The alternative to thread cutting is a "roll forming" process. Thread rolling is a chipless process that has both advantages and disadvantages. Because there is no chip removal during the thread rolling cycle, the blank must be sized to the approximate pitch diameter prior to rolling. For class-two threads, the blank must be held to within .0015. The tolerance is less than .001 for class-three.

Rolling to a shoulder is difficult because of the skewed angle of the rolling dies. Because of "work hardening" and material metallurgy, some material can not be rolled successfully. Axial elongation factors should be considered for each material. Perishable tool costs are also higher for the rolling process.

Let's consider the advantages of both processes:

Chasing	Rolling
Regrindable chasers	Velocity - 100 SFM +
No blank preparation	Thread strength
Thread close to shoulder	Work hardening
Ease of short run changeover	32 Microinch or better finish
Economical tool costs	Chipless
Surface treatments improve life	Consistency due to blank prep
Special & coarse pitch thread forms
Most material can be thread cut successfully

These are some of the factors to consider when deciding whether to cut or roll. Where a question exists as to which method is best, it is important to consult with a suitable source and submit the application details to consider both options.