MAR 2 4 1958

DESIGNING PARTS FOR

Cold and Hot Heading

OF

^TrT**

INDUSTRIAL FASTENERS INSTITUTE

> •'\< 1 '
J t0543l.'5 ft&S^'

CONTENTS

Introduction 5

Design for Heading and Save 9

What heading is . . . beginning with the right design . . . importance
to engineers . . . examples of vast savings

How Heading Produces Better Parts at Lower Cost 11

Advantages of heading method . . . improved quality . . . three extra

benefits . . . economy of mass production . . . research and future de
velopment . . . importance of better tools and dies

Machines and Processes 17

Cold heading method . . . solid and open dies . . . single and double
or triple blow nmchines . . . transfer headers . . . hot heading methods

Designing Parts for Heading 25

Metal flow . . . diameters . . . volume . . . lengths . . . tolerances . . . fillets
. . . shoulders . . . extrusions . . . cuppingribbing . . . lugs and fins
. . . ...
tapers and swell necks . . . identifications . . . slotting . . . knurling . . .

summary of design recommendations

Designing for Secondary Operations 45

Discusses such widely used secondary operations as bending . . .

. . . drilling . . . piercing . . . swaging . . . thread rolling and thread cut
ting. Also, use of automatic feed mechanisms

Heading Materials 53
Includes data on carbon and alloy steels . . . stainless steels . . . copper
and copper alloys . . . aluminum and nickel and their alloys

Drawings and Specifications 67

Dimensions . . . center line . . . tolerances . . . threads . . . drilled holes

. . . points . . . and other related data

Effect of Electroplating on Dimensions 77

Data on the effects of electroplating . . . uniformity of deposit . . .

points for the consideration of platers'. .-. and a table of platings, coat
ings and finishes

Appendix 81

Useful tables and data on hardness conversion . . . material weight

conversion . . . coarse thread series fine thread series . . . corrosion
. . .

guide . . . volume formulae . . . fractions and decimal equivalents

Index— General 93

Index— Application 95
 INTRODUCTION
Cold and hot heading processes are effecting sub
stantial savings for manufacturers who use large
quantities of small metal products such as fasten
ing devices, special pins, and spacers. The parts are
made by cold or hot forming at high speeds, in
heading or forging machines, and at much less cost
than by conventional cutting or milling processes.
What's more, the headed parts are actually of
higher quality.
However, if a user of such parts is to achieve
maximum savings, he must follow certain principles
in the design of his products. Unfortunately, until
now there has been no text or reference volume to
which he could turn to familiarize himself with the
design "ground rules."
To fill this void, a group of engineers and tech
nicians from various heading companies prepared
the text of this manual. The Industrial Fasteners
Institute believes that its use by designers of com
ponents and by detailers will eventuate in lower
costs and better products.
 The COLD HEADING PROCESS
Raw material for producing cold headed parts is a coil
of hot-rolled steel rod. Rolled to close specifications, it is
carefully inspected, dipped in hot acid to remove rust and
scale, washed and finally neutralized in lime.

The coil is then fed into the part making machine. For
small sizes, coils are welded end-to-end and fed continu
ously.

1. Red from Ceil 2. Straightening, Drawing, (Enlarged) Blank

Shearing
Straightener

3. Forming

■(DO First Hammer "Up■

leti" the Blank to
HEADING is a the Above Shape

very versatile process . . .

it forms . . .
Chamfer
Second Hammer with
HEADS COLLARS

IV
SQUARES FLATS Cupped Head Forms
a Round Head with
a Chamfer

KNURLING AND RIBBING

WR' TAPERS
&o
4. Pointing

Pfl
PROJECTION AND FINS AND MANY
OTHER SHAPES

Fed in at the end of a fixed die, the

part is rolled forward by the movable
die and drops out at end of stroke with
threads perfectly formed.
 Why HEADING
Is Important to You

Heading SAVES TIME AND MONEY

. . . through high-speed production
. . . because of lower raw material costs
. . . and less wasted scrap

Heading PRODUCES A BETTER PRODUCT

. . . with a fine, attractive surface finish
. . . forming tougher parts
. . . with greater resistance to shock and fatigue
. . . because of an unbroken grain flow

Heading INSURES TOP PERFORMANCE

. . . with dependability in the toughest applications
. . . and long-term uniformity of product
. . . because of automatic quality check of material

Heading PROVIDES WIDER APPLICATION VERSATILITY

. . . with a full range of sizes
. . . and an unlimited variety of eccentric shapes
. . . from all ferrous and non-ferrous materials
. . . with secondary as well as primary operations

Top Management will find this manual helpful in its unrelenting search for
cutting costs without impairing quality and in its concern for faster produc
tion involving savings in equipment and space as well as time.

Purchasing Executives will welcome the data in this manual which repeatedly
shows how they may make vast savings when purchasing small parts and at
the same time procure parts of higher quality and more dependable, uni
form service.

Designing Engineers will find this manual helpful for reviewing basic ele
ments of design involved in the heading process in connection with their own
designing problems or requirements. It will also provide a source of ideas for
redesigning parts already in wide use in order to reduce costs and still provide
products of higher quality than those made by premium-priced operations.
A variety of cold-formed ports produced
for assembly in typical electrical products.
 D ESIGN FOR HEADING -and save!

Here are typical examples of how heading has reduced production costs:
•
A headlamp adjusting screw, redesigned so that it now is a headed part,
saves an automobile parts manufacturer $22,000 per year
•
A roller pin, now a headed part, saves $8,000 annually for a lawn mower
manufacturer
•
By using a headed part, the cost of double-duty packing and floor-leveling
bolts has been reduced $30,000 a year for an appliance manufacturer
Design for heading permitted these savings and similar savings for all other
parts illustrated throughout this manual.

WHAT IS "HEADING?"
Heading is a process of manufacture with virtually no
at high speeds,
scrap loss, of super-tough, high-quality low
parts at a veryunit cost. Many
assemblies in production today offer ample opportunity for redesign of their
parts and fasteners to those made by the heading process. Many parts, now
made by screw machines and automatic bar machines, also can be adapted
for heading. Other items— assemblies of two or more pieces— can be replaced
by one headed part through redesign and simplification.

"RIGHT" FROM THE START

Designers familiar with the principles governing the production of headed
parts specify them for low-cost fabrication. In addition, having learned to
perceive the basic elements that reduce the cost of such parts, they recognize
conditions where advice now from a specialist can get it "right" from the start,
and save dollars in the future.

EFFECTIVE AREA FOR COST REDUCTION

This manual provides for the engineer the basic elements of design as they
affect costs. With this information, the engineer, already highly trained in his
field, can intelligently study the process in connection with his own designs.
It
is frequently true that the items under consideration represent a
comparatively small portion of the total assembly cost. Engineers and man
agement quite properly watch the costs and design of major components; they
rarely get into the specialized area of heading principles. Because the design
of fasteners and fastener-like parts is thus generally neglected, this often
becomes the remaining area where substantial cost reductions can be made
most easily.

ENDLESS POSSIBILITIES
Because headed parts now are used in an assembly is no reason to assume
that further cost savings are impossible to attain. Unfortunately, many special
headed parts are made without specific knowledge on the part of the maker
as to how the parts are to be used and exactly what is expected of them. The
customer, therefore, often pays for special tolerances, premium priced heads
and secondary operations which may not be required. Application No. 1
shows an example of changing the design of a part already cold headed, to
effect a saving of an additional 10 per cent of its cost.

