Design Recommendation for Screw

Machine Products

Ashwin Joseph Mathews Sucheth Jayan Choorappetty

A V S S L Koushik Pavan Kumar Kandregula Hari Kishore

Ajmal K C C Abhishek

Pranoy Arun Gurudayal Suryavanshi

Gopakumar M
Characteristics, Applications and Economic Production Quantities

● The production of screw-machine products can use one of three basic machine types :
Swiss type, Single spindle and Multi spindle.

● Typical Characteristics : Cylindrical Shape,May or may not threaded, May have internal
axial hole with more than one diameter, Knurls and threads of different sizes and pitch can
be used.

● Typical Applications : Ballpoint pens, Electrical devices, pins, valves.Single- and multiple-
spindle machines are used to produce a variety of close-tolerance components, including
rivets, nuts, screws, bolts, and other fasteners; shafts; spacers; washers. etc.

● Economic Production Quantities : Usually small lots are preferred.Output rates vary with
the size of the part, the amount of stock to be removed, and the machinability of the
workpiece material.Setup times run from under 1 h to 8 h.Multiple-spindle machines
require more tooling than single-spindle machines.
SCREW THREADS:
There are three common thread classes in the unified system.

Class 1: Loosest fit and the broadest dimensional tolerances.

Class 2: Closer fits and tolerances.

Class 3: Precise or critical applications.

Standard nomenclature:
Std. method of designation : 1/4–20–UNC–3A

Thread making process: Hand dies, Thread milling, Thread grinding, Single point
threading etc.

Materials: Steel , aluminum, brass, copper etc.

DESIGN RECOMMENDATIONS
● Standard sizes and shapes of bar stock should be used in preference to
special diameters and shapes. This is to conserve material and reduce
machining.
● Although complex form tools and counterbores are costly, they are advisable
since they lower the cost in the long run for mass production
● Designer should specify standard common sizes for holes, screw
threads,etc., so that readily available cutting tools can be used instead of
those which must be specially fabricated.
● All features should be located on one end of the part only so that all
machining can be performed on the screw machine before cutoff. Secondary
operations should be minimized.
EXTERNAL FORMS
•When hexagonal or square rods are turned
to make cylindrical rods of dimension equal
to the distance between two opposite sides,
small variation in centering can result in a
loss of cylindricity. To overcome this the
designed cylinder should be 0.25mm or
0.1inch smaller than the stock size
•There are limitation in the length of the
form tool that are used for turning the parts.
The length should not be more that 2.5 times
the smallest diameter of the part to be
produced
● Sidewalls of grooves and other surfaces
that are perpendicular to the axis of the
workpiece should have a slight draft to
prevent tool marks on the machined
surface as the tool is withdrawn.
● The recommended draft is 0.5 degree or
more.
 UNDERCUTS
•Because standard tool slides in screw machines operate at right
angles to the axis of the workpiece, an angular undercut, internal or
external, is difficult to produce and should be avoided whenever
possible.
•Annular grooves are easier to incorporate in the external surface of
the part than as an internal recess. External grooves can be
incorporated into form tools. Internal recesses require tools with both
axial and transverse motion. If there is a choice, design parts to
contain external grooves.
 DESIGN RECOMMENDATIONS FOR SCREW THREADS
External Threads Internal Threads

Threads should not Thread relief/

terminate too close undercut needs
to a shoulder ... to be provided

...nor near large

diameters

● The width of the relief depends on

the size of the part, coarseness of the thread, and
throat angle of the threading tool.
● No more than 60 or 65 percent of the thread
height is required for adequate thread
strength (requires only 75% of full thread
torque ).
The design of threaded products should include a
● For internal threads, where tap breakage may chamfer at the ends of the external threads and a
be a problem, limit the depth of the threaded countersink at the ends of the internal threads.
portion to two diameters.
Range of required root radius Means for avoiding burrs in threaded parts.

Min R = 0.25 mm ( preferred )

= 0.08mm ( very minimum )
Sharp Corners:
● Avoid sharp corners in the design of screw-machine parts. Sharp corners cause
weakness and more costly fabrication of form tools.
● When a sharp corner is required, it can be produced within specified limits, which are
usually close enough to meet the functional requirements of the part.
● An inside corner can be made “sharp” by providing an undercut at the corner. This would
eliminate the inevitable radius produced by a form at this intersection.

Fig:Undercuts supply corner space, if needed, with fewer problems than sharp corners
Spherical Ends:
● When a spherical end is required on a screw-machine part, it is better to
design the radius of the spherical end to be larger than the radius of the
adjoining cylindrical portion.
● This procedure eliminates the need for a blending of two surfaces that may
not be perfectly concentric and which usually are formed by separate tools.

Fig:Make spherical ends with a large radius to avoid problems of blending surfaces formed by separate cutters.
Holes
● The bottom shape of blind holes should be that made by a standard drill point.
● Standard drill points are most economical.
● If flat bottoms are required, some drill-point depression in the center should be
allowed.
● For flat bottom holes drill point with 3 mm depth is preferred.
● It is better to limit the depth of blind holes to 3 to 4 times the diameter.
Slots and Flats
● Slots and Flats can be produced with a concave surface at the bottom or end.
● Radius of the concave surface will be same as that of the milling cutter used.
● By transverse feeding of the cutter, the bottom or end can be made flat.
● Permit curved bottoms of slots and flats if possible.
Knurls
•Knurling is obtained by displacement of the material when the knurl is pressed
against the surface of a rotating work blank.
•Knurling tools, which have teeth of uniform pitch, are used for producing straight,
diagonal or diamond knurls on cylindrical surfaces.
•Cylindrical knurls are used for knurling on screw machines, automatic lathes and
cylindrical die thread rolling machines.
•The most commonly used knurls are those which produce straight, diagonal and
diamond patterns on the work.
 MACHINE SCREW THREADS AND SPACED SCREW THREAD

● Machine Screw threads : Used on bolts,set screws,machine screws and

designed to mate with preformed threads in nuts or tapped holes.

● Spaced threads:used on wood screws,self tapping screws and designed

to form it’s own thread ,usually in a predrilled hole.
 DRAFTING RECOMMENDATIONS

Dimensions

When dimensioning a drawing:

•Use a common reference line or surface for all dimensions
except diameters.

•Be sure that all distances are clearly dimensioned.

•Show the dimensional relationships for concentricity,

eccentricity (if intended), squareness, angularity, and surface
finish. A - preferred dimension to show the
depth of the keyway.
The depth cannot be measured from the
•Measurable surface roughness should be designated.
top center of the part because the
material has been removed.
•When a specific concentricity is required for a threaded surface,
be sure that the concentricity limits take into consideration the
tolerance limits of the threads.
•Internal recesses are often dimensioned
incorrectly. The use of the common axis of the
part as a datum line is the key to correct
dimensioning.

Preferred dimensioning of recesses is shown in C. A and B

views show dimensions that are difficult to measure.

Tapers

•The preferred method for dimensioning both inside and outside tapers is to specify the end diameters
and the length, and not the angle of the taper.

•However, when the tapered surface extends to the end of the part, the edge may be chamfered or
radiused to remove a sharp edge. This produces a measuring problem, since the diameter to be
measured will have been removed.
TOLERANCE
RECOMMENDATIONS