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Product Background

A fastener or fastening is a hardware device that mechanically joins or affixes two or more objects
together. In general, fasteners are used to create non-permanent joints that is, joints that can be
removed or dismantled without damaging the joining components. Welding is an example of
creating permanent joints. Steel fasteners are usually made of stainless steel, carbon steel, or alloy
steel. There are few types of fastener available at the home appliance stores worldwide. Fastener
is widely use in assembly process. In other words, every object need fastener to combine two or
more parts into one whole new unit. For instance the product that used fastener are assembly of
door and hinge, chairs, lamps or anything that requires screw and bolt. Fasteners come in many
different forms. Table below shows few types of fastener and its example.

Table 1: Types of Fastener

Bolt Screw Nut Washer Rivets

Sheet Metal Screws


Carriage bolt Cap Nuts
Sheet metal screws Belleville
Also known as a “coach” (SMS) have sharp The cap nut, also POP Rivets
bolt, has a domed or known as the acorn Conical
cutting threads that (Open End)
countersunk head. The nut, gets its name Washers POP Rivets, also
cut into sheet metal,
square section under the from its shape. The Belleville known as blind
plastic or wood. They
head grips into the part nut has a domed top to conical rivets, are used to
have a fully threaded
being fastened preventing prevent contact with washers are a connect two
shank and sometimes
the bolt from turning when the external thread. type of washer pieces of material
have a notched point
the nut is tightened. that adds extra in quick, efficient
at the tip to aid in chip
tension to a way.
removal during thread
fastener
cutting.
assembly.

Deck Screws
Hex Finish Nuts Large Flange
Our deck screws Lock Washers
Socket Cap Screws feature a type 17 point
Hex finish nuts are POP Rivets
Socket cap screws are used for fastening to a - Split Ring
(notched point at the Split ring lock Also known as
available in button socket, hex cap screw, socket blind rivets, they
tip) to aid in chip washers are
button flange socket head, cap screw or bolt. The are used to
removal during thread used to prevent
flat socket, and socket cap. most common nuts, connect two
cutting which allows nuts, bolts and
Driven with a socket hex finish nuts are hex pieces of material
for an easy screws from
wrench or a hex Allen key. shaped with internal in quick, efficient
installation in wood vibrating loose.
threads and driven way.
and composite deck
with a wrench.
materials.
Product Processes

In this product processing, screw is the main highlight in the fastener product. Screws are generally
made from low to medium carbon steel wire, though this material can be substituted for other
inexpensive metals, such as brass, nickel alloys, and an aluminium alloy. The quality of the metal,
however, must be high to avoid cracking and breaking in the screw. Screws are manufactured
using a variety of methods, and smaller screws or screws with unique designs can only be made
by the “machining” process. The machining process is exact, time-consuming, and more expensive
than the process to make other screw types. The process starts with “cold-heading,” in which a
wire is fed through a pre-straightening machine. The straightened wire is then cut into designated
lengths, and then the head is cut into a pre-programmed shape. After this is done the blank screws
are fed to thread-cutting machines, being correctly ordered to make sure they’re in the right
position to be fed in. They are then cut in a variety of ways to give them the thread that you see on
a screw. This can take two to three rounds or trips through a machine before the desired thread is
created.

Chart 1: Screw manufacturing process

Thread
turning
Manufacturing Innovation Production.

Turning process for screw thread is not the convenient way to use in large scale production. The
bulk of all screws are made with the “thread-rolling” method, the method used in mass-production.
Thread rolling is not a metal cutting process. Rolling changes physical properties, hardening and
strengthening the material

Benefits from thread rolling process:

• Lower costs.
• Increased production.
• Faster lead times.
• Stronger threads.
• Improved finish.
• More accurate profile.
Diagram 2: screw processing flow chart by thread rolling method. [1]
A thread rolling screw is a fastener that has threads specially configured so that it will form threads
as it enters a hole. There are several types. One type has a cross section that resembles a triangle
with rounded corners. Only three points on the screw thread will be at full diameter. The spaces of
lesser diameter between these points reduce the torque required to rotate the screw into the hole.
A disadvantage is that it does not provide the full holding strength of a screw that has a continuous
circular full diameter thread. [3]

Another type utilizes a tip portion with a plurality of threads of increasingly larger diameter. These
threads are not continuously circular. That is, one or more recesses or relieved areas will be located
on the crest of each thread. These recessed areas reduce friction during the process of installing
the fastener in the hole. The reduced friction reduces the torque. While workable, it would still be
desirable to further reduce the torque, yet provide good holding strength. Also, the type having a
single large notch extending up the first few threads tends to create chips when forming the threads
in the hole. Loose chips can create problems with electronic equipment. [3]

In thread rolling dies to which this invention relates, workpieces are transformed into finished
screws by a rolling process as the workpieces pass between a pair of elongated generally planar
dies. One of the dies is stationary, and the other die is displaced relative to the other to produce a
surface material flow on the workpiece to thereby form a continuous helical thread path on the
screw. In the thread rolling die machines for which the invention has particular applicability, a
shorter die of a pair of dies is held in stationary relationship while the longer die is moved in a
direction generally parallel to a longitudinal reference plane. The axis of rotation of the body of
the workpiece travels longitudinally as the workpiece rolls between the pair of dies. The diameter
of the finished thread is controlled by the diameter of the workpiece and the distance between the
dies at the finished end of the stroke. The dies are configured so that as the workpiece rolls across
the dies, the desired threading is formed on the workpiece. Thread rolling is also accomplished
using cylindrical or planetary dies and machines and this invention is applicable to all known
configurations. [4]
Diagram 3: Thread rolling machine. [2]