NO INFLEXIBLE RULES
A major objective in the preparation of this manual was to provide a

statement of simple, helpful principles covering operations that possess few

hard and fast rules. The amount of material that can be upset in a header,
for example, varies with the kind of material used, the shape of the part, the
equipment available, skill of the manufacturer, and many other factors.
In the following chapters, we have attempted to describe some of the
limitations of the processes, and to state "rules of thumb" that represent the
composite experience and abilities of the heading industry under normal
conditions.

Application No. 1

Redesign of Headed Parts

saves additional 10 per cent
This square-shouldered tie bolt was produced pre
viously in a double-blow machine, and the threads
were rolled on. This seemed to be the ultimate in
the design of this bolt.
Further study, however, showed that the square
shoulder was unnecessary. By changing the design
to one with a winged shank, one blow of the head
ing hammer was saved. This design was equally
satisfactory, and the tie bolt, of steel, now is pro
duced by a single blow of the heading hammer, and
threads rolled on, as before. This change, even
though it involved only the elimination of one very
fast hammer blow, has proved to be worthwhile.

10
 How HEADING PRODUCES BETTER
PARTS AT LOWER COST
The best known, and most commonly used, products of the cold-and hot-
heading industry are standard bolts, screws, rivets, nuts, nails, and similar
items. There are many well established producers, ranging in size from the
small plant to large, multi-plant organizations with nationwide service. The
complexity of their operations varies from making simple headed items to
supplying a vast number of secondary and related operations.
Their products range from the simple nail to the special part that is
headed, drilled, trimmed, heat treated, centerless ground, and plated. Their
one common denominator is that all their headed parts begin with a strong
blank, forged from a length of wire or a rod at high speed, and are completed
with a minimum of scrap. The basic operations can be performed either cold
or hot, depending upon the characteristics of the part and the material from
which it is made.

HEADING METHOD HAS IMPORTANT ADVANTAGES

Previous to the perfection of heading processes, screw machines were
widely used in the manufacture of fasteners. Screw machines can be used
advantageously under certain circumstances, and a number of heading firms
have screw machine departments, in which they produce the short runs and
parts that require sharp angles and special tolerances which are the specialties
of such equipment. The two processes— heading and machining— supplement
each other best when the designer and the buyer of the headed parts under
stand the advantages of both methods.

Application No. 2

HEADING 1
saves 33 per cent
,556, in o
The redesign of this part, a holder for the
550 oo
springs on automobile hoods and trunk
lids, resulted in a saving of 33 per cent. to
' o
The spring holder was machined pre to
viously from bar stock, involving several ]
1
different operations that removed nearly
one-half the total weight of the original IO
stock. This was a wasteful, time-consum
ing, costly process.
oo
The part now is produced from steel by 0) 0)
cold-heading, leaving only the finished ,,500,
operations to be performed, saving about .493
one-third of the original unit cost.

11
 Application No. 3

COLD HEADING
cuts costs in half
A saving of more than 55 per cent was effected by
converting this automobile clutch spacer stud from
o
screw machine to header production.
This small stud was made from bar stock on
— CO St
CMcvi ro
screw machines at a cost of {9.00 per thousand, in
the belief that it was necessary because of the close
tolerance— only .005" on the shanks.
When redesigned for cold-heading, however, the
.1/4 , . 346 . .'/«.
340
tolerances have been maintained easily, and the
part now is produced from coiled steel wire at a
cost of only $4.00 per thousand, making possible
a saving of $5.00 per thousand pieces.

Application No. 4

LARGER AND BETTER . . . .310

.300
costs less

x -t- H
The tenon of this automobile door-latch rivet was °
T--
to
enlarged, to enable it to be made by cold-heading ( L_

operations, yet the slightly larger part costs only \

in m
about one-half as much as the original smaller part. * m
The part previously was made by screw machine o9
operations from bar stock at a cost of approxi II II
mately $6.00 per thousand pieces. The diameter of
*S oC\J
IO
2
the tenon, as originally designed, was determined ___
only by the size of the hole into which it was fitted.
Redesigning this rivet entailed increasing the size
of the tenon by only .025", which required a cor
.105 .130
responding increase in the size of the hole into
101 .125
which it was fitted. The rivets now are made, ready
,.165, REDESIGNED
for shearing, with minimum scrap loss, at a cost .160 PART
of only $3.10 per thousand, a clear saving of nearly
FORMER
50 per cent. PART

Application Nos. 2, 3 and 4 show three parts that clearly illustrate the cost
savings and other benefits that can be achieved when the heading process is
adopted for the manufacture of parts formerly made on screw machines.

QUALITY IMPROVED
An added, important advantage of the heading process— over and above
lower costs— is improved quality. A forged ( headed ) part is stronger than one
formed by the cutting away of metal or by die casting; flow lines of the forged
material follow the contours of the headed parts. In addition, some materials
that cannot be cut freely can be readily upset. Application No. 5 illustrates
this point.

12
 Application No. 5

.758 ,
.742

Quality higher . . .
IN

/!
cost lower

.31/64
This part previously was machined from

\
non-ferrous bar slock by the customer, but

\
conversion to cold-heading now supplies
^-SHARP
the semi-finished part at a saving of nearly
50 per cent of its original cost. < .562
After conversion to cold-heading, this
.557 CM
part now is being produced with a mini u. ro
2
mum of scrap loss, and at high operating 01
speeds. The threads, now rolled on the CD CO
shank, are much harder, due to the cold

55
working, than were the cut threads. The
customer performs only the required fin
ishing operations, and the completed part

i i i
i i i
costs only a little more than one-half its

i i i
I I 1

i
former price.

:
.
HEA0E0 PART FINISHED BY
CUSTOMER

THREE EXTRA BENEFITS

Cold formed parts have smooth, bright, burnished surface. This finish
a

usually considered attractive and no further processing required. Hot

is
is

headed parts, because of the nature of the process, do not have comparably
a

by
bright finish. However, any degree of finish can be attained readily

a
secondary finishing operation.
One of the greatest, yet one of the least-known, advantages of the heading
process that the headed parts need not be concentric, as with screw machine
is

or bar machine operations. Offsets, squares, flats, and other non-concentric

shapes are standard products for the header, often effecting substantial sav
ings on related parts, as well.
The heading process, in addition, type of automatic inspection, for the
is
a

operation of forming reveals hidden defects in the stock, such as seams, lami
nations and piping.

EXCELLENT FOR LONG RUNS

The greatest economies of the heading process are realized where long
production runs are possible. The cost of the necessary tools and dies and the
set-up time are distributed over large number of pieces, making the unit
a

cost lower. Therefore, advisable to order annual, instead of smaller, re

is
it

quirements wherever possible, to take full advantage of heading economy.

13
 Application No. 6

. Slanted pins hold

i blades firmly
ft

Non-concentric is no problem
These hacksaw blade holders were redesigned, yielding a cost saving of
75 per cent, as well as providing stronger pins to hold the blade in place,
and eliminating a manual periling operation.
The parts previously were made by drilling a hole through the flat
tened portion of each holder and periling a pin into place to hold the
hacksaw blade, a costly operation.
Both blade holders were redesigned for cold-heading. The material
used is steel. The pins now are formed by extrusion as the parts are
flattened. The integrally-formed pins are slanted slightly backward to
hold the blade firmly, and they are stronger and better able to withstand
the vibration and tension of evervdav use.

