All this talk about exact diameter is a load of s**te.
That formulae setup was dreamt up by some armchair wizard who had nothing better to do with his time.
First off the theory is all wrong to start. All this crap about D x pi / P = Nc is wrong because a knurl wheel is a gear and gears are made to mate on their Pitch Circle Diameters not the OD or the root so if you are using the wrong formulae how can you get a correct job.
I'll prove this two ways - first theory based on D x Pi etc. Lets take a 2" bar and a knurl that has teeth measured 30 thou apart.
So 2" x Pi = 2 x 3.1416 = 6.2832" Now divide 6.2832 by 0.030" [ the pitch of the knurl ] and we get 209.44 teeth. Perfect we now have a doubled up knurl [ big fanfare etc ] but we haven't taken into account the DEPTH of the knurl. You do need a depth don't you ?? it's not just etched on the bloody surface, so we will say that this 30 thou pitch knurl has a depth of
15 thou, that's on radius so it's a total depth of 30 thou on diameter.
So lets do the figures again using the root of the knurl, because that's where the OD of the knurl wheel will finish up.
2" - 0.030" [ the depth ] x 3.1416 [ pi ] = 1.970 x 3.1416 = 6.1889 Now divide this by 0.030" [ the pitch ] and we get 206.30 teeth
So we have 206.30 teeth at the root but 209.44 on the OD Three teeth difference, which proves the formulae is crap because at some point as you wind in you go from 209.44 to 206.30 teeth. Metal is plastic and will 'flow', if you only had to go once round you would get errors but knurling is a continuous rotating process and it levels out any differences, hence the three theoretical teeth.
Second method - practical. Practical for anyone not fully understanding the word is defined by one having to get up off ones arse and go out into the workshop and get ones hand mucky.
Practical - a useful word to remember.
OK first off this is a knurl test bar to prove the formulae is just an old wives tale.
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This is just a steel bar about 1" in diameter with a skim taken off it to clean up. Then just using the dials I have stepped this in 5 thou steps [ diameter ] so the start end is 25 thou thou smaller than the chuck end.
I have no idea what the diameters are and the steps are only roughly 5 thou steps. The idea is I don't need to know because it's not relevant.
Now starting at the small end we do a straight knurl and run up to the chuck, under power, same setting.
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This is the finished job. You can see the steps. You can also see that even though there are 6 different diameters of God knows what size all the knurls have come out good.
Now if that formulae old wives tale was correct at least some would have come out cack handed but they haven't because going back to the theory buster the difference between ONE tooth is only 1/3 of the depth so at some point infeeding you have to hit that and once you do the flow of the knurl will guarantee that it carries on.
Now can I get back and get some bloody work done ??
-- Regards,
John Stevenson Nottingham, England.
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