PIPE THREAD CUTIING MACHINE

in partial fulfillment of the requirement for the award of degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
BY

Under the guidance of----------------------------

2004-2005

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Register number: _________________________

This is to certify that the project report titled POWER
GENERATION

USING

SPEED

BRAKE

submitted

by

the

following students for the award of the degree of bachelor of

engineering is record of bonafide work carried out by them.
Done by
Mr. /Ms._______________________________

In partial fulfillment of the requirement for the award of

degree in

Bachelor of Mechanical Engineering

During the Year (2004-2005)

_________________
Head of Department

Coimbatore 641651.
Date:

_______________
Guide

Submitted for the university examination held on

___________

_________________
Internal Examiner
Examiner

________________
External

---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
At this pleasing moment of having successfully
completed our project, we wish to convey our sincere
thanks and gratitude to the management of our college
and

our

beloved

chairman

, who provided all

the facilities to us.
We would like to express our sincere thanks to our
principal , for forwarding
us to do our project and offering adequate duration in
completing our project.
We are also grateful to the Head of Department
Prof.

.., for her constructive

suggestions & encouragement during our project.

With deep sense of gratitude, we extend our earnest

&

sincere

thanks

to

our

guide

.., Department of
Mechanical for her kind guidance & encouragement
during this project.
We also express our indebt thanks to our TEACHING
and NON TEACHING staffs of MECHANICAL ENGINEERING
DEPARTMENT,.(COLLEGE NAME).

SYNOPSIS
In ordinary hand threading the tap may be shaken so that thread
may not be formed correctly. The thread may be formed in
angular position. There is also a change for the breakage of tap.
So a skilled person is need for tapping. This process is also taking
more time. The same conditions apply for threading also.

With the use of this machine, all this disadvantages

can be avoided. Even an unskilled person can be making
a thread by using this machine. By just setting the work
piece in the chuck, the thread can be formed easily by
rotating the hand wheel. The time consumed is very less.
Both

internal

and

external

thread

accurately by using this machine.

can

be

formed

Suitable sized tape

and die sets are used to form the required internal and
external thread respectively.

INTRODUCTION

The most important element of any machine is screw

threads without screw threads. There can not be any
development in the field of engineering. Even machine

tools operated by computers. Lead screw threads for

moving different slides. The size of screw threads for
different purposes varies a fraction of mm to as high as
300mm. These screw threads are made in quantities
from one to several millions. Some screws are to be very
accurate and some screws can be very rough. A number
of processes are available for manufacturing screw
threads. The correct process is selected so that the
required quantity and quality of screw threads are
produced at the lower cost. Those basic processes are
used in the manufacture of threads. They are casting
process can be used for producing both external and
internal threads. Die casting or investment casting
methods are used for producing screw threads in plastics.
Metal cutting process like thread milling, thread
grinding and thread chasing are used for producing large
variety of screw threads in different sizes. Thread rolling
process is used in the mass production of screw threads
in ductile materials. Only external threads can be
produced in this process. The process is generally
restricted to produce simple threads in standard forms.

A C MOTORS

An electric motor is an electromechanical device that

converts electrical energy into mechanical energy. Most
electric

motors

magnetic

fields

operate
and

through

the

interaction

of

current-carrying

conductors

to

generate force. The reverse process, producing electrical

energy from mechanical energy, is done generators such
as an alternator or a dynamo some electric motors can
also be used as generators, for example, a traction motor
on a vehicle may perform both tasks. Electric motors and
generators

are

commonly

referred

to

as

electric

machines.

Electric motors are found in applications as diverse

as industrial fans, blowers and pumps, machine tools,
household appliances, power tools, and disk drives. They
may be powered by direct current, e.g., a battery
powered

portable

device

or

motor

vehicle,

or

by

alternating current from a central electrical distribution

grid or inverter. The smallest motors may be found in
electric wristwatches. Medium-size motors of highly
standardized

dimensions

and

characteristics

provide

convenient mechanical power for industrial uses. The

very largest electric motors are used for propulsion of
ships, pipeline compressors, and water pumps with
ratings in the millions of watts. Electric motors may be
classified by the source of electric power, by their internal
construction, by their application, or by he type of motion
they give.

The

physical

principle

behind

production

of

mechanical force by the interactions of electric current

and a magnetic field, Faradays law of induction, was
discovered by licheal Faraday in 1831. Electric motors of
increasing efficiency were constructed from 21 through
the end of the 19th century, but commercial exploitation
of electric motors large scale required efficient electrical
generators and electrical distribution networks. First
commercially successful motors were made around 1873.

Some devices convert electricity into motion but do

not generate usable mechanical were as a primary
objective, and so are not generally referred to as electric
motors.

For

example,

magnetic

solenoids

and

loudspeakers are usually described as actuators and

transducers,

respectively,

instead

of

motors.

Some

electric motors are used to produce torque or force.

4.3.1 PRINCIPLE OF OPERATION

A large percentage of AC motors are induction

motors. This implies that there is no current supplied to
the rotating coils (rotor windings). These coils are closed
loops which have large currents induced in them. Threephase currents flowing in the stator windings leads
establish a rotating magnetic field in the air gap. This
magnetic field continuously pulsates across the air gap
and into the rotor. This is a single phase representation of
windings and current flow.

Fig 4.4 A C Motor

The rotor consists of copper or aluminum bars connected

together at the ends with rings.

Fig 4.5 Rotor

As magnetic flux cuts across the rotor bars, a voltage

is induced in them, much as a voltage is induced in the
secondary winding of a transformer. Because the rotor
bars are part of a closed circuit (including the end rings),
a current circulates in them. The rotor current in turn
produces

a magnetic

field

that

interacts with

the

magnetic field of the stator. Since this filed is rotating and

magnetically interlocked with the rotor, the rotor is
ragged around with the stator field.

4.3.2 SPECIFICATIONS

Voltage : 230v

Frequency

: 50Hz

Hase

: single

Feed

: 1440 rpm

: 180w

WORM GEAR BOX

Worm Gear

Worm Gears

Backed by 50 years of experience with precision mechanical

parts, PIC Design carries an impressive line of worm gears,
designed and sold as worm and gear pairs. We offer worm and
gear design expertise, many standard sizes to choose from, and
custom manufacture of worm gears to print. In addition, we can
modify standard worm gears when a full custom build isnt an
option.
What varieties of worm gears do you offer
We feature an extensive selection of worm gear options,
including:
Right Hand Worm Gears
Left Hand Worm Gears
Anti-Backlash Worm Gears
Worm and Wheel Sets

 Miniature Worm Gears

303 Stainless Steel Worms
Bronze Worm Gears

What sizes and specifications do you offer for

worm gears
With both standard and custom worm gears available in the
below ranges, we can meet just about any need for gear
reduction, offering ratios up to 360:1. Details include:
Pitch - 48 and 64
Ratios - 7.5:1 to 360:1
Worm Starts - 1, 2, 4
Gear OD - 5/8 to 5 5/8
Bores - 1/8 to
Typical Worm Gear Applications
Working primarily in the manufacturing, electronics, optics, and
control systems industries, our worm gears are used in motion
applications where precision is paramount, including lens
positioning and adjustment, and sensor drives. Worm gears are
also used in the following products:
Encoders
Potentiometers
Cameras

 Microscopes
Turntables

We are always available to answer any additional questions you

may have about our worm gear offerings. Please contact PIC
Design today for more information or a quotation.
Precision Bearings
A leader in the mechanical product manufacturing industry, PIC Design
features a wide selection of precision bearings, with custom and stock
products available to suit any customer need. As with all of our other
mechanical components, our bearings are compatible with many other
PIC products if you have any questions on compatibility or
corresponding parts, dont hesitate to get in touch with us. Our 50 years
of experience allow us to expertly assist with any part selection issues
you may have. In addition, we have full access to the RBC Bearings
product and knowledge base, allowing us to pass on this additional
benefit to you.
What Are the Specification Ranges for Your
Bearings
With many, many part numbers in stock, we are one of your best
resources to get the bearing that you need, when you need it. Our stock
ball bearings are available within the following ranges; certain custom
options can be manufactured as well.
Bore - .040 to 1.5
Outside Diameter - .125 to 2.625
Grade - ABEC 1, 3, 7
Type - Shielded, Sealed, Open

Mounting - Plain, Flanged

Radial Load - Up to 3000 lbs
What Types of Bearings Do You Carry
Our extensive inventory and custom capabilities allow us to carry all
varieties of bearings, in materials such as 440 C stainless steel, 52100
steel, sintered bronze, and PTFE. Bearing options include, but arent
limited to:
Sleeve Bearings
Ball Bearings
Cam Followers
Plain Bearings
Bearing Spacers
Precision Balls
Thrust Bearings
Thin Section Bearings
Rod Ends
Extended Inner Race Bearings
Linear Bearings

We can also offer full bearing and component assembly services.

What Are Typical Bearing Applications?