RESEARCH ASSURES CONTINUED HEADING PROGRESS

Through the research and development programs of the heading industry,
techniques have been perfected so that now parts that could not be headed
only a few years ago are in routine production. And it is reasonable to expect
that many parts that are difficult to produce today will be routine in the not-
so-far-distant future. Application Nos. 7 and 8 show how parts once con
sidered impossible to make by heading, now are produced as a matter of
routine.

BETTER TOOLS AND DIES IMPROVE PRODUCTS

Recent developments have been unusually rapid. Better and faster auto
matic machines improve product quality and reduce costs. New and special

14
 Application No. 7

Roll threading permitted

faster production at
lower cost.
Redesigned Bolt is stronger, costs 2/3 less
A clear saving of 67 per cent of the cost of this
mounting bolt, as well as elimination of a costly
operation, was realized when this bolt was re
designed. It is used as a mounting brace, and to
adjust the height of the blades of a power lawn
mower.
The bolt was produced originally by welding a
forged eye to a threaded rod made by screw ma
chine operations. The bolt was assembled and bent
into the proper shape.
This mounting bolt was reduced to a single part
by first heading a ball on the end of a length of
steel rod, flattening the ball, drilling a hole through
the flattened portion, rolling the thread and bend
ing the rod to the required shape. The new part is
stronger, with no welded area, avoiding the costly
manual welding operation, and its rolled thread is
stronger and more wear resistant than the threads Welding operation re
previously cut on the shank. quired in two-piece con
struction was eliminated
by cold heading bolt in
one piece.

Application No. 8

Complex throttle lever made

more economically by heading
An estimated saving of 60 per cent was
attained by redesigning this throttle lever
for automobile automatic transmissions,
to eliminate an assembly operation, and to
make a stronger part.
The part was made formerly by man
ually assembling the cast iron head to the
steel shaft.
The new part, made of steel, has been
redesigned for cold-heading, and now is
made in one piece, eliminating the manual
assembly and yielding a stronger part, all
at less cost.

15
 coatings of wire and blanks make possible upsets more severe than were
practical only five years ago. Tool design has advanced, and dies made of
more-durable materials often yield runs of up to 500,000 pieces, instead of
the previously "normal" run of perhaps 50,000 pieces. This slower rate of die
wear also makes much closer tolerances practical for the finished parts. Appli
cation No. 9 shows the effect of the use of carbide die.

Application No. 9

Ultra-close tolerances - 9/16

are practical in
Here is a good example of the ultra- /
|
~-N'
close tolerances achieved under spe * i
cial circumstances by the use of car 1
bide dies, to save more than 25 per , 357
cent of the original cost of these 353
parts. 00
■•*
A hinge pin for automobile doors, ID
previously was cold headed .004"/
.342
.006" oversize and ground to a fin
.341
ished size tolerance of .001".
After redesigning for the carbide
tooling, the pins now are produced 00
by cold heading steel wire to the
'
finished .001" tolerance, thereby \ ZJ
eliminating all grinding operations
formerly needed to achieve accurate 1/4
dimensioning.

HEADING PROCESS SAVES TIME CUTS COSTS

Application No. 10 Application No. 11

.mi P■

RIDGED-HEAD LOCK SCREW SHAFT FOR VENETIAN BLIND ASSEMBLY

The old method was costly: cut the blank
from rod stock on a screw machine, grind
the head to form ridged head in a second
operation. With the new method the entire
blank is cold-formed in one step.
Knurled shaft section anchors into top cross-
piece; straight-sided end fits into ridged
discs. Made by cold-forming the blank com
plete with shoulder and slab-sided end —
then rolling on the knurl. It•s fast, simple,
low cost!
 A Cold Parts Former which
results in high production rates
and savings in scrap loss.

M ACHINES AND PROCESSES

It is advantageous for the designer to be familiar with the machine used in
the heading industry in order to apply the principles of design discussed in
the following pages of this manual.Therefore, this brief discussion and
description of the equipment and processes is included.
Heading, both cold and hot, is done on special machines called headers,
which resemble horizontal presses. The usual operation consists of auto
matically feeding wire from a coil into a header where "blanks" are cut off,
and transferred to a die.
Each blank is held in the die with This protruding
a portion protruding.
end is struck one or more blows by forming hammers, after which the headed
part is automatically ejected. The entire operation is performed at high speed.

COLD HEADING •

For cold heading, the raw material, usually wire in coils or rod, enters the
machine at room temperature, with the header running continuously. Cold
headers are classified according to the number of blows they deliver to each
piece and the type of dies used to hold and shape the blank.

17
 11has been demonstrated— again and again
—that manufacturing parts by the heading
process results in a savings of thousands
of dollars and greatly accelerates produc
tion. The photo shows a typical part.

The smallest cold headers in general use are designed to make parts having
diameters as small as H 6 inch. Double-blow machines will run up to 250
pieces per minute, and single-blow equipment, 420 or more per minute. The
largest headers are designed for 1" diameter work at a maximum rate of 50
per minute. The longest piece headed on commonly used equipment is about
6", but some specially-built machines will handle longer pieces.
Two types of dies are used in cold headers— solid and open. Headers may
have one solid die, or one pair of open dies, or several solid dies. In the latter
' case, the blank is transferred automatically from one die to the next between
blows of the hammer.

THESE PARTS ARE COLD-FORMED AT LESS COST

Application No. 12 Application No. 13

I our. *
'tstTIS
w'3 h -\~T

. 4\
% 0*9

ROLLER SHAFT FOR CABINET DRAWER SCREW FOR SEWING MACHINE

Formerly, the blank was made in 4 cuts on a
screw machine — and 3 tiny projections
which anchor the rollers were welded on!
Now the entire part is cold-formed — projec
tions and all— then, ends are trimmed.
"Combined" operations cut costs! When you
cold-form, separate "knurling" steps aren•t
needed. In one step the dies turn wire stock
Into finished blanks, complete with knurled
SOLID DIE
This is a cylindrical one-piece die with
a hole of the proper size and
shape extending axially through its center. A "knockout" pin extends par
tially into the hole from the rear. For the heading operation, the blank is cut
off and pushed into the open end of the hole until it butts against the knockout
pin; the portion of the blank extending beyond the die is hit one or more
blows by heading hammers of the proper shape; then the knockout pin ad
vances into the die, pushing out the headed part so that it drops from the
machine.

OPEN DIE
This consists of a pair of blocks, each called a die, with matching semi

circular grooves, which form a round hole extending axially through the
assembly when the two matching faces are put together. One of these dies
remains fixed, while the other can move a limited distance from the fixed die.
In operation, the movable die separates from the fixed die, and the wire
moves from the back of the dies, into the hole between them. When the
proper length of material extends beyond the front face of the dies, the
movable die is advanced toward the fixed die, the wire is clamped tightly
between them, then together they move laterally slightly, thus shearing
off the length of wire between the dies while gripping it tightly. Heading
hammers of the proper shape strike one or more blows on the portion of wire
extending beyond the dies, forming the head. The dies separate, releasing the
grip on the headed piece, which falls from the machine, and the cycle is ready
to repeat.

SINGLE BLOW, DOUBLE BLOW, ETC.

