What Are The Key Processes of Lead Screws?

As the 'skeleton' of mechanical transmission, the precision and lifespan of lead screws directly determine the performance of equipment. From CNC machines to automated production lines, stringent control of process quality standards is crucial for ensuring transmission efficiency. This blog will reveal the technical specifications and quality behind the manufacturing of lead screws.

The scientific principles of material selection

The core material of trapezoidal lead screws must meet both high strength and wear resistance standards. Carbon steel and stainless steel ensure stability during cutting processes and under load conditions. Carbon steel, especially medium carbon steel such as C45, has excellent toughness, strength, and machinability, making it an ideal choice. Through heat treatment, the hardness and wear resistance of trapezoidal screws are further enhanced, making them suitable for high-load applications. Stainless steel's superior corrosion resistance makes it outstanding in humid or corrosive environments, so stainless steel trapezoidal lead screws are more suitable for specific industries like food processing and chemical manufacturing.

Precision control of thread processing

The thread profile angle error must be controlled within ±15 arc seconds. When using CNC whirl milling technology, the radial runout of the machine spindle must not exceed 0.005 mm. During the precision grinding stage, CBN wheels should be used, with the grit size selected from the W40-W50 range, ensuring a surface roughness Ra ≤ 0.8 μm.

Lead error compensation technology is a core process that uses laser interferometry to monitor cutting paths in real-time and dynamically adjust tool compensation values. For P5 grade precision lead screws, the cumulative lead error over any 300mm length must be ≤0.023mm, which equates to a precision of one-third the diameter of a human hair.

The stringent inspection process for finished products

The CMM (Coordinate Measuring Machine) performs full inspections on critical dimensions, with the pitch diameter tolerance of threads controlled at 6g precision level. Dynamic testing uses a preload loading device, running continuously for 24 hours under 1.2 times the rated load, with temperature rise not exceeding 35°C and vibration values ≤ 4.5μm. Salt spray tests simulate harsh environments; after 240 hours of neutral salt spray testing, the surface corrosion area must be less than 3%. For special fields such as medical and aerospace, gamma-ray testing is also required to ensure there are no micron-level defects internally.

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