Our bearings are used in an enormous range of mechanical applications.
Past customers have used our bearings in the following ways, just to
name a few:
Control Systems (Sensor Drives) - Encoders, Potentiometers, Resolvers
Research/Quality - Gauges, Dials
Electronics - Gyroscopes, Motors
Manufacturing - Rollers, Slides
Gears

Whether the need is to transfer motion or transmit power, PIC

Design has the complete range of gearing to fulfill any
application requirement. Standard gears and assemblies are
available for operation on parallel and right-angle shafts, with
gear racks for linear motion applications.
Gears one stop solutions right from concept designing to final
production & performance testing. We cater to industrial needs
for power transmissions! Top Gear has hard won reputation for
quality products & production excellence through highly skilled
& trained workforce of more than 200 people supported by more
than 70 Sub Contractors.
The technical skills of the employees enhanced through regular
training programs, continued investment in the latest equipments
for advance manufacturing capability, fulfilling customer
commitments of prompt delivery their changing demands
through our resourceful planning system & our continuous

efforts has resulted in long term relations with retained

customers for more than decade !
Top Gear offers comprehensive drive solutions to various
industrial sectors which include petrochemicals, material
handling, power plants & thermal stations, textile, plastic,
machine tools, steel plant, chemical & pharmaceuticals,
construction equipments, earth moving machines & have special
expertise in one stop solutions for sugar plants. Top Gear has
capability to offer wide range of drive solutions and range starts
from 0.17 Kw & 100 Nm to 750 Kw 4500 KNm capacity gear
boxes!
Specifications

Size

Description

Drawing Number

LS Worm Gear Actuator

VM-WG-S

top

Dimension Drawings/Standard Materials of Construction

(contact factory for optional materials)

Size

Description

Above Ground - Butterfly Valve

Drawing Number

4" - 16"

Above Ground Worm Gear for BFV

Materials of Construction List

VM-3A08
VM-3A08-M

18" - 20"

Above Ground Worm Gear for BFV

Materials of Construction List

VM-3G24
VM-3G24-M

18" - 36"

Above Ground Worm Gear for BFV

Materials of Construction List

VM-3H24
VM-3H24-M

36" - 48"

Above Ground Worm Gear for BFV

Materials of Construction List

VM-3L24
VM-3L24-M

54" - 84"

Above Ground Worm Gear for BFV

Materials of Construction List

VM-3P24
VM-3P24-M

Buried Service - Butterfly Valve

4" - 20"

Buried Service Worm Gear for BFV

Materials of Construction List

VM-4A02
VM-4A02-M

24" - 36"

Buried Service Worm Gear for BFV

Materials of Construction List

VM-4F02
VM-4F02-M

36" - 66"

Buried Service Worm Gear for BFV

Materials of Construction List

VM-4H02
VM-4H02-M

72" - 84"

Buried Service Worm Gear for BFV

Materials of Construction List

VM-4M02
VM-4M02-M

Above Ground - Plug Valve

4" - 12"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7A08
VM-7A08-M

14" - 18"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7E18
VM-7E18-M

14" - 18"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7G12
VM-7G12-M

20" - 24"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7M18
VM-7M18-M

24"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7N30
VM-7N30-M

30" - 36"

Above Ground Worm Gear for Plug Valve

Materials of Construction List

VM-7R24
VM-7R24-M

Buried Service - Plug Valve

4" - 12"

Buried Service Worm Gear for Plug Valve

Materials of Construction List

VM-8A02
VM-8A02-M

14" - 16"

Buried Service Worm Gear for Plug Valve

Materials of Construction List

VM-8E02
VM-8E02-M

18" - 24"

Buried Service Worm Gear for Plug Valve

Materials of Construction List

VM-8J02.5
VM-8J02.5-M

30" - 36"

Buried Service Worm Gear for Plug Valve

Materials of Construction List

VM-8R02
VM-8R02-M

Spur Gear - Plug Valve

20" - 24"

VM-SG3
VM-SG3-M

Spur Gear for Plug Valve

Materials of Construction List

top
Instruction Manuals

Size

Description

Drawing Number

3" - 24"

Butterfly Valve

BFV-OM1

30" 108"

Butterfly Valve

BFV-OM2

3" - 48"

Plug Valve

CCPV-OM2

top

Technical Data
Description

Drawing Number

Worm Gear Actuator Mounting Positions

VM-2000-WGA

Manual Actuators

White Paper

top

By William P. Crosher

The concept of the "worm gear" dates back to

ancient times. Over the centuries, the design and
use of this gear has evolved and improved. It
describes a gear that contains a spiral or "worm"
like groove in it. Its early applications mainly
involved the drawing of water, but today it has
many varied applications-from power transmission
to manufacturing.
This comprehensive professional reference on the
subject covers not only the design and
manufacture of worm gears, but also issues
regarding performance, maintenance, failure
analysis, as well as applications.

The author has extensive experience in the field

and has written this book for gear designers and
manufacturers, gear users, as well as for
mechanical engineering students.
Publisher: ASME
Publish Date: 2002
Pages: 300
Language: English
ISBN: 0791801780
Atlas Gear Company has been servicing the Special
Machine Builders Industry since 1946. Located in the
Detroit suburb of Madison Heights, Michigan, our
15,000 square foot facility has provided the solution to
many machine builders' problems over the years. We
are proud of the many specialties that we can offer to
the industry. Whether it be small parts production or
one of our many other services, our well trained and
experienced technicians provide you with the maximum
quality, service and in-house production control. Our
versatility, flexibility and our vast range of machining
capabilities have made us an industry leader. We
continue to expand and are pleased to offer many

additional Sales Offices for your convenience.

We welcome you to browse through our site and familiarize
yourself with our many services. We look forward to
adding your companies name to our distinguished list of
satisfied customers.

Please don't hesitate to call one of our Sales

Representatives or fax us with your unique problem and I'm
sure you will be pleased with our solution.
Introduction

A worm gear is used when a large speed reduction

ratio is required between crossed axis shafts which
do not intersect. A basic helical gear can be used
but the power which can be transmitted is low. A
worm drive consists of a large diameter worm
wheel with a worm screw meshing with teeth on
the periphery of the worm wheel. The worm is
similar to a screw and the worm wheel is similar to
a section of a nut. As the worm is rotated the
wormwheel is caused to rotate due to the screw
like action of the worm. The size of the worm
gearset is generally based on the centre distance
between the worm and the wormwheel.

If the worm gears are machined basically as

crossed helical gears the result is a highly stress
point contact gear. However normally the
wormwheel is cut with a concave as opposed to a
straight width. This is called a single envelope
worm gearset. If the worm is machined with a
concave profile to effectively wrap around the
wormwheel the gearset is called a double
enveloping worm gearset and has the highest
power capacity for the size. Single enveloping
gearsets require accurate alignment of the wormwheel to ensure full line tooth contact. Double
enveloping gearsets require accurate alignment of
both the worm and the wormwheel to obtain
maximum face contact.

Diagram showing the different worm gear options available.

The double enveloping (double throat/double globoid )

option is the most difficult to manufacture and set up.
However this option has the highest load capacity, near
zero backlash capability, highest accuracy and extended
life capability.

A more detailed view showing a cylinderical worm and an

enveloping gear. The worm is shown with the worm
above the wormwheel. The gearset can also be arranged
with the worm below the wormwheel. Other alignments
are used less frequently.

Nomenclature
As can be seen in the above view a section through the
axis of the worm and the centre of the gear shows that ,
at this plane, the meshing teeth and thread section is
similar to a spur gear and has the same features
n = Normal pressure angle = 20o as standard
= Worm lead angle = (180 / ) tan-1 (z 1 / q)(deg)
..Note: for n= 20o should be less than 25o

b a = Effective face width of worm wheel. About 2.m (q

+1) (mm)
b l = Length of worm wheel. About 14.m. (mm)
c = clearance c min = 0,2.m cos , c max = 0,25.m cos
(mm)
d 1 = Ref dia of worm (Pitch dia of worm (m)) = q.m (mm)
d a.1 = Tip diameter of worm = d 1 + 2.h a.1 (mm)
d 2 = Ref dia of worm wheel (Pitch dia of wormwheel) =( p
x.z/ ) = 2.a - d 1 (mm)
d a.2 = Tip dia worm wheel (mm)
h a.1 = Worm Thread addendum = m (mm)
h f.1 = Worm Thread dedendum , min = m.(2,2 cos - 1 ) ,
max = m.(2,25 cos - 1 )(mm)
m = Axial module = p x / (mm)
m n = Normal module = m cos (mm)
M 1 = Worm torque (Nm)
M 2 = Worm wheel torque (Nm)
n 1 = Rotational speed of worm (revs /min)
n 2 = Rotational speed of wormwheel (revs /min)
p x = Axial pitch of of worm threads and circular pitch of
wheel teeth ..the pitch between adjacent threads = . m.
(mm)
p n = Normal pitch of of worm threads and gear teeth (m)
q = Worm diameter factor = d 1 / m - (Allows module to
be applied to worm ) selected from (6 6,5 7 7,5 8
8,5 9 10 11 12 13 14 17 20 )
p z = Lead of worm = p x. z 1 (mm).. Distance the thread
advances in one rev'n of the worm. For a 2-start worm
the lead = 2 . p x
R g = Reduction Ratio

 = coefficient of friction
= Efficiency
Vs = Worm-gear sliding velocity ( m/s)
z 1 = Number of threads (starts) on worm
z 2 = Number of teeth on wormwheel

Worm gear design parameters

Worm gears provide a normal single reduction range of
5:1 to 75-1. The pitch line velocity is ideally up to 30
m/s. The efficiency of a worm gear ranges from 98% for
the lowest ratios to 20% for the highest ratios. As the
frictional heat generation is generally high the worm box
must be designed disperse heat to the surroundings and

lubrication is an essential requirement. Worm gears are

quiet in operation. Worm gears at the higher ratios are
inherently self locking - the worm can drive the gear but
the gear cannot drive the worm. A worm gear can
provide a 50:1 speed reduction but not a 1:50 speed
increase....(In practice a worm should not be used a
braking device for safety linked systems e.g hoists. .
Some material and operating conditions can result in a
wormgear backsliding )
The worm gear action is a sliding action which results in
significant frictional losses. The ideal combination of
gear materials is for a case hardened alloy steel worm
(ground finished) with a phosphor bronze gear. Other
combinations are used for gears with comparatively light
loads.