Most cold headers are single- or double-blow machines. In a single-blow
header, the heading hammer strikes each blank only once; in double- or
triple-blow headers, the blank is struck two or three blows, each delivered
by a different heading hammer.

TRANSFER HEADERS
These are specially designed solid-die cold headers, equipped with sev
eral ( usually three or four ) dies, with a separate heading hammer for each
die. They do considerably more work on the blank than standard two-blow
machines. In these headers, the blank is transferred automaticallv between
blows, with one completed part dropping from the final die at each stroke
of the slide.
One specialized type of transfer header known as a bolt maker forms the
head on the blank, can trim the head to the required shape, may point the
end, and roll a thread.

19
A y2-inch cold header which speeds production, slashing unit costs.
Header sizes refer to diameter of the largest wire the machine can handle.

20
 The most common use of this header is for making bolts. Some variations
or a combination of these operations also can be employed to make certain
non-bolt, special products.
Another transfer-type header, called a nut former, starts with round wire
or rod. In several successive steps, it makes a square or hexagon nut with a
hole readv for threading.

REHEADERS
A second heading operation can be performed on headed parts to make

upsets beyond the capacities of the equipment normally used. Parts usually
are annealed to convert them to their most malleable condition before re-
heading.

COLD ROD HEADERS

Another special type of cold header is the cold rod header, designed to
head long blanks. It is an open-die header with the bed cut away so that
blanks of practically any length can be headed.
The raw material is straightened and cut to length by other equipment.
The straight blanks are fed manually, or semi-automatically, to the heading
dies and the headed parts are ejected from the end of the header.

This %-inch Solid Die Double Stroke Header permits the produc
tion of many special cold-forged products heretofore considered
impractical as well as standard varieties of bolt and screw blanks.

21
A large transfer-type header used for making special parts and bolts.

22
HOT HEADING
Hot headers, in general, are similar to cold headers in both design and
operation. Most hot headers are of the open-die type, usually with several
grooves in their mating faces. The blank is transferred from groove to groove
between blows. Hot headers may be run continuously or intermittently, as
determined by the process.
These headers usually are used for work of diameters larger than can be
handled efficiently in cold headers, or for heading bars more than 6" long.
Automatic hot headers make 80 to 120 pieces per minute. Some of the newer
transfer-type machines for forging nuts and similar parts, turn out as many
as 225 pieces per minute. The speed of manually operated hot headers de
pends upon the size of the work and the operator's skill and stamina.
Straight bars are the usual raw material for hot heading. The entire bars
can be preheated, or they can be cut to length and the ends to be upset can be
heated. They are then fed, either automatically or manually, to the headers.
The temperature to which the bars are heated is determined by the material
and the amount of upset they must undergo. Normally, steel bars are heated
to a bright
o red color for hot heading.
o T . „ .
Typical C Hot u
...
Headed
,
Parts
Automatic Forging Machines, such as the 3-inch
machine above, produce quality headed parts
faster and consequently at much lower cost per unit.

HEATING FOR HOT HEADING

Gas- or oil-fired furnaces usually are used to heat the bars for hot heading.
If the entire length of the bars is to be heated, the furnace must be large
enough to hold several bars at the same time. The heated bars are fed from
one end of the furnace to the machine, and additional bars are charged into
the furnace as required.
When only the end to be upset is heated, the furnace must have one or
more slots or holes in its side. The blanks are inserted into these slots or holes
only far enough to heat the necessary amount of material.
The use of electricity for heating bars for hot heading has increased in
recent years. Temperatures may be controlled accurately with electric
heating, and scale formed on the blanks is less than is formed in gas
or oil furnaces. Electric heating is done by resistance or induction methods.
For resistance heating, the blanks are cut to proper length and the portion
to be heated is placed between two electrodes through which current flows
to heat the material to forging temperature. For induction heating, the por
tion to be heated is passed through an energized coil, which induces a cur
rent inside the blank for very rapid heating.

24
 D ESIGNING PARTS FOR HEADING
In the heading process, metal is made to flow into practically any shape or
form within the plastic flow limits of the material. In cold heading, the metal is
formed cold without preliminary heating. In hot heading, the metal is heated
before heading, to improve its malleability and to extend the limits of the
work that can be done upon it. Basically, however, both processes are the
same, and similar design principles apply, regardless of which method of

heading is used.
This section outlines for the design engineer some of the general prin
ciples of metal flow involved in heading processes. It is important, however,
to point out that these rules are based on the headability of low carbon steel.
Other materials have different characteristics from low carbon steel, which
might require some modifications of the design rules. In addition, methods
and equipment vary between producers.

25
 DIAMETERS
Many producers can cold-head wire and rod up to %" in diameter, and
some can handle slightly larger sizes. In hot heading, because of the pre
heating, rods up to 3" in diameter can be headed, although relatively few
producers are equipped to handle this extreme size.
Most producers prefer to cold head whenever possible. the quantity If
ordered is small however, or if the size of the product is beyond the cold
heading range, or if the upset is unusually large or oddly shaped, or if the
material is not suitable for cold heading, the producer may elect to use the
hot heading process.
In either case the design engineer is assured of the parts meeting the
specified dimensional and physical requirements.

VOLUME OF MATERIAL IN HEAD FORM

"Volume," used in the heading industry, is the mass of
as commonly
material upset in the desired form. This volume, or mass, is expressed in
terms of the length of stock measured in units of its own diameter, as illus
trated in Fig. 1.

The working formula for calculating the number of diameters in the

upset is:

A
Volume of upset portion D2H
— - = —=— = Number of diameters in upset.
Volume of one diameter a3

■D K The practical limits of the length of stock, or

111
volume, which can be upset with one and two
■o s
0 Z blows are two and one-quarter and four and one-
p •D
half diameters respectively, as shown in Fig. 2.
1 _l
•O o
X >■ For practical purposes on multiple-blow op
erations, however, the number of blows neces
sary is the ratio of two diameters to the total
number of diameters in the volume to be upset,
for example:
F 9-1
Sy2" of 1" diameter stock = 3M> diameters
_cK -4* 3!4 diameters -H 2 diameters = 2 blows required

In hot heading, another factor that must be considered is the number of

blows that can be struck effectively on one forging heat. A good general rule
to follow is that on one forging heat, stock under 1" diameter can be struck
three blows, and stock over 1" in diameter can be struck four blows.
It well to keep in mind that the cost of heading operations is reduced
is
to a minimum by designing parts for the smallest number of blows and for
the fewest reheats.

26
 UPSET DIMENSIONING NOMOGRAPH
WIRE SIZE
DIA. (INS.)
UPSET DIA.
(INS.)
3 —— 3.0

■6.0 UPSET VOL.

(CU.INS.)
•5.0 NO. OF WIRE DIAMS.
100 IN UPSET
2 2.0 UPSET LENGTH
4.0 (INS.)

