Threaded fastener with dual reinforcing leads for facilitating manufacture of the fastener, thread rolling die for forming the threaded fastener, and method of manufacturing the threaded fastener

A method of forming a threaded fastener from a blank member, comprising the steps of:

• providing a pair of thread rolling dies wherein each one of said pair of thread rolling dies comprises a body portion having a longitudinal axis;
• a working face disposed upon said body portion;
• a plurality of first, primary thread rolling die threads, disposed upon said working face of said body portion and oriented at a predetermined angle with respect to said longitudinal axis of said body portion, for forming a first, primary thread lead, comprising a plurality of first, primary threads, upon a blank member during a thread rolling process, wherein said plurality of first, primary thread rolling die threads are spaced from each other by means of first predetermined transversely spaced distances such that said first, primary threads will be successively formed upon said blank member at first predetermined positions which are spaced from each other by means of first predetermined axially spaced distances;
• and a plurality of sets of second, auxiliary thread rolling die threads, disposed upon said working face of said body portion at positions transversely interposed between said plurality of first, primary thread rolling die threads and oriented at a predetermined angle with respect to said longitudinal axis of said body portion, for forming a dual set of second, auxiliary thread leads, each comprising a plurality of second, auxiliary threads, upon said blank member during said thread rolling process, wherein said plurality of second, auxiliary thread rolling die threads, comprising each one of said plurality of sets of second, auxiliary thread rolling die threads, are spaced from each other by means of second predetermined transversely spaced distances;
• positioning said pair of thread rolling dies with respect to each other such that said working faces of said pair of thread rolling dies are oppositely disposed toward each other in a spaced apart mode;
• interposing said blank member between said oppositely disposed spaced apart working faces of said pair of thread rolling dies;
• and
• rolling said blank member between said pair of spaced apart thread rolling dies such that, as a result of said disposition of said plurality of sets of second, auxiliary thread rolling die threads, for forming said dual set of second, auxiliary threads, between said plurality of first, primary thread rolling die threads, when said plurality of first, primary threads are successively being formed upon said blank member at the first predetermined positions, the distances, through which material portions of said blank member utilized for forming said plurality of first, primary threads upon said blank member need to be moved, is effectively minimized thereby, in turn, minimizing the number of revolutions that said blank member must undergo during said entire thread forming process whereby, in turn, the length dimensions of said pair of thread rolling dies, required to completely form said threaded fastener from said blank member, may be correspondingly minimized.