Specifications
BS721 Pt2 1983 Specification for worm gearing Metric
units.
This standard is current (2004) and provides information
on tooth form, dimensions of gearing, tolerances for four
classes of gears according to function and accuracy,
calculation of load capacity and information to be given
on drawings.

Worm Gear Designation

Very simply a pair of worm gears can be defined by
designation of the number of threads in the worm ,the
number of teeth on the wormwheel, the diameter factor
and the axial module i.e z1,z2, q, m .
This information together with the centre distance ( a ) is
enough to enable calculation of and any dimension of a
worm gear using the formulea available.

Worm teeth Profile

The sketch below shows the normal (not axial) worm
tooth profile as indicated in BS 721-2 for unit axial
module (m = 1mm) other module teeth are in proportion
e.g. 2mm module teeth are 2 times larger
Typical axial modules values (m) used for worm gears are
0,5 0,6
4,0
5,0

0,8 1,0
1,25 1,6 2,0 2,5 3,15
6,3 8,0 10,0
12,5 16,0 20,0 25,0
32,0 40,0 50,0

Materials used for gears

Material

Notes

applications

Acetal /
Nylon

Low Cost, low duty

Toys, domestic
appliances, instruments

Cast Iron

Excellent machinability,
medium friction.

Used infrequently in
modern machinery

Carbon
Steel

Low cost, reasonable

strength

Power gears with

medium rating.

Hardened
Steel

High strength, good

durability

Power gears with high

rating for extended life

Low Cost, low duty

Toys, domestic
appliances, instruments

Worm

Wormwheel
Acetal
/Nylon

Phos Bronze Reasonable strength, low

Normal material for

Cast Iron

friction and good

compatibility with steel

worm gears with

reasonable efficiency

Excellent machinability,
medium friction.

Used infrequently in
modern machinery

Backlash / quality Grades

A worm gear set normally includes some backlash during
normal manufacture to allow for expansion of the gear
wheel when operating at elevated temperaturs.
The
backlash is controlled by adusting the gear wheel tooth
thickness.
BS 721 includes a table of backlash limits related to the
accuracy grade. The standard lists 5 accuracy grades.
AGMA and DIN provide a similar grading system
Grade 1 relates to critical applications
where minimum backlash is required i.e
instruments /metering
Grade 2 relates to precision drives such
as machine tools
Grade 3,4,5 relates to industrial drives
with working temperatures of about 120o
C

Design of a Worm Gear

The following notes relate to the principles in BS 721-2
Method associated with AGMA are shown below..
Initial sizing of worm gear.. (Mechanical)
1) Initial information generally Torque required (Nm),
Input speed(rpm), Output speed (rpm).
2) Select Materials for worm and wormwheel.
3) Calculate Ratio (R g)
4) Estimate a = Center distance (mm)
5) Set z 1 = Nearest number to (7 + 2,4 SQRT (a) ) /R g
6) Set z 2 = Next number < R g . z 1
7) Using the value of estimated centre distance (a) and
No of gear teeth ( z 2 ) obtain a value for q from the table
below. (q -value selection)
8) d 1 = q.m (select) ..
9) d 2 = 2.a - d 1
10) Select a wormwheel face width b a (minimum
=2*m*SQRT(q+1))
11) Calculate the permissible output torques for strength
(M b_1 and wear M c_1 )
12) Apply the relevent duty factors to the allowable
torque and the actual torque
13) Compare the actual values to the permissible values
and repeat process if necessary
14) Determine the friction coefficient and calculate the

efficiency.
15) Calculate the Power out and the power in and the
input torque
16) Complete design of gearbox including design of
shafts, lubrication, and casing ensuring sufficient heat
transfer area to remove waste heat.

Initial sizing of worm gear.. (Thermal)

Worm gears are often limited not by the strength of the
teeth but by the heat generated by the low efficiency. It is
necessary therefore to determine the heat generated by
the gears = (Input power - Output power). The worm
gearbox must have lubricant to remove the heat from the
teeth in contact and sufficient area on the external
surfaces to distibute the generated heat to the local
environment. This requires completing an approximate
heat transfer calculation. If the heat lost to the
environment is insufficient then the gears should be
adjusted (more starts, larger gears) or the box geometry
should be adjusted, or the worm shaft could include a fan
to induced forced air flow heat loss.

Formulae

The reduction ratio of a worm gear ( R

=z

/z

eg a 30 tooth wheel meshing with a 2 start worm has a reduction of 15

Tangential force on worm ( F

Axial force on worm ( F

Output torque ( M
diameter /2

wa

wt

)= axial force on wormwheel

wt

=F

ga

= 2.M

) = Tangential force on gear

) = Tangential force on wormwheel * Wormwheel reference

= F gt* d

/2

Relationship between the Worm Tangential Force F

gt

/d

wt

and the Gear Tangential force F

Relationship between the output torque M 2and the input torque M

= ( M 1. d

/d

).[ (cos

- tan ) / (cos

. tan ( + ) ) ]

Separating Force on worm-gearwheel ( F s )

Sliding velocity ( V s )...(m/s)

V s (m/s ) = 0,00005236. d 1. n 1 sec

= 0,00005235.m.n (z 12 + q 2 ) 1/2
Peripheral velocity of wormwheel ( V p) (m/s)

= 0,00005236,d 2. n

Friction Coefficient
Note: The values of the coeffient of friction as provided in
the table below are based on the use of phosphor bronze
wormwheels and case hardended , ground and polished
steel worms , lubricated by a mineral oil having a
viscosity of between 60cSt, and 130cSt at 60 deg.C .

Cast Iron and Phosphor Bronze .. Table x 1,15

Cast Iron and Cast Iron.. Table x 1,33
Quenched Steel and Aluminum Alloy..Table x 1,33
Steel and Steel..Table x 2
Friction coefficients - For Case Hardened Steel Worm / Phos Bros Wheel
Sliding Friction
Sliding Friction
Speed Coefficient Speed Coefficient
m/s

m/s

0,145

1,5

0,038

0,001

0,12

0,033

0,01

0,11

0,023

0,05

0,09

0,02

0,1

0,08

10

0,018

0,2

0,07

15

0,017

0,5

0,055

20

0,016

0,044

30

0,016

Efficiency of Worm Gear

The efficiency of the worm gear is determined by dividing the output Torque M2
with friction = by the output torque with zero losses i.e = 0
First cancelling [( M 1. d 2 / d 1 ) / M 1. d 2 / d 1 ) ] = 1
Denominator = [(cos n / (cos n . tan ] = cot

= [(cos

- tan ) / (cos

. tan + ) ] / cot

= [(cos

- .tan ) / (cos

+ .cot )]

Graph showing worm gear efficiency related to gear lead angle ( )

Self Locking
Referring to the above graph , When the gear wheel is
driving the curve points intersecting the zero efficiency
line identify when the worm drive is self locking i.e the
gear wheel cannot drive to worm. It is the moment
when gearing cannot be moved using even the highest

torque acting on the worm gear. The

self-locking limit occurs when the worm lead
angle ( ) equals atan (). (2o to 8o )
possible

It is often considered that the static coefficient of friction

is most relevant as the gear cannot be started.
However in practice it is safer to use the, lower, dynamic
coefficient of friction as this comes into play if the gear
set is subject to vibration.

