces material, thus the diameter of the blank is generally smaller than that of the finished rolled thread’s diameter. In this case, the average precision can be achieved if the blanks are machined at tight tolerances of about 0. inches. There is a further recommendation to include a 37-degree chamfer threaded at the end of each section to reduce the risk of chipping and an approximately 45-degree final chamfer.

3. Strength

The inclusion of cold working in thread rolling increases tensile strength by at least 30% more than cut threads. Rolled threads have an improved fatigue strength ranging from 50% to 75%. In this case, threads exhibit no loss of fatigue strength even if they are heated up to 500 degrees Fahrenheit. Some machines produce stronger threads that do not require expensive outside heat treatment. Generally, rolled threads are smoother and are damage-resistant when being handled.  

4. Speed

The speed of thread rolling can go up to 200 feet per minute when working on materials like high-carbon steel and brass. However, buyers can obtain better results by employing slower speed. Thread rollers can achieve significant speed when the roller held in a holder is attached to the cross-slide while being presented radially or tangentially. The speed is slower if the roller is held on a swing stool. This is because of a lack of rigidity of the holder on the swing type. 

5. Applicable material

It is vital to select a suitable material to enhance the accuracy and quality of the threads produced. Generally, if the material is hard, it becomes equally hard to be rolled, which might affect the service life of the dies. Also, as buyers purchase thread rolling machines, they should note that hollow profiles result in blank ovals due to the forces involved. On average, a suitable material should have a minimum elongation of 12%, a maximum hardness of about 40 HRC, and a maximum tensile strength of MPa. Furthermore, to improve the dies’ durability, some have coatings like CVD and PVD. 

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Summary