Case Study | Automotive

Axle Tube Thread Rolling: Dual PCV-30 Systems

Midstates delivered two turnkey Kira PCV-30 systems for an automotive driveline program running combined keyway and thread-forming operations on axle tubes. The application combined rigid workholding, protected-axis control zones, and Fette rolling-head integration to maintain repeatable thread quality.

Capability Tags

Combined Services

1 Provider Fixture design, automation, machine sales, and turnkey delivery coordinated by one Midstates team.
Machine Sales
Automation
Turnkey Systems
Fixture Design

Application Capabilities

thread rolling keyway machining custom machine dual-system deployment axle-tube process

Visual Proof

Kira PCV-30 production machine configured for axle-tube thread rolling.
PCV-30 turnkey machine build
Custom fixture assembly used to hold axle tubes during keyway and thread rolling operations.
Custom axle-tube workholding fixture
Batch of axle tubes prepared for keyway and thread processing.
Axle-tube production batch

Production Challenge

The customer needed to form threads and machine keyways on axle tubes with repeatable results across two systems. The process had to protect the rolling head and fixture hardware while supporting high-force thread-forming operations and controlled changeovers.

Critical Constraints

Combined Operation

One process flow had to cover keyway machining and rolled-thread forming on the same part family.

Thread Quality

Setup and process controls had to repeatedly pass GO/NO-GO thread verification for two thread families.

Machine Protection

Axis motion and clamp state had to be interlocked around the Fette rolling-head envelope to avoid collisions.

Solution Architecture

Midstates implemented two Kira PCV-30 30-taper systems (MS0454 and MS0455) with custom hydraulic fixturing, safety interlocks/light curtains, and an integrated Fette rolling-head drive package. Macro-driven clamp and unclamp sequences, protected-zone logic, and dedicated setup procedures were used to keep tool and fixture motion controlled during thread-forming.

Measured Outcome

Deployment

2 turnkey systems

Thread Families

2-1/8-16 and 2-3/8-16

Runoff Protocol

24-hour test + customer runoff

Operation Scope

Keyway + rolled thread on axle tubes

Why This Worked

The project combined process development, fixture engineering, and thread-head setup discipline in one package. By controlling clamp sequencing, axis protection, and thread-roll calibration as a single system, Midstates reduced setup variability and made dual-machine replication practical.

Source basis: MP4339 Rev2 quote package, factory run-off acceptance forms, and build photos from the Midstates project archive.

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