Worm Design /Gear Wear / Strength Equations to

BS721
Note: For designing worm gears to AGMA codes AGMA
method of Designing Worm Gears
The information below relates to BS721 Pt2 1983
Specification for worm gearing Metric units. BS721

provides average design values reflecting the experience

of specialist gear manufacturers. The methods have
been refined by addition of various application and duty
factors as used. Generally wear is the critical factor..
Permissible Load for Strength
The permissible torque (M in Nm) on the gear teeth is
obtained by use of the equation
M

= 0,0018 X

b.2

. m. l

bm.2

. d 2.

f.2

( example 87,1 Nm = 0,0018 x 0,48 x 63 x 20 x 80 )

X b.2 = speed factor for bending (Worm wheel ).. See
Below
bm.2 = Bending stress factor for Worm wheel.. See Table
below
l f.2 = length of root of Worm Wheel tooth
d 2 = Reference diameter of worm wheel
m = axial module
= Lead angle
Permissible Torque for Wear
The permissible torque (M in Nm) on the gear teeth is
obtained by use of the equation
M c = 0,00191 X

c.2

.Z. d

cm.2

.m

1,8
2

( example 33,42 Nm = 0,00191 x 0,3234 x 6,7 x 1,5157 x

801,8 x 2 )

c.2

= Speed factor for wear ( Worm wheel )

cm.2 = Surface stress factor for Worm wheel

Z = Zone factor.
Length of root of worm wheel tooth
Radius of the root = R r= d 1 /2 + h
R r= d 1 /2 + m(1 +0,25 cos)

ha,1

(= m) + c(= 0,25.m.cos )

l f.2 = 2.R r.sin-1 (2.R r / b a)

Note: angle from sin-1(function) is in radians...
Speed Factor for Bending
This is a metric conversion from an imperial formula..
X b.2 = speed factor for bending = 0,521(V) -0,2
V= Pitch circle velocity =0,00005236*d 2.n

(m/s)

The table below is derived from a graph in BS 721. I cannot see how this works as a
small worm has a smaller diameter compared to a large worm and a lower speed
which is not reflected in using the RPM.
Table of speed factors for bending
RPM (n2)

RPM (n2)

0,62

600

0,3

10

0,56

1000

0,27

20

0,52

2000

0,23

60

0,44

4000

0,18

100

0,42

6000

0,16

200

0,37

8000

0,14

400

0,33

10000

0,13

Additional factors

b.2

b.2

The formula for the acceptable torque for wear should be modified to allow
additional factors which affect the Allowable torque M c
M

c2

= M c. Z L. Z M.Z

/K

The torque on the wormwheel as calculated using the duty requirements (M e) must
be less than the acceptable torque M c2 for a duty of 27000 hours with uniform
loading. For loading other than this then M e should be modified as follows
M

e2

= M e. K S* K

Thus
uniform load < 27000 hours (10 years) M
Other conditions M e2 M c2

c2

Factors used in equations

Lubrication (Z L)..
Z L = 1 if correct oil with anti-scoring additive else a lower value should be selected
Lubricant (Z M)..
Z L = 1 for Oil bath lubrication at V s < 10 m /s
Z L = 0,815 Oil bath lubrication at 10 m/s < V s < 14 m /s
Z L = 1 Forced circulation lubrication
Surface roughness (Z R ) ..
Z R = 1 if Worm Surface Texture < 3 m and Wormwheel < 12 m
else use less than 1
Tooth contact factor (K C
This relates to the quality and rigidity of gears . Use 1 for first estimate
K C = 1 For grade A gears with > 40% height and > 50% width contact
= 1,3 - 1,4 For grade A gears with > 30% height and > 35% width contact
= 1,5-1,7 For grade A gears with > 20% height and > 20% width contact
Starting factor (K S) ..
K S =1 for < 2 Starts per hour
=1,07 for 2- 5 Starts per hour
=1,13 for 5-10 Starts per hour
=1,18 more than 10 Starts per hour

Time / Duty factor (K H) ..

K H for 27000 hours life (10 years) with uniform driver and driven loads
For other conditions see table below
Tables for use with BS 721 equations
Speed Factors
X c.2 = K V .K R
Note: This table is not based on the graph in BS 721-2 (figure 7) it is based on
another more easy to follow graph. At low values of sliding velocity and RPM it
agrees closely with BS 721. At higher speed velocities it gives a lower value (e.g at
20m/s -600 RPM the value from this table for X c.2 is about 80% of the value in BS
721-2
Table of Worm Gear Speed Factors

Note -sliding speed = Vs and Rotating speed = n2 (Wormwheel)

Sliding speed K

m/s

Rotating Speed K

rpm

0,5

0,1

0,75 1

0,96

0,2

0,68 2

0,92

0,5

0,6

0,8

0,55 20

0,73

0,5

0,63

0,42 100

0,55

10

0,34 200

0,46

20

0,24 500

0,35

30

0,16 600

0,33

10

50

0,98

Stress Factors
Table of Worm Gear Stress Factors
Other
metal
(Worm)

Metal
(Wormwheel)

P.B.

0,55 C.Steel
0,4%
C.I.
%
C.Ste
C.Ste Case.
el
el
H'd

Bending
(bm )

Wear (

MPa

cm

MPa

Phosphor
Bronze
69
Centrifugal cast

8,3 8,3

9,0

15,2

Phosphor
Bronze
63
Sand Cast Chill
ed

6,2 6,2

6,9

12,4

Phosphor
Bronze
Sand Cast

49

4,6 4,6

5,3

10,3

Grey Cast Iron

40

6,2

4,1 4,1

4,1

5,2

0,4% Carbon
steel

138

10,7 6,9

0,55% Carbon
steel

173

15,2 8,3

Carbon Steel
(Case
hardened)

276

48,3 30,3

15,2

Zone Factor (Z)

If b a < 2,3 (q +1)1/2 Then Z = (Basic Zone factor ) . b a /2 (q +1)1/2
If b a > 2,3 (q +1)1/2 Then Z = (Basic Zone factor ) .1,15

Table of Basic Zone Factors

q
z
6
1

6,5 7

7,5 8

8,5 9

9,5 10 11 12

13 14 17 20

1,0 1,0 1,0 1,0 1,0 1,1 1,1 1,1 1,1 1,1 1,20 1,2 1,3 1,4 1,5
45 48 52 65 84 07 28 37 43 6
2
6
18 02 08

0,9 1,0 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2
1,3 1,3 1,4 1,5
1,28
91 28 55 99 44 83 14 23 31 5
2
6
47 75

0,8 0,8 0,9 1,1 1,2 1,2 1,3 1,3 1,3 1,3 1,39 1,4 1,4 1,5 1,6
22 9
89 09 09 6
05 33 5
65 3
22 42 32 74

0,8 0,8 0,9 1,0 1,2 1,7 1,3 1,4 1,4 1,4 1,51 1,5 1,5 1,6 1,7
26 3
81 98 04 01 8
28 6
9
5
45 7
66 98

0,9 0,9 1,0 1,1 1,2 1,3 1,4 1,4 1,5 1,6 1,63 1,6 1,6 1,7 1,8
47 91 5
22 16 15 17 9
5
1
2* 52 75 65 86

1,1 1,1 1,1 1,2 1,2 1,3 1,4 1,5 1,5 1,6 1,69 1,7 1,7 1,8 1,9
31 45 72 2
87 5
38 21 88 25 4
14 33 18 28

1,3 1,3 1,3 1,4 1,4 1,5 1,6 1,7 1,72 1,7 1,7 1,8 1,9
16 4
7
05 52 4
14 04 5
4
6
46 8

1,4 1,4
1,5 1,6 1,7 1,73 1,7 1,7 1,8 1,9
1,5
37 62
57 23 15 8
53 78 68 6

15 1,6 1,6 1,7 1,74 1,7 1,7 1,8 1,9

73 04 48 2
3
67 9
8
7

1
0

1,6 1,7 1,74 1,7 1,7 1,8 1,9

8
28 8
73 98 88 8

1
1

1,7 1,75 1,7 1,8 1,8 1,9

32 3
77 02 92 87

1
2

1,76

1
3

1,7 1,8 1,8 1,9

8
06 95 92
1,7 1,8 1,8 1,9
84 06 98 98

1
4

1,8
1,9 2
11

Duty Factor
Duty - time Factor K

K
Impact from Prime
mover

Uniform Load
Motor Turbine
Hydraulic motor

Expected
Impact From Load
life
hours
Uniform Medium
Load
Impact

Strong
impact

1500

0,8

0,9

5000

0,9

1,25

27000

1,25

1,5

60000

1,25

1,5

1,75

0,9

1,25

1,25

1,5

1,25

1,5

1,75

Light impact
1500
multi-cylinder engine
5000
27000

Medium Impact
Single cylinder engine

60000

1,5

1,75

1500

1,25

1,5

5000

1,25

1,5

1,75

27000

1,5

1,75

60000

1,75

2,25

Worm q value selection

The table below allows selection of q value which provides a
reasonably efficient worm design. The recommended centre
distance value "a" (mm)is listed for each q value against a range
of z 2 (teeth number values). The table has been produced by
reference to the relevant plot in BS 721
Example
If the number of teeth on the gear is selected as 45 and the
centre distance is 300 mm then a q value for the worm would be
about 7.5
Important note: This table provides reasonable values for all worm
speeds. However at worm speeds below 300 rpm a separate plot
is provided in BS721 which produces more accurate q values. At
these lower speeds the resulting q values are approximately 1.5
higher than the values from this table. The above example at less
than 300rpm should be increased to about 9
Table of Center distances "a" relating to q values and Number of teeth on
Worm gear z 2
Number of Teeth On Worm Gear (z 2)

20 25 30 35 40 45 50 55 60 65 70 75 80

15 25 38 52 70
0
0
0
0
0

6. 10 15 25 35 48 66
5 0
0
0
0
0
0
7

70

11 17 25 35 47 62 70
0
0
0
0
0
0
0

7.
12 18 24 33 42 55 67
50 80
5
0
0
0
0
0
0
0
8
8.
5

25 50 80

28 90

12 18 23 30 38 47 57 70
0
0
0
0
0
0
0
0
13 13 18 22 28 35 42 50 60
700
0
0
0
0
0
0
0
0
0
10 13 17 22 28 33 40 45
520
0
0
0
0
0
0
0
0

40 70

9.
5

25 50 70

10 12 15 20 23 30 35
400
0
0
0
0
0
0
0
10 13 16 20 23 27
320
0
0
0
0
0
0

10

26 55 80

11

25 28 55 75

12

10 13 15 18 22
250
0
0
0
0
0

28 45 52 80

13

AGMA method of Designing Worm Gears

10 13 15
100
0
0
0

27 45 52 75 90 105

The AGMA method is provided here because it is relatively easy to use and
convenient- AGMA is all imperial and so I have used conversion values so all
calculations can be completed in metric units..