*-:
12
-+- 50
II
•4.0
10
•3.0
-±- 20 9
3.0

•4-1 10 8

2.0
• 1.0 -- 5 2.0

.9

5
— -.8

-.7
•1.0 1.0
5 _
8 . .6 1.0 9
2. _ - 8
16 .9 f- 0.5
I ■.7
8
2"
1. .7 6
16
= "^ . .5

\
4 .6
3
8 0.1
■r- .4

i- 16
±- -5
\:: ,

'
1
10
CM

.15"

i- -.2 -.01
Fig. 3
16
.005 Locate diameter of upset (.65") on
line B, and upset length (.15") on
line D. Join to get upset volume
(.0498 cu. ins.) on line C. Locate
1. shank diameter (.25") on line A,
8 and draw a line through volume on
-.001 line C to get number of wire diam
eters in upset on line E (4).
- .0005
.05

-L — .0001
16

— .05

28
LENGTHS
Length of a headed part is the dis
tance from the extreme end of a given
piece to the nearer largest diameter of
LENGTH
the upset portion. When the upset is lo
cated between the ends to form a collar,
the length of the headed part is consid
LENGTH
ered to be the distance from the extreme
end of the longer section to the nearer
largest diameter of the upset. Some
examples of the measurement of length LENGTH
of headed parts are shown in Fig. 4.
As general rule the length, for
a
cold heading, should be between one
diameter of the stock and 6", for the most LENGTH

economical operation. If the length is Fig. 4

shorter than one diameter, handling becomes difficult and usually requires
special tooling. For parts longer than 6", special equipment, such as rod
headers, may be required.
For hot heading operations, the length is limited by the ability of the
producer and the equipment available. Lengths of less than four diameters
may require secondary operations. As the length increases, production speed
is reduced because the headed parts become more difficult to handle.

TOLERANCES
When designing headed parts, it is good engineering practice to specify
as liberal tolerances as the application will permit. Often, this introduces
additional economies, for tool and die life are increased and longer produc
tion runs with less downtime are possible.

SHANK TOLERANCES
The most commonly used shank diameters, and tolerance ranges for
shank and shoulder diameters, are shown in Table A, following page. (A
shoulder is an upset portion located between the head and the shank. )
Type 1 tolerances are held easily on most production machines; they
should be specified wherever possible, as they are by far the most economi
cal to meet. When the characteristics of the headed part require hot head
ing, slightly greater tolerances than Type 1 may be necessary.
When closer, hence more costly, tolerances are required, Type 2 toler
ances may be specified. Quite often, they can be held on production headers
without secondary finishing operations. However, some special tooling may
be necessary, depending upon the size and shape of the part and the heading
equipment available.

29
 Tolerance Ranges
Nominal Shank Inches
Diameter
Inches
Typel Type 2 Type 3

Vis through Vu .008 .004 .002

V* .010 .005 .0025

5/l6 .012 .006 .003

Vt .013 .006 .003

Vie and Vt .015 .007 .0035

•/is and Vt .017 .008 .004

% .018 .009 .0045

y, .020 .009 .0045

1 .022 .010 .005

TABLE A
TOLERANCE RANGES FOR SHANK AND SHOULDER DIAMETERS
The tolerance range applicable to a shoulder diameter is the same
tolerance range as listed for the shank diameter of equal size.

The application of tolerances closer than Type 2 often will require some
secondary operations. Type 3 tolerances should be considered only as in
dicative of what might be specified, if necessary, and where cost is of sec
ondary importance to close adherence to the specified dimensions.
The figures shown in Table A are tolerance ranges, and they may be
applied as desired ( plus or minus, plus only, or minus only ) , although it is
recommended that they be used unilaterally on the low side of the nominal
diameter (minus only) wherever possible.
Shanks should be specified in the fractional sizes shown in Table A, for
these standard sizes of stock are often more readily available. For special

applications, however, any decimal or fractional size may be specified.

HEAD TOLERANCES

Head tolerances are difficult to define, because they vary with the style
of the head. When close head tolerances are required, it is recommended that
the heading producer be consulted. When such tolerances are not critical,
however, tolerances shown in Table B may be specified.
These are tolerance ranges, and may be applied bilaterally (plus or
minus), or unilaterally (plus only, or minus only), as required. Generally,
they are applied plus or minus to the total shown.

30
 Tolerance Ranges
Nominal
Shank
Diameter For Upset For Upset
Inches Height Diameter
Inches Inches

'/l6 .008 .014

H .010 .018
Vn .012 .021
lA .014 .025

Vu .015 .029
% .017 .032
7/l6 .019 .036
Vi .021 .040

V> .025 .048

K .028 .055
H .032 .062
1 .036 .070

TABLE B
TOLERANCE RANGES FOR UPSET HEIGHTS AND DIAMETERS

LENGTH TOLERANCES
The recommended length tolerances for headed parts are shown in Table
C, below.

These also are tolerance ranges, and it is recommended that they be

specified bilaterally.

For Diameters Up to and Including %"

Tolerance
For Lengths
Range

up to r W
Over 1" to 2" Vie"
Over 2" to 6" Vx"
Over 6" W

For Diameters Over %"

Tolerance
For Lengths
Range

Up to 1" Ms'
Over 1" to 2"
Over 2" 3/l6"

TABLE C
LENGTH TOLERANCES FOR HEADED PARTS

31
FILLETS
Sharp interior corners in load-carrying parts are points of stress concen
tration; if the part is loaded dynamically, these corners are trouble spots
that may precipitate an early failure. Rounded corners or fillets, however,
permit smoother transfer of stresses, offsetting the possibility of premature
failure. Good engineering practice, therefore, requires the use of generous
fillets at all sharp bends and corners.
Fortunately, the formation of fillets is an inherent characteristic of the
heading process; sharp corners usually are attained by subsequent (sec
ondary ) operations. Thus, by taking advantage of this tendency of headed
parts production, the strength of a part is improved, and there is a definite
saving in overall costs.
It is recommended that parts have fillets with a radius of approximately
10 to 13 per cent of wire diameter, with a plus tolerance.

SPECIAL FEATURES
SHOULDERS
In addition to forming a head, enlargement of the diameter of the blank
can be accomplished on some other portions of the part as well, as shown in
Fig. 5, below. This may be round, square, oval or non-concentric.
The volume of the shoulder must be considered as part of the head when
computing the volume of the upset. Tolerances for shoulders are the same
as those applicable to shanks of the same diameter.

SQUARE ROUND OFFSET OBROUND

Fig. 5

POINTS
Header points are limited to cold headed parts, generally with a length
less than nine (9) times the smallest diameter at the point's end. For all

parts beyond these limitations, the point usually has to be machined in a

32
 Application No. 16

Square to round saves 65 per cent

Approximately 65 per cent of the original
cost of this locking stud was saved simply ~■\\
by changing the square tenon to round
1
form. 1
This part was produced by screw ma
chines and additional machining opera
tions which, in this case, were wasteful,
because no really close tolerances were
required. The cost was about $45.00 per
thousand.
When the part was redesigned for cold-
heading production, the tenon, designed to
fit into a square-holed mating part, was
made round and pressed into the approxi
mately square shape when it was fitted FORMER
into the square hole. The upper portion of PART
the steel stud was untouched, yet this sim
ple conversion of the tenon is responsible REDESIGNED
for reducing the price from about $29.00 PART
to $16.00 per thousand.

Nominal
Point Point
Shank
Length Diameter
Diameter
E- Inches d-lnches
Inches

TABLE D
POINT DIMENSIONS FOR UNTHREADED Me .015 .050
Yt .031 .109
SHANKS OF HEADED PARTS

Me .057 .156
E ,K y, .063 .203

5/l6 .078 .250

3A .094 .313

7/l6 .110 .359

.125 .409
5/a

.156 .500
.188 .609

subsequent operation. Table D details dimensions of typical header points

formed on an unthreaded shank.