Diagram 4: Thread rolling machine. [5]

Using the process with two Rolling Dies the workpiece is typically placed on a supporting blade.
At least one rolling slide has a feed movement to perform the forming process. Simultaneously the
dies are rotating synchronously in contact with the workpiece, whereas the profile will be formed
out. Infeed thread rolling is based on one parameter: workpiece lead = rolling die lead. This results
in a synchron rotational movement of part and dies. No axial movement occurs. Necessary rolling
force is defined by thread diameter and length. [5]
Quality Control And Quality Assurance Of The Product.

1. Use suitable material hardness to avoid wear of die.

Each set of tools has an effective lifetime which is defined by a maximum number of operating
cycles which may be performed before the accumulated wear precludes further use. There are
several factors which may change the effective lifetime of a tool set. For example, the rate of tool
wear is proportional to the material hardness of the workpieces, where the rate of die wear
increases as the material hardness increases. Consequently, the effective lifetime of a die set which
is used to form threads on workpieces composed of relatively hard stainless steel is lower than the
effective lifetime of an identical die set which is used to form threads on workpieces composed of
relatively soft carbon steel.

2. Setting the dimension precision of the thread.

A 30° chamfer will give an approximate 45° angle after rolling. When rolling harder materials a
lower chamfer angle [25-28°] is preferred so thread roll life is not compromised. [6]

Diagram 5: Chamfer angle. [6]


3. Correct Tooling For Rolls.

Rolls are designed to incorporate the maximum number of starts allowed to fit in attachment.

Table 2: Tooling for Rolls. [6]


Material Producing Product.

Screws and bolts are usually made of steel. Where great resistance to weather or corrosion is
required, like in very small screws or medical implants, materials such as stainless steel, brass,
titanium, bronze, silicon bronze or monel may be used. Galvanic corrosion of dissimilar metals
can be prevented using aluminium screws for double-glazing tracks for example by a careful
choice of material. Some types of plastic, such as nylon or polytetrafluoroethylene (PTFE), can be
threaded and used for fastenings requiring moderate strength and great resistance to corrosion or
for the purpose of electrical insulation. Often a surface coating is used to protect the fastener from
corrosion like bright zinc plating for steel screws, to impart a decorative finish or otherwise alter
the surface properties of the base material. Selection criteria of the screw materials includes size,
required strength, resistance to corrosion, joint material, cost and temperature.

The softer the material, the easier it is to roll threads. Harder materials result shorter die life. Some
hard-to-roll material, such as stainless steel, produces excellent thread finish with a compromised
tool life. [6]

Table 3: Formability Index. [6]


There are some materials factor in producing screw. Difference materials exhibits different
properties. In steel, sulfur creates flakes and slivers. In aluminum, Bismuth creates flakes and
slivers. Sulfur, Bismuth, and Lead aid in the machining process, but hinder the thread finish when
cold forming. A tradeoff exists between machining speed and thread finish. Sulfur and Lead allow
for high speeds and feeds in machining, but the thread finish can suffer.

In other words, Screws are generally made from low to medium carbon steel wire, but other tough
and inexpensive metals may be substituted, such as stainless steel, brass, nickel alloys, or
aluminum alloy. Quality of the metal used is of utmost importance in order to avoid cracking. If a
finish is applied to the screw, it must be of a compatible makeup. Steel may be coated or plated
with zinc, cadmium, nickel, or chromium for extra protection. [7]
List Of References

[1] Samanta, Akash & Dutta, Arindam. (2012). A Noble Approach of Process Automation in
Galvanized Nut, Bolt Manufacturing Industry. IAES International Journal of Robotics and
Automation (IJRA). 1. 10.11591/ijra.v1i2.346.
[2] Koepfer, Chris. "Technology Gamble Pays Off." Modern Machine Shop, February 1995, pp.
94-104.
[3] Greenslade, Joe E. "Thread rolling screw." U.S. Patent No. 5,088,869. 18 Feb. 1992.
[4] Flanagan, J. D., & Faucher, B. R. (2005). U.S. Patent No. 6,947,800. Washington, DC: U.S.
Patent and Trademark Office.
[5] Profiroll Technologies, Thread Rolling, access at:
https://www.profiroll.com/en/process/thread-and-profile-rolling/ , access on 27 September 2019.
[6] CJWINTER A Brinkmen International Group, The Basics of Thread Rolling, access at:
https://www.pmpa.org/docs/default-source/technical-conference/pdf-
handout3aebd2ae46706df9a22bff0000aff8c6.pdf?sfvrsn=0 ,access on 28September 2019.
[7] Kramer, Jennifer "Screw ." How Products Are Made . . Retrieved September 27, 2019 from
Encyclopedia.com: https://www.encyclopedia.com/manufacturing/news-wires-white-papers-and-
books/screw

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