Good proportions indicate that for a centre to centre distance = C the mean worm
dia d 1 is within the range
Imperial (inches)
(C

0,875

/3)

d1

( C 0,875 / 1,6 )

(C

0,875

/2)

d 1 ( C 0,875 / 1,07 )

Metric ( mm)

The acceptable tangential load (W t)

(W t)

all

= C s. d

all

0,8
2

.b a .C

.C v . (0,0132) (N)

The formula will result in a life of over 25000 hours with a case hardened alloy steel
worm and a phosphor bronze wheel
C s = Materials factor
b a = Effective face width of gearwheel = actual face width. but not to exceed 0,67 .
d1
C m = Ratio factor
C v = Velocity factor

Modified Lewis equation for stress induced in worm gear teeth .

a = W t / ( p n. b a. y )(N)
W t = Worm gear tangential Force (N)
y = 0,125 for a normal pressure angle n = 20o

The friction force = W

W f = f.W t / (. cos

) (N)

= worm lead angle at mean diameter

n = normal pressure angle

The sliding velocity = V

V s = .n 1. d

/ (60,000 )

d 1 = mean dia of worm (mm)

n 1 = rotational speed of worm (revs/min)

The torque generated at the worm gear = M

T

= W t .d

(Nm)

/ 2000

The required friction heat loss from the worm gearbox

H

loss

=P

in

(1-)

= gear efficiency as above.

values

C s = 270 + 0,0063(C )3... for C 76mm ....Else

C s (Sand cast gears ) = 1000 for d

C s (Chilled cast gears ) = 1000 for d

64 mm ...else... 1860 - 477 log (d

1

200 mm ...else ... 2052 -456 log (d

C s (Centrifugally cast gears ) = 1000 for d

1 )

635 mm ...else ... 1503 - 180 log (d

values

NG = Number of teeth on worm gear.

NW = Number of starts on worm gear.
mG = gear ration = NG /NW

values

C v (V s > 3,56 m/s ) = 0,659 exp (-0,2167 V s )

C v (3,56 m/s V s < 15,24 m/s ) = 0,652 (V s)
C v (V s > 15,24 m/s ) = 1,098.( V s )

f values

-0,774

-0,571

f (V s = 0) = 0,15
f (0 < V s 0,06 m/s ) = 0,124 exp (-2,234 ( V s ) 0,645
f (V s > 0,06 m/s ) = 0,103 exp (-1,1855

WORKING
PRINCIPLE
In this machine the work is threaded by holding
the work piece in three jaw self-centering chuck.
The tool is held in the adapter. The adapter is
fitted on the hallow shaft. By giving force and
turning the handle the spindle moves towards the
work piece. By moving this external thread is
formed on the work piece. After the formation of
thread, the handle is rotated in the reverse
direction; the die is removed from the work piece.

ADVANTAGES
1. Accurate threading can be done
2. Setting and operating time is less
3. Number of skilled labour is less
4. Centering of work is easy
5. Both internal and external treading can be done
6. It is used for mass production.

DISADVANTAGES
1. Only single start thread can be done.

2. Threading can be done by

Screw Thread Cutting

SCREW THREAD CUTTING

Screw threads are cut with the lathe for
accuracy and for versatility. Both inch and metric
screw threads can be cut using the lathe. A thread
is a uniform helical groove cut inside of a
cylindrical workpiece, or on the outside of a tube
or shaft. Cutting threads by using the lathe
requires a thorough knowledge of the different
principles of threads and procedures of cutting.
Hand coordination, lathe mechanisms, and
cutting tool angles are all interrelated during the
thread cutting process. Before attempting to cut
threads on the lathe a machine operator must
have a thorough knowledge of the principles,
terminology and uses of threads.
Figure 3-74. Screw thread types.

Figure 3-73. Screw thread terminology.

Angle of the thread is the angle formed by

the intersection of the two sides of the
threaded groove.

Depth is the distance between the crest and

root of a thread, measured perpendicular to the
axis.

Major diameter is the largest diameter of a

screw thread.

Minor diameter is the smallest diameter of a

screw thread.

Pitch diameter is the diameter of an

imaginary cylinder formed where the width of
the groove is equal to one-half of the pitch.
This is the critical dimension of threading as
the fit of the thread is determined by the pitch
diameter (Not used for metric threads).

Threads per inch is the number of threads per

inch may be counted by placing a rule against
the threaded parts and counting the number of
pitches in 1 inch. A second method is to use

Screw Thread Terminology

The common terms and definitions below are
used in screw thread work and will be used in
discussing threads and thread cutting.

External or male thread is a thread on

the outside of a cylinder or cone.

Internal or female thread is a thread on

the inside of a hollow cylinder or bore.

Pitch is the distance from a given point

on one thread to a similar point on a
thread next to it, measured parallel to the
axis of the cylinder. The pitch in inches is
equal to one divided by the number of
threads per inch.

the screw pitch gage. This method is

especially suitable for checking the finer
pitches of screw threads.

Lead is the distance a screw thread

advances axially in one complete
revolution. On a single-thread screw, the
lead is equal to the pitch. On a doublethread screw, the lead is equal to twice the
pitch, and on a triple-thread screw, the
lead is equal to three times the pitch
(Figure 3-74).

A single thread is a thread made by cutting

one single groove around a rod or inside a
hole. Most hardware made, such as nuts and
bolts, has single threads. Double threads have
two grooves cut around the cylinder. There can
be two, three, or four threads cut around the
outside or inside of a cylinder. These types of
special threads are sometimes called multiple
threads.

Crest (also called "flat") is the top or

outer surface of the thread joining the two
sides.

A right-hand thread is a thread in which the

bolt or nut must be turned to the right
(clockwise) to tighten.

A left hand thread is a thread in which the

bolt or nut must turn to the left
(counterclockwise) to tighten.

Thread fit is the way a bolt and nut fit

together as to being too loose or too tight.

Metric threads are threads that are measured

in metric measurement instead of inch
measurement.

Root is the bottom or inner surface

joining the sides of two adjacent threads.
Side is the surface which connects the
crest and the root (also called the flank).

Screw Thread Forms

The most commonly used screw thread forms are
detailed in the following paragraphs. One of the
major problems in industry is the lack of a standard
form for fastening devices. The screw thread forms
that follow attempt to solve this problem; however,
there is still more than one standard form being used
in each industrial nation. The International
Organization for Standardization (IS0) met in 1975
and drew up a standard metric measurement for
screw threads, the new IS0 Metric thread Standard
(previously known as the Optimum Metric Fastener

The American (National) screw thread form is

divided into four series, the National Coarse
(NC), National Fine (NF), National Special (NS),
and National Pipe threads (NPT), 11 series of this
thread form have the same shape and proportions.
This thread has a 60 included angle. The root
and crest are 0.125 times the pitch. This thread
form is widely used in industrial applications for
fabrication and easy assembly and construction of
machine parts. Table 7-9 in Appendix A gives the

System). Other thread forms are still in general use

today, including the American (National) screw
thread form, the square thread, the Acme thread, the
Brown and Sharpe 29 worm screw thread, the
British Standard Whitworth thread, the Unified
thread, and different pipe threads. All of these
threads can be cut by using the lathe.

The IS0 Metric thread standard is a simple

thread system that has threaded sizes ranging
in diameter from 1.6 mm to 100 mm (see
Table 7-8 in Appendix A). These metric
threads are identified by the capital M, the
nominal diameter, and the pitch. For
example, a metric thread with an outside
diameter of 5 mm and a pitch of 0.8 mm
would be given as M 5 x 0.8. The IS0 metric
thread standard simplifies thread design,
provides for good strong threads, and
requires a smaller inventory of screw
fasteners than used by other thread forms.
This IS0 Metric thread has a 60 included
angle and a crest that is 1.25 times the pitch
(which is similar to the National thread
form). The depth of thread is 0.6134 times
the pitch, and the flat on the root of the
thread is wider than the crest. The root of the
ISO Metric thread is 0.250 times the pitch
(Table 7-9).

The Brown and Sharpe 29 worm screw thread

uses a 29 angle, similar to the Acme thread. The
depth is greater and the widths of the crest and
root are different (Table 7-9 in Appendix A). This
is a special thread used to mesh with worm gears
and to transmit motion between two shafts at right
angles to each other that are on separate planes.
This thread has a self-locking feature making it
useful for winches and steering mechanisms.