EXTRUSIONS
The term "extrusion," as used in the heading industry, refers to the re
duction of section of wire or rod to smaller diameter than that of the
a

a
by

original stock forcing the material into die of smaller size to obtain
a

33
shank, as shown in Fig. 6, below. This step can be performed either as a
primary operation, when the upset is formed, or as a secondary one on an
other machine.
Extrusion is done by making the die with a hole at the front end large
enough for the blank to enter, but extending only as far into the die as this
larger diameter is required. It then angle-connects to a smaller hole which
continues to the opposite end of the die. The blank enters the die readily,
but when it reaches the smaller hole, it must be forced, or extruded, into it.
Extrusion can be done at one or both ends of the blank.

APPROX.

/
f
A*
t

\
Fig. 6

The most common purpose of the extrusion of headed parts is to reduce

the section of the shank so that, as threads are rolled subsequently upon it,
the finished part will have the same outside diameter on both its threaded
and unthreaded portions, as shown above in Fig. 6.
Similar reductions often are required to reduce an end portion of the
shank of a headed part to a smaller diameter for some other purpose. Ex
trusion results in a saving of material ( there is no scrap loss ) , and in substan
tial economies in production time, compared with such other methods as
turning, grinding, and milling, for accomplishing similar reductions.
The extrusion process is subject to the following restrictions:
( 1 ) The amount of reduction by extrusion should not exceed approximately

20 per cent of the original stock diameter. For greater reduction, a sec

ondary operation may be required.

(2) The die or tool used to extrude the material must have a lead-in angle,
so that the headed part will have an angle of approximately 14 degrees

( 28 degrees included ) between the shank and the extruded section. If

34

COLD-FORMING SLASHES COSTS IMPROVES QUALITY

 necessarv, this angle can be removed by secondary operations to pro
duce a square shoulder.
(3) Materials sometimes affect the ability to extrude successfully, and the
producer should be consulted if the use of unusual materials is con
sidered.
TABLE E

MAXIMUM DIAMETERS (INCHES)

CUPPING (OR DIMPLING) OF CUPS AT BASE

Cupping, sometimes called "dim

Cup Included Angle
pling," refers to punching a conical in Shank
Diameter
dentation into the end of a shank, Inches
90° 120°
usually to facilitate the peen-riveting
of the end. Table E, right, shows the
Vl6 %4

'/«
recommended maximum dimension at 3/l6 Vu

the base of the two styles of cups— 90°

'/«
Viz 3/l6

'/*
Vl6 Vn
and 120°.

3/8

'/4
5/l6
Vis "/32
RIBBING
Ribs are small ridges of stock on the shank, extending downward from
the head, as shown in Fig. 7, below. They may be required for tight driving,

^TlT^r^

Fig. 7. Typical examples of Ribbing

35

ONE OPERATION SIMPLER DESIGN FASTER PRODUCTION

.
.
.

Application No. 19 Application No. 20

[ill

TV ANTENNA STUD OF BRASS CENTER POST FOR LIGHTER

Note tiny shoulder lugs; they bite into the Sp~-:-,:zed head form with tubular top per-
bakelite when tubular stud rolled over, simpler design and much improved
is

and prevent turning of the piece when the operation. Note 7. angle on hexa-
y

wing nut tightened on the threaded end lar — obviously impossible to pro-
is

to hold antenna arms. a screw machine.

so that the fastenerwill not fall out of a hole before permanent assembly is
completed. This is often helpful if an assembly is to be turned over or moved
before riveting or applying nuts, for example. Ribs made in the heading
process will be cheaper than knurls in a secondary operation for the same
purpose, and the fastener is not weakened by reduction of the shank section.
If the object is to provide limited resistance to turning, ribbing formed
during heading usually will be lower in cost than the common alternate fea
tures of lugs, fins or square necks.
Because the amount of ribbing that can be provided is dependent upon
so many such related factors as type of material, shape and size of the re
mainder of the upset, etc., it is best to allow the producer as much latitude
as possible. Generally, the height of ribbing is like that of knurling, and

lengths of ribs over one times the shank diameter may offer difficulty. Some
side taper on the rib under the head will aid in filling out the forms.

LUGS AND FINS

Lugs and fins under the head usually are more effective to prevent rota
tion of a part in a hole than ribbing and often more economical than the
traditional square neck. If such a part is used in volume, particular consid
eration should be given as to whether the part to be assembled could be
modified to receive a lug or a fin under the head.
Lugs and fins are best devised by consultation with a heading engineer
since the degree and design of the upset that can be achieved without in
curring the expense of an additional heading blow may require some
exper imen tation .
Fig. 8, below, shows some tvpical examples of lugs and fins to prevent
rotation of parts in holes.

Fig. 8. Examples of Lugs and Fins

36
TAPERS AND SWELL NECKS
These features may be called for if ribs, for example, will not fulfill the
necessary function. Tapers must be minor and should not extend much more
than one shank diameter of length
under the head. Full length tapers
are comparatively rare. Some typical
tapers and swell necks are shown in
Fig. 9, on the right.

IDENTIFICATION
Many parts are given identification
marks in the heading operation, when
one or more letters, numbers, or other
marks can be placed on top of the head
to indicate the manufacturer, the part
number, the material, etc. Usually
these identification marks are raised
( embossed ) above the level of the bal
ance of the head; they also may be im
Fig. 9
pressed into the head, but this is more
Tapers and Swell Necks
difficult and expensive from a tooling
standpoint. Decorative designs can be
supplied by this same procedure.

SLOTTING
In many cases, it is possible to put a slot in the head, or elsewhere on the
blank, when the part is formed. The screwdriver slot in many round-head
screws, for instance, can be made in the heading operation. Many hexagonal
sockets and a large number of other special slots and recesses are made in
headers. Most screwdriver slots, however, are sawed into the heads in sec

ondary operations.

KNURLING OF HEADS
Another case in which an operation can be eliminated by careful plan
ning is that of knurling applied to the edge of the head of a part. To apply a
fine knurl to the straight-sided head requires secondary operations. However,
with only a two-degree taper on the head's edge, a medium-to-coarse knurl
TAPER ON HEAD AND
I
— STRAIGHT SIDE OR can be applied during
MED. TO COARSE KNURL FINE PITCH KNURL
the heading operation
with substantial sav
ings. The sketches
shown in Fig. 10 illus
KNURL MAY BE FORMED KNURLING DONE IN
IN HEADING OPERATION SECONDARY OPERATION trate this point.
Fig. 10

37
 Application No. 21

Material saved by cold heading

"collar studs"
These collared studs for automobile con
vertible tops were produced by screw ma < 3/4
chines and other finishing operations. o 0 50
Since redesigning for cold heading, how
ever, the part now is made to the same II
s
dimensions and form, with stronger o
threads, at a saving of more than 50 per
fP-11 oo Oi
q in
cent. I in
The former operations included ma
■
chining the shanks to form the collar, ■ ;
threading both shanks, and slotting the 00
end of the smaller diameter shank. <i op N
(S
The collared steel studs now are pro
>
duced by cold heading, which forms the
5
blank with collar, rolls threads on both
u>
shanks, and slots the end of the smaller
shank. The rolled threads are stronger and 0D
harder than the previously machined
threads, so the stud is improved, and at less
than one-half the original cost.

