Day by day the application of thread milling process is enhancing in industry because of its inherent advantages over other thread cutting techniques. The current study dwells on the interference issue, which is generated during thread milling. It was observed that there are two sources of interference on the thread produced, i.e., interference induced during mill penetration and during full machining. This interference leads to an overcut on the thread; thus, it produces a dimensionally inaccurate thread. The interference produced by penetration is much more when compared to interference generated during full machining of thread. Thus, there is a pressing need to analyze interference during penetration. So, this study evaluates different applied penetration strategies and the level of interference produced. Further, the study suggests modified penetration strategies in order to reduce the interference produced and hence create more accurate thread. This investigation is supported by analytical modeling and experimental exploration.

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