The square screw thread is a power

different values for this thread form.

The British Standard Whitworth thread form

thread has a 55 thread form in the V-shape. It has
rounded crests and roots.

The Unified thread form is now used instead of

the American (National) thread form. It was
designed for interchangeability between
manufacturing units in the United States, Canada,
and Great Britain. This thread is a combination of
the American (National) screw thread form and
the British Whitworth screw thread forms. The
thread has a 60 angle with a rounded root, while
the crest can be rounded or flat. (In the United
States, a flat crest is preferred.) The internal
thread of the unified form is like the American
(National) thread form but is not cut as deep,
leaving a crest of one-fourth the pitch instead of
one-eighth the pitch. The coarse thread series of
the unified system is designated UNC, while the
fine thread series is designated UNF. (See Table
7-9 in Appendix A for thread form and values.

The American National 29 Acme was designed

to replace the standard square thread, which is
difficult to machine using normal taps and
machine dies. This thread is a power transmitting
type of thread for use in jacks, vises, and feed
screws. Table 7-9 lists the values for Acme
threads.

The four fits are described as follows:

Class 1 fit is recommended only for screw

thread work where clearance between mating
parts is essential for rapid assembly and
where shake or play is not objectionable.

Class 2 fit represents a high quality of thread

product and is recommended for the great
bulk of interchangeable screw thread work.

transmitting thread that is being replaced

by the Acme thread. Some vises and lead
screws may still be equipped with square
threads. Contact areas between the threads
are small, causing screws to resist
wedging, and friction between the parts is
minimal (Table 7-9 in Appendix A).

Class 3 fit represents an exceptionally high

quality of commercially threaded product and
is recommended only in cases where the high
cost of precision tools and continual checking
are warranted.

Class 4 fit is intended to meet very unusual

requirements more exacting than those for
which Class 3 is intended. It is a selectivefit
if initial assembly by hand is required. It is
not. as yet. adaptable to quantity production.

The spark plug thread (international metric

thread type) is a special thread used
extensively in Europe, but seen only on
some spark plugs in the United States. It
has an included angle of 60 with a crest
and root that are 0.125 times the depth.
Different types of pipe thread forms are in
use that have generally the same
characteristics but different fits. Consult
the Machinery's Handbook or a similar
reference for this type of thread.

THREAD FIT AND CLASSIFICATIONS

The Unified and American (National) thread
forms designate classifications for fit to ensure
that mated threaded parts fit to the tolerances
specified. The unified screw thread form specifies
several classes of threads which are Classes 1A,
2A, and 3A for screws or external threaded parts,
and 1B, 2B, and 3B for nuts or internal threaded
parts. Classes 1 A and 1 B are for a loose fit where
quick assembly and rapid production are important
and shake or play is not objectionable. Classes 2A
and 2B provide a small amount of play to prevent
galling and seizure in assembly and use. and
sufficient clearance for some plating. Classes 2A
and 2B are recommended for standard practice in
making commercial screws. bolts. and nuts.
Classes 3A and 3B have no allowance and 75
percent of the tolerance of Classes 2A and 2B A
screw and nut in this class may vary from a fit
having no play to one with a small amount of play.
Only high grade products are held to Class 3
specifications.

Thread Designations
In general. screw thread designations give the
screw number (or diameter) first. then the thread per
inch. Next is the thread series containing the initial
letter of the series. NC (National Coarse). UNF
(Unified Fine). NS (National Special). and so forth.
followed by the class of fit. If a thread is left-hand.
the letters LH follow the fit. An example of
designations is as follows:

Two samples and explanations of thread designations

are as follows:

No 12 (0.216) -24 NC-3. This is a number 12

(0.216-inch diameter) thread. 24 National
Coarse threads per inch. and Class 3 ways of
designating the fit between parts. including
tolerance grades. tolerance positions. and
tolerance classes. A simpler fit.

Four distinct classes of screw thread fits

between mating threads (as between bolt and nut)
have been designated for the American (National)
screw thread form. Fit is defined as "the relation
between two mating parts with reference to ease of
assembly. " These four fits are produced by the
application of tolerances which are listed in the
standards.

Metric Thread Fit and Tolerance

The older metric screw thread system
has over one hundred different thread
sizes and several ways of designating the
fit between parts. including tolerance
grades. tolerance positions. and tolerance
classes. A simple system was devised
with the latest ISO Metric thread
standard that uses one internal fit and two
external fit designations to designate the
tolerance (class) of fit. The symbol 6H is
used to designate the fit for an internal
thread (only the one symbol is used). The
two symbols 6g and 5g6g are used to
designate the fit for an external thread. 6g
being used for general purpose threads
and Sg6g used to designate a close fit. A
fit between a pair of threaded parts is
indicated by the internal thread (nut)
tolerance fit designation followed by the
external thread (bolt) tolerance fit
designation with the two separated by a
stroke. An example is M 5 x 0.8Sg6g/6H. where the nominal or major
diameter is 5 mm. the pitch is 0.8 mm.
and a close tit is intended for the bolt and
nut. Additional information on ISO
metric threads and specific fits can be
found in any updated engineer's
handbook or machinist's handbook.
THREAD CUTTING TOOL BITS

1/4-28 UNF-2A LH. This is a l/4-inch

diameter thread. 28 Unified Fine threads per
inch, Class 2A fit, and left-hand thread.

tool bit must be ground for the exact shape of the thread form.
to include the root of the thread (Figure 3-75).
For metric and American (National) thread forms. a flat
should be ground at the point of the tool bit (Figure 3-76).
perpendicular to the center line of the 600 thread angle. See
the thread form table for the appropriate thread to determine
the width of the Sat. For unified thread forms. The tip of the
tool bit should be ground with a radius formed to fit the size
of the root of the thread. Internal unified threads have a flat
on the tip of the tool bit. In all threads listed above. The tool
bit should be ground with enough side relief angle and
enough front clearance angle (Figure 3-76). Figure 3-77
illustrates the correct steps involved in grinding a threadcutting tool bit.

Figure 3-75. V-shaped thread cutter.

Figure 3-76. Relief angles on a thread cutting tool bit.

Cutting V-threads with a 60 degrees

thread angle is the most common thread
cutting operation done on a lathe. Vthreads with the 60 degree angle are used
for metric thread cutting and for
American (National) threads and Unified
threads. To properly cut V-shaped
threads. the single point

Figure 3-77. Grinding a thread cutting tool bit.

For Acme and 29 worm screw threads, the cutter

bit must be ground to form a point angle of 29. Side
clearances must be sufficient to prevent rubbing on
threads of steep pitch. The end of the bit is then
ground to a flat which agrees with the width of the
root for the specific pitch being cut. Thread-cutting
tool gages (Figure 7-78) are available to simplify the
procedure and make computations unnecessary.
To cut square threads, a special thread-cutter bit is
required. Before the square thread-cutter bit can be
ground, it is necessary to compute the helix angle of
the thread to be cut (Figure 7-79). Compute the helix
angle by drawing a line equal in length to the thread
circumference at its minor diameter (this is
accomplished by multiplying the minor diameter by
3.1416 [pi]). Next, draw a line perpendicular to and at
one end of the first line, equal in length to the lead of
the thread. If the screw is to have a single thread, the
lead will be equal to the pitch. Connect the ends of the
angle so formed to obtain the helix angle.
The tool bit should be ground to the helix angle.
The clearance angles for the sides should be within
the helix angle. Note that the sides are also ground in
toward the shank to provide additional clearance.
The end of the tool should be ground flat, the flat
being equal to one-half the pitch of the thread to
produce equal flats and spaces on the threaded part.
Figure 3-78. Common gages for checking threading tool bits.

Figure 3-79. Thread tool bit for square threads.

When positioning the thread-cutter bit for use,

place it exactly on line horizontally with the axis of
the workpiece. This is especially important for threadcutter bits since a slight variation in the vertical
position of the bit will change the thread angle being
cut.

with the lead screw. A control is available to reverse

the direction of the lead screw for left or right-hand
threading as desired. Be sure the lead screw turns in
the proper direction. Feed the cutter bit from right to
left to produce a right-hand thread. Feed the cutter
bit from left to right to produce a left-hand thread.

Figure 3-80. Positioning thread cutter bit.

The thread-cutter bit must be positioned so that

the centerline of the thread angle ground on the bit
is exactly perpendicular to the axis of the
workpiece. The easiest way to make this
alignment is by use of a center gage. The center
gage will permit checking the point angle at the
same time as the alignment is being effected. The
center gage is placed against the workpiece and
the cutter bit is adjusted on the tool post so that its
point fits snugly in the 60 angle notch of the
center gage (Figure 3-80).
In cutting threads on a lathe, the pitch of the
thread or number of threads per inch obtained is
determined by the speed ratio of the headstock
spindle and the lead screw which drives the
carriage. Lathes equipped for thread cutting have
gear arrangements for varying the speed of the
lead screw. Modern lathes have a quick-change
gearbox for varying the lead screw to spindle ratio
so that the operator need only follow the
instructions on the direction plates of the lathe to
set the proper feed to produce the desired number
of threads per inch. Once set to a specific number
of threads per inch, the spindle speed can be
varied depending upon the material being cut and
the size of the workpiece without affecting the
threads per inch.