DOUBLE HEADS OR COLLARS

Features like double heads and collars often can be made complete in
the header, but there are severe limitations in the size of the second section
that can be formed. Open die headers usually are used for this work, and
the diameter of the second section must be small enough to drop from the

38

TOUGHEST JOBS GREATLY SIMPLIFIED BY HEADING PROCESS

Application No. 22 Application No. 23

m Innnnnnm
u**:*kiuuuiuul-j

STEEL KNOB FOR SEWING MACHINE F0LDING FURNITURE FASTENER

Plastic handle is later moulded to knurled Curved shoulder fits against tubular leg. End
end. Note the collar: it keeps the plastic of shank is inserted through leg and spun
from flowing too far — and forms a stop down to hold tight. Flat brace is placed
which locks screw end in place when tiaht- against rounded shoulder; end is rolled over
 Application No. 24

3/8-24 UNF 2A LH

Knurled and threaded stud costs less by heading

This knurled and threaded stud was re all costly operations.

designed for cold heading at a saving of
about 60 per cent over the previous ma
chining operations. Stronger threads are
obtained on the new stud, as well.
The stud was machined entirely, in
cluding the two pointed ends, the threaded
shanks and the knurled center section—
The redesigned part is produced from
steel entirely by cold heading, where the
knurl is formed at the center, the threads
are rolled, and the ends pointed. Threads
are stronger because of the cold forming,
and more wear-resistant than the formerly
cut threads.

dies as they are released; this dimension is not more than V3 to V> larger than
the diameter of the wire being used. The upset sections should be at least
one diameter apart.
Double heads or collars that exceed these limits usually can be made by
a secondary upsetting or machining operation. Examples of collars that can
be made successfully by cold heading are shown throughout this text.

39

PRODUCTION IS ACCELERATED COSTS ARE REDUCED

Application No. 25 Application No. 26

t.O'0
.aba

TERMINAL FOR CONDENSER

POST FOR SMALL TRANSFORMERS
Note collar lugs which bite into molded in
sulation and prevent piece from turning
when nut is tightened on threaded contact
Cadmium plated steel stud used as insert in
insulated molded part of automotive igni
tion system. Serrations in shoulder prevent
part from "turning loose." Cost was very
high when produced on screw machines.
 s.•UMMARY OF
DESIGN RECOMMENDATIONS
DIAMETER
Cold -headed parts can be formed from wire up to %" diameter and
slightly larger. Diameters of hot headed parts range up to 4". When possible,
most manufacturers prefer to cold head. ( See page 26 )

VOLUME IN UPSET
Volume of material in the upset is expressed in terms of length of stock
given in units of its own diameter.
—one blow upsets 2 % diameters,
—two blows upset 4% diameters,
—multiple blows upset 2 diameters with each blow.
Keep upset volume whenever possible within two blows limit. ( See page

26)

LENGTH
The length of a headed part is the distance from the extreme end to the
nearer largest diameter in the upset. For cold headed parts keep length be
tween one diameter and 6 inches. For hot headed parts keep length greater
than four diameters. ( See page 29)

TOLERANCE
Tolerances often govern final cost of the part. Allow as liberal tolerances
as the part's application will permit. ( See page 29 )

FILLETS
Good engineering practice dictates use of generous fillets at all sharp
bends and interior corners to permit smooth flow of stress. Allow fillets with
a radius at least 10 per cent of the diameter of the wire from which the part
is headed. ( See page 32 )

SHOULDERS
If a shoulder under the head is formed during heading, its volume must
be considered as part of the head when calculating total upset volume. ( See

page 32)

POINTS
Specify a point only when actually required by the application. (See
page 32)

40
EXTRUSION
Diameter of the extruded section should be at least 80 per cent of the
diameter of the original stock diameter. Allow a lead-in angle of about 14°
(28° included angle) between the shank and the extruded section. (If nec
essary, this taper can be removed in a subsequent operation. ) ( See page 33 )

RIBBING
Keep length of ribs less than one shank diameter. Allow slight side taper
through the ribbed length. (See page 35)

LUGS AND FINS

The volume of material in the lugs or fins should be considered as part
of the head in calculating total upset volume. (See page 36)

TAPERS AND SWELL NECKS

Tapers should be minor and not extend more than one shank diameter
under the head. Full length tapers are rare. Volume of material in tapers or
swell necks should be considered as part of the head in calculating upset
volume. ( See page 37 )

IDENTIFICATION
Raised markings are preferable. ( See page 37 )

KNURLING
A medium-to-coarse straight knurl with a 2° taper can be applied to the
side of an upset during the heading operation. Fine knurls or knurls of other
design are applied in a secondary operation. (See page 37)

DOUBLE HEADS AND COLLARS

Keep diameters of double heads or multiple collars within 50 per cent
larger than the shank diameter. Also keep a minimum of one diameter be
tween upset sections. ( See page 38 )

GENERAL
The rules and recommendations offered here are consistent with normal
abilities throughout the heading industry. Different manufacturers employ
ing special techniques may surpass certain of these recommendations in the
production of a particular part. Also, because of material or some peculiar
design feature, it is possible some producers may not be able to meet one or
more of the recommendations. For maximum economy in the design of any
headed part, consult the heading engineer of any manufacturer.

41
 Application No. 27
COLD HEADING PROCESS
saves 50 per cent
-1/4-20 UNC 2ft
Headed Parts
IN A WIDE
E VARIETY OF INDUSTRIES
?/16|,
RESULT IN
Producing this special knurled head bolt by
screw machine was slow and costly. • greatly reduced costs
By using the cold-heading process, the
same part was produced faster, to closer tol • higher production rates
erances, and at only one-half the former cost
—saving 50%. • closer tolerances

Application No. 28
HEADING MACHINE Application No. 29
makes this part much faster 13/32
THIS COLD HEADED
Made from a single
DESIGN
I piece of rod, this shift-
saved 63 per cent
AHHgn'J er interlock lever is
built A two-piece rubber grommet insert
■1 with two right angles was giving unsatisfactory holding
j» in a single operation performance when manufactured by
ill |
when produced in a heading the screw machine method. The
li| machine. The obvious result is in- problem was to produce the part at
tlJ creased savings in time and money, less cost and to give better per
since the former operation was a formance.
two-stage job. With cold heading, the part Cold heading, with double head
does not have to be moved in the die while
it is forged in two blows of the punch. The
entire operation is made from continuous
ing, was the answer. It reduced the
cost 63% and eliminated failures
which resulted from screw machin
VI
links of rod at high speeds. ing.

Application No. 30
Application No. 31
COLD-HEADING
this electric sweeper part COLD HEADING
saves $4.12 perM this spacer stud saves 66 per cent
This electric sweeper part is used in The above spacer stud for automobile
conjunction with a sweeper handle clutches was produced at $9 per M by the
to lock in position when unused. It screw machining method.
was formerly manufactured at $6 Today, cold heading this part permits
per M. mass production, close tolerances, and a
The same part manufactured by savings of 66% over the former screw
cold heading now costs only $1.88 machining process.
per M— a savings of over 65%.

Application No. 32
Cost reduced by 50 per cent
This control plug originally made
on a punch press is now produced
by cold heading at a cost reduc
tion of 50%. Cold heading this
part is faster and it results in
closer tolerances in addition to
the 50% savings in cost.