Direction of feed. For cutting standard 60 righthand threads of the sharp V-type, such as the metric
form, the American (National) form, and the Unified
form, the tool bit should be moved in at an angle of
29 to the right (Figure 3-81), (Set the angle at 29
to the left for left-hand threads). Cutting threads with
the compound rest at this angle allows for the left
side of the tool bit to do most of the cutting, thus
relieving some strain and producing a free curling
chip. The direction is controlled by setting the
compound rest at the 29 angle before adjusting the
cutter bit perpendicular to the workpiece axis. The
depth of cut is then controlled by the compound rest
feed handle.

Figure 3-81. External threading setup.

For Acme and 29 worm threads, the compound

rest is set at one-half of the included angle (14 1/2)

The carriage is connected to the lead screw of

the lathe for threading operations by engaging the
half nut on the carriage apron

and is fed in with the compound rest. For square

threads, the cutter bit is fed into the workpiece at an
angle perpendicular to the workpiece axis.

THREAD CUTTING OPERATIONS

Before cutting threads, turn down the workpiece to
the major diameter of the thread to be cut and
chamfer the end. Engineering and machinist's
handbooks have special tables listing the
recommended major and minor diameters for all
thread forms. These tables list a minimum and a
maximum major diameter for the external threads,
and a minimum and maximum minor diameter for
internal threads. Table 7-10 in Appendix A lists the
most common screw thread sizes. The difference
between the maximum and minimum major
diameters varies with different sizes of threads.
Coarse threads have a larger difference between
the two than fine threads. It is common practice,
when machining threads on the lathe, to turn the
outside diameter down to the maximum major
diameter instead of the minimum major diameter,
thus allowing for any error.
The workpiece may be set up in a chuck, in a
collet, or between centers. If a long thread is to be
cut, a steady rest or other support must be used to
help decrease the chance of bending the
workpiece. Lathe speed is set for the
recommended threading speed (Table 7-2 in
Appendix A).

After making the first pass check for proper pitch

of threads by using one of the three methods in
Figure 3-84. After each pass of the threading tool bit,
the operator must move the threading tool bit out of
the threaded groove by backing out the compound
rest handle, taking note of the setting. Traverse the
carriage back to the start of the thread and move the
compound rest dial back to the original setting plus
the new depth of cut. At the end of each cut, the half
nut lever is usually disengaged and the carriage
returned by hand. (The cross slide dial can also be
used to move the tool bit in and out, depending on
the preference of the operator.)
After cutting the first depth of thread, check for
the proper pitch of threads by using one of the three
methods in Figure 3-84. If the thread pitch is correct
as set in the quick-change gearbox, continue to cut
the thread to the required depth. This is determined
by measuring the pitch diameter and checking the
reference table for-the proper pitch diameter limits
for the desired tit.
Some lathes are equipped with a thread chasing
stop bolted to the carriage which can be set to
regulate the depth of cut for each traverse of the
cutter bit or can be set to regulate the total depth of
cut of the thread.
When the thread is cut the end must be finished in
some way. The most common means of finishing the
end is with a specially ground or 45 degree angle
chamfer cutting bit. To produce a rounded end, a
cutter bit with the desired shape should be specially
ground for that purpose.
Metric Thread Cutting Operations

Metric threads, are cut one of two ways by using

the lathe, designed and equipped for metric
measurement or by using a standard inch lathe and
converting its operation to cut metric threads. A
metric measurement lathe has a quick-change gear
box used to set the proper screw pitch in millimeters.
An inch- designed lathe must be converted to cut
metric threads by switching gears in the lathe
headstock according to the directions supplied with
each lathe.

Figure 3-82.Thread chasing dial.

To cut threads, move the threading tool bit into

contact with the work and zero the compound rest
dial. The threading tool bit must be set at the right
end of the work; then, move the tool bit in the first
depth of cut by using the graduated collar of the
compound rest. Position the carriage half nut lever
to engage the half nut to the lead screw in order to
start the threading operation. The first cut should
be a scratch cut of no more than 0.003 inch so the
pitch can be checked. Engaging the half nut with
the lead screw causes the carriage to move as the
lead screw revolves. Cut the thread by making a
series of cuts in which the threading tool follows
the original groove for each cut. Use the thread
chasing dial, Figure 3-82, to determine when to
engage the half nut so that the threading tool will
track properly. The dial is attached to the carriage
and is driven by means of the lead screw. Follow
the directions of the thread chasing dial, Figure 383, to determine when to engage the half nut lever.

THREADS PER INCH

When to Engage

TO CUT

Split Nut

Even Number

Engage at any

Most lathes come equipped with a set of

changeable gears for cutting different, or
nonstandard screw threads. Follow the directions in
the lathe operator manual for setting the proper
metric pitch. (A metric data plate may be attached to
the lathe headstock.) Most lathes have the capability
of quickly attaching these change gears over the
existing gears then realigning the gearing. One
change gear in needed for the lead screw gear and
one for the spindle, or drive gear.

diameter to the desired diameter measurement.

Convert the linear pitch in millimeters, to threads per
inch by dividing the linear pitch of 2.5 by 25.4 to get
the threads per inch ( 10.16 TPI).
Now a 8-13 TPI thread micrometer can be used to

of

Graduation on

Threads

The Dial

measure the pitch diameter for this metric thread. To

sum up how to convert metric threads to inch
measurement:

Convert major diameter from millimeters to

inch measure.

Odd Numbers Of

Engage at Any

Thread

Main Division

Convert pitch and pitch diameter to inch

measure.

Fractional Number

Threads, e.g. 11

Of

Engage at any other

Set quick change gears according to

instructions.

Threads

Main Division 1 & 3 or 2 & 4

Other Fractional Threads
Engage at Same Division
Every Time

Thread that are A

Engage at Any Time That

Multiple of the

Split Nut Meshes

Number of the
Threads per Inc
in the Lead Screw

Figure 3-83. Thread chasing dial instructions.

The metric thread diameter and pitch can be

easily measured with a metric measuring tool.
If there are no metric measuring tools
available, the pitch and diameter must be
converted from millimeters to inch
measurement, and then a inch micrometer and
measuring tools can be used to determine the
proper pitch and diameter. Millimeters may be
converted to inch measurement either by
dividing millimeters by 25.4 inches or
multiplying by 0.03937 inches.

Set up the lathe for thread cutting as in the

preceding paragraphs on screw thread cutting, Take a
light trial cut and check that the threads are of the
correct pitch using a metric screw pitch gage. At the
end of this trial cut, and any cut when metric
threading, turn off the lathe and back out the tool bit
from the workpiece without disengaging the half-nutlever. Never disengage the lever until the metric thread
is cut to the proper pitch diameter, or the tool bit will
have to be realigned and set for chasing into the thread.
After backing the tool bit out from the workpiece,
traverse the tool bit back to the starting point by
reversing the lathe spindle direction while leaving the
half-nut lever engaged. If the correct pitch is being cut,
continue to machine the thread to the desired depth.
NOTE: If the tool bit needs to be realigned and
chased into the thread due to disengagement, of the
half-nut lever or having to remove the piece and start
again, then the lathe must be reset for threading. Start
the lathe, with the tool bit clear of the workpiece
engage the lever. Allow the carriage to travel until the
tool bit is opposite any portion of the unfinished
thread; and then turn off the lathe, leaving the engaged.
Now the tool bit can be set back into a thread groove
by advancing the cross slide and reference. Restart the
lathe, and the tool bit should follow the groove that
was previously cut, as long as the half-nut lever stays
engaged.

For example, a thread with a designation

M20 x 2.5 6g/6h is read as follows: the M
designates the thread is metric. The 20
designates the major diameter in millimeters.
The 2.5 designates the linear pitch in
millimeters. The 6g/6h designates that a
general purpose fit between nut and bolt is
intended. Therefore, to machine this metric
thread on a inch designed lathe, convert the
outside diameter in millimeters to a decimal
fraction of an inch and machine the major

Figure 3-84. Checking threads per inch.

TAPERED SCREW THREADS

Tapered screw threads or pipe threads can be cut
on the lathe by setting the tailstock over or by using
a taper attachment. Refer to the references for taper
per inch and nominal measurements of tapered
thread forms. When cutting a tapered thread, the tool
bit should be set at right angles to the axis of the
work. Do not set the tool bit at a right angle to the
taper of the thread. Check the thread tool bit
carefully for clearances before cutting since the bit
will not be entering the work at right angles to the
tapered workpiece surface.
MEASURING EXTERNAL V-SHAPED
SCREW THREADS
The fit of the thread is determined by its pitch
diameter. The pitch diameter is the diameter of the
thread at an imaginary point on the thread where the

Thread micrometers are marked on the frame to

specify the pitch diameters which the micrometer is
used to measure. One will be marked, for instance,
to measure from 8 to 13 threads per inch, while
others are marked 14 to 20, 22 to 30, or 32 to 40;
metric thread micrometers are also available in
different sizes.
The procedure in checking the thread is first to
select the proper micrometer, then calculate or
select from a table of threads the correct pitch
diameter of the screw. Lastly, fit the thread into the
micrometer and take the reading.
The 3-wire method is another method of
measuring the pitch diameter for American
National (60 degree) and Unified threads. It is
considered the "best' method for extremely
accurate measurement. Page A-28 in Appendix A
shows three wires of correct diameter placed in
threads with the micrometer measuring over them.

width of the space and the width of the thread are

equal. The fact that the mating parts bear on this
point or angle of the thread, and not on the top of it,
makes the pitch diameter an important dimension to
use in measuring screw threads.
The thread micrometer (Figure 3-85) is an
instrument used to gage the thread on the pitch
diameter. The anvil is V-Shaped to fit over the Vthread. The spindle, or movable point, is coneshaped (pointed to a V) to fit between the threads.
Since the anvil and spindle both contact the sides of
the threads, the pitch diameter is gaged and the
reading is given on the sleeve and spindle where it
can be read by the operator.

The pitch diameter can be found by subtracting the

wire constant from the measured distance over the
wires. It can be readily seen that this method is
dependent on the use of the "'best'" wire for the
pitch of the thread. The "best" wire is the size of
wire which touches the thread at the middle of the
sloping sides. in other words, at the pitch diameter.
A formula by which the proper size wire may be
found is as follows: Divide the constant 0.57735 by
the number of threads per inch to cut. If. for
example, 8 threads per inch have been cut, we
would calculate 0.577358 = 0.072. The diameter of
wire to use for measuring an 8-pitch thread is
0.072.
The wires used in the three-wire method should
be hardened and lapped steel wires. they, should be
three times as accurate as the accuracy desired in
measurement of the threads. The Bureau of
Standards has specified an accuracy of 0.0002 inch.
The suggested procedure for measuring threads is
as follows:

Figure 3-85. Thread micrometer.

m = (D +3 W)-1.5155
n
Where m = micrometer measurement over wires,

After the three wires of equal diameter have

been selected by using the above formula, they are
positioned in the thread grooves as shown on page
A-28 in Appendix A. The anvil and spindle of an
ordinary micrometer are then placed against the
three wires and the reading is taken. To determine
what the reading of the micrometer should be if a
thread is the correct finish size. use the following
formula (for measuring Unified National Coarse
threads): add three times the diameter of the wire to
the diameter of the screw; from the sum, subtract
the quotient obtained by dividing the constant
1.5155 by the number of threads per inch. Written
concisely, the formula is:

M= PD+CPD=M-C
M = measurement over the wires
PD = pitch diameter

D = diameter of the thread,

C = N constant (This is found in Table 7-11

in Appendix A)

n = number of threads per inch,

The "best" wire size can be found by
converting from inch to metric, or by using
Table 7-11 in Appendix A.

W = diameter of wire used

Example: Determine m (measurement over wires) for
1/2 inch, 12-pitch UNC thread. We would proceed to solve
as follows:
where W = 0.04811 inch

An optical comparator must be used to

check the threads if the tolerance desired is
less than 0.001 inch (0.02 mm). This type of
thread measurement is normally used in
industrial shops doing production work.

D = 0.500 inch
CUTTING INTERNAL THREADS
n=12
Then m = (0.500+ 0.14433) - 155155
12
m = (0.500 + 0.14433) -0.1263
m = 0.51803 inch (micrometer measurement)
When measuring a Unified National Fine thread, the
same method and formula are used. Too much pressure
should not be applied when measuring over wires.
Metric threads can also be checked by using the threewire method by using different numerical values in the
formula. Three-wire threads of metric dimensions must
have a 60 angle for this method.

Internal threads are cut into nuts and

castings in the same general manner as
external threads. If a hand tap is not available
to cut the internal threads, they must be
machined on the lathe.
An internal threading operation will usually
follow a boring and drilling operation, thus
the machine operator must know drilling and
boring procedures before attempting to cut
internal threads. The same holder used for
boring can be used to hold the tool bit for
cutting internal threads. Lathe speed is the
same as the speed for external thread cutting.

Figure 3-86. Internal thread cutting.

To prevent rubbing, the clearance of the cutter

bit shank and boring tool bar must be greater for
threading than for straight boring because of the
necessity of moving the bit clear of the threads
when returning the bit to the right after each cut.
The compound rest should be set at a 29 angle
to the saddle so that the cutter bit will feed after
each cut toward the operator and to his left.

CUTTING EXTERNAL ACME THREADS

The first step is to grind a threading tool to
conform to the 29 included angle of the thread. The
tool is first ground to a point, with the sides of the
tool forming the 290 included angle (Figure 3-88).
This angle can be checked by placing-the tool in the
slot at the right end of the Acme thread gage.

Although the setup shown in Figure 3-86 would

be impractical on extremely large lathes, it allows
a degree of safety on common sized machines by
having the compound ball crank positioned away
from any work holding device that would be in
use on the lathe, eliminating the possibility of the
operator's hands or the compound rest contacting
the revolving spindle and work holding devices.
Figure 3-88. Acme thread cutting tool bit

If a gage is not available, the width of the tool bit

point may be calculated by the formula:

Width of point= 0.3707P -0.0052 inch

Where P = Number of threads per inch
Be sure to grind this tool with sufficient side
clearance so that it will cut. Depending upon the
number of threads per inch to be cut, the point of the
tool is ground flat to fit into the slot on the Acme
thread gage that is marked with the number of
threads per inch the tool is to cut. The size of the flat
on the tool point will vary depending upon the thread
per inch to be machined.
Figure 3-87. Left-hand threading.

Cutting 60 left-hand threads. A left-hand thread

is used for certain applications where a right-hand
thread would not be practicable, such as on the left
side of a grinder where the nut may loosen due to
the rotation of the spindle. Left-hand threads are
cut in the same manner as right hand threads, with
a few changes. Set the feed direction lever so that
the carriage feeds to the right, which will mean
that the lead screw revolves opposite the direction
used for right-hand threading. Set the compound
rest 29 to the left of perpendicular. Cut a groove
at the left end of the threaded section, thus
providing clearance for starting the cutting tool
(see Figure 3-87). Cut from left to right until the
proper pitch dimension is achieved.

After grinding the tool, set the compound rest to

one-half the included angle of the thread (14 1/2) to
the right of the vertical centerline of the machine
(Figure 3-89). Mount the tool in the holder or tool
post so that the top of the tool is on the axis or center
line of the workpiece. The tool is set square to the
work, using the Acme thread gage. This thread is cut
using the compound feed. The depth to which you
feed the compound rest to obtain total thread depth is
determined by the formula given and illustrated in
Table 7-9 in Appendix A. The remainder of the Acme
thread-cutting operation is the same as the Vthreading operation previously described. The
compound rest should be fed into the work only
0.002 inch to 0.003 inch per cut until the desired
depth of thread is obtained.

0.4872 x 1/6= 0.081 inch

Cutting the 29 worm screw thread (Brown and
Sharpe). The tool bit used to cut 29 worm screw
threads will be similar to the Acme threading tool, but
slightly longer with a different tip. Use Table 7-9 in
Appendix A to calculate the length of the tool bit and
tip width. The cutting is done just like cutting an
Acme thread.
CUTTING SQUARE THREADS
Because of their design and strength, square

Figure 3-89. Acme and 29 degree worm thread setup.

Figure 3-90. Using one wire to measure an acme

The formulas used to calculate Acme thread

depth are in Table 7-9 in Appendix A. The single
wire method can be used to measure the accuracy
of the thread (Figure 3-90). A single wire or pin
of the correct diameter is placed in the threaded
groove and measured with a micrometer. The
thread is the correct size when the micrometer
reading over the wire is the same as the major
diameter of the thread and the wire is placed
tightly into the thread groove. The diameter of the
wire to be used can be calculated by using this
formula:
Wire diameter = 0.4872 x pitch
Thus, if 6 threads per inch are being cut, the wire
size would be:

threads are used for vise screws, jackscrews, and

other devices where maximum transmission of power
is needed. All surfaces of the square thread form are
square with each other, and the sides are
perpendicular to the center axis of the threaded part.
The depth, the width of the crest, and root are of
equal dimensions. Because the contact areas are
relatively small and do not wedge together, friction
between matching threads is reduced to a minimum.
This fact explains why square threads are used for
power transmission.
Before the square thread cutting tool can be ground,
it is necessary first to determine the helix angle of the
thread. The sides of the tool for cutting the square
thread should conform with the helix angle of the
thread (Figure 3-79).
For cutting the thread, the cutting edge of the tool
should be ground to a width exactly one-half that of
the pitch. For cutting the nut, it should be from 0.001
to 0.003 of an inch larger to permit a free fit of the
nut on the screw.
The cutting of the square thread form presents
some difficulty. Although it is square, this thread, like
any other, progresses in the form of a helix, and thus
assumes a slight twist. Some operators prefer to
produce this thread in two cuts, the first with a
narrow tool to the full depth and the second with a
tool ground to size. This procedure relieves cutting
pressure on the tool nose and may prevent springing
the work. The cutting operation for square threads
differs from cutting threads previously explained in
that the compound rest is set parallel to the axis of the
workpiece and feeding is done only with the cross
feed. The cross feed is fed only 0.002 inch or 0.003
inch per cut. The finish depth of the thread is
determined by the formula.