42
Application No. 33
Cost of Air Conditioning part slashed
©I
The above compressor mounting bolt for
a room air conditioner unit was formerly
produced by screw machining at a cost of
$60 per M.
After redesigning the part for cold
heading it was mass-produced at a cost of
$23.44 per M— a savings of over 60%.
Application No. 35
Higher quality . lower cost
This industrial gate valve stem must be
manufactured under close control in
chemistry, physicals and tolerances. Stain
less steel, Monel and bronze are the most
common materials used.
By the hot-heading upset method,
material savings were made . . . there was a
more uniform grain flow, higher wear-
resistant properties, closer tolerance con
trol, minimum scrap loss.
Application No. 37
HOT HEADING
saves money and metal
3E
3 1/8
This Monel metal power shaft, over 44
inches long, is now produced by hot head
ing at a savings of more than 2600 pounds
of costly materials. Waste of the expen
sive Monel materials was eliminated, ma
chining time was cut to a minimum, and
the finished part successfully met every
requirement.
Application No. 34
COLD HEADING
this part saved $1000
This aluminum screw
was formerly produced
with 8 holes drilled in
the head. Necessary jigs
and set-up time made
this a costly operation.
Redesigning for cold heading, the
entire process was accomplished in
a single operation, mass produced at
a savings of $7 per M— saving almost
$1,000 the first year.
Application No. 36
Closer tolerances— without added cost
This tee-head industrial chain pin, made
from medium or low carbon alloy, is widely
used in heavy industrial chains. Formerly
produced by drop forging or casting, it is
now hot headed at no increased cost and
with less than 4% scrap loss.
Application No. 38
HOT HEADING
saves 45 per cent in materials
I 1/8-7 UNC 2A
7h
V I 1/2
3 1/6 M±. im 7 1/8
The above special oval countersunk head
bolt is made of steel, hardened and tem
pered. Formerly produced on screw ma
chines, it is now made as a hot-headed
blank with hardening, tempering, machin
ing all over, slotting, pointing and cut
threading. Mass production results in
greatly increased dollar savings in addition
to approximately 45% in materials.
43
 M

LESS SCRAP WITH HEADING

At the top is seen the amount of scrap
which remains with the screw-machine
method. The lower illustration shows
the negligible amount of scrap in
volved when using the headi6u process.

44
 D ESIGNING FOR SECONDARY
OPERATIONS
Often, one or more secondary operations are required to complete a part as
specified. Such operations are employed to change the part's shape, hold
closer tolerances, add such features as threads, grooves, holes, slots, etc., im
prove physical properties, change surface finish, add protective or decorative
coatings, etc. Many secondary operations can be performed with automatic
feed at high speeds, thus reducing handling costs to a minimum.
The following is a brief discussion of some of the widely used secondary
operations, most of which are quite familiar.

BENDING
Headed parts may be bent in one or more
planes by any method suited to the material of
which the part is made, to the physical limits
imposed by the characteristics of the material
itself. Single-plane bending is simpler to ac
complish than multiple-plane bending.

BOX MILLING
Refers to the removal of material, usually from the shank, so that the
diameter of some portion of the part is reduced, such as machining a tenon
on a bolt or stud.

BROACHING
This that forms symmetrical or irregular grooves,
is a cutting operation
slots, keyways, square holes, splined holes, and other odd shapes, external
or internal, where other machining operations are impractical.

COINING
Usually involves the use of a punch press, which subjects the headed
part to pressure, causing the metal to flow into the form of the dies.

COUNTERBORING
Used to enlarge the diameter at the end of a hole.

COUNTERSINKING
A bevel into the end of a hole, usually performed on a drill press. In many
cases, alight countersinking operation is required to remove burrs or other
sharp edges from the ends of a drilled hole.

CUT-OFF
Includes the straightening and cutting off of blanks from coils of wire

45
or from metal rods; it may include the cutting off of a portion of the shank
from the headed part.

DRILLING
Done on standard or specialized drill
presses, or automatic machines. Drilling in
cludes cotter pin holes through the shanks of
headed parts, wire holes through the head,
holes in the ends or completely through the
entire length of headed parts.
Fig. 12

FLATTENING
Flattening and similar punch press
work, utilizing headed or formed parts
as basic materials, offers many odd-
shaped configurations not readily fab
ricated by other methods, and at con
siderably less cost. Examples of this
type of secondary operation are shown
in the sketches in Fig. 13.
Fig. 13
FACING
This operation involves the use of a cutting tool that machines the ends,
shoulders, or any flat face of the part.

FORM TURNING
This operation involves using a tool having the desired form. As the work
is rotated, usuallv in an automatic lathe, the forming tool removes the un
wanted metal, imparting its own shape to the portion of the product being
formed.

GRINDING
Performed where specified tolerances of the part's diameters require ex-

FORMED IN ONE OPERATION AT LOWER COST

Application No. 39 Application No. 40

^-L^l=^^^^^=^H
«i -■»
t 1
\SPEC■FH 1
eto m.ma*

ss ■■9
A ■!&£■
.QtO A tSmc»+rtm*

SCREW FOR CAMERAS

Impossible to make on a screw machine be
cause of its recessed head, small size and
tight tolerances. Cold-formed for "peanuts"
to meet all specifications — and used by the
PIN FOR AUTO HEATER
Part is completely formed in one operation.
Metal is displaced to make both the widened
collar and the smaller pin-end during one
treme accuracy or fine finish. Usually done on centerless grinders, because of
their high production rates as compared with other grinding equipment.

GROOVING
Operations performed to cut or roll grooves in any portion of the headed
part, as required.

KNURLING
Knurling usuallv is a
«
rolling operation similar \
^
to thread - rolling, the
knurl impression on the
rolling dies imparting
their pattern to the metal
being knurled. Fig. 14

MILLING
Usually performed on standard milling machines, to form flat areas on
the heads or shoulders of headed parts.

PIERCING
Perforating holes through portions,
usually flattened, of headed parts, with
greater roundness and accuracy than is
possible with drilling. Most piercing
work is done on a punch press.

POINTING
Special points, such as dog, cone,
needle, or other intricate shapes that
cannot be formed in the heading op
erations, may be machined on the end
of the shank of the headed product.

POLISHING Fig. 16

Imparts a high polish, or luster, to headed products. Many methods of

polishing are used, such as barrel tumbling, buffing, grinding with very fine
abrasive paper on the edges of disks, etc.

SHAVING
Performed by cutting tools that remove very small quantities of material
from the outer surfaces of headed parts.

SLOTTING

^^W
This may be accomplished in many
instances by putting the slot on the head
or on the blank at the same time as the
part is formed. Fig. 17

47
SWAGING
Used to a limited extent to reduce the diameter, or change the shape of
shanks by a series of blows from small hammers operating at high speed in
specially designed swaging machines.
TAPPING
The production of internal threads in a hole in a part, usually done on
tapping machines with multiple taps for high speed production. Tapping
also may be done on drill presses, lathes, or similar equipment.

THREAD ROLLING
Screw threads can be produced more rapidly and economically by rolling
than by any other method. One of the most important advantages of the
thread rolling process is that no stock is wasted; another is that the cold
working action makes the rolled threads 10 to 20 per cent stronger than cut
threads. Rolled threads also have a harder surface and provide greater wear
resistance.
Rolled threads are produced on cold and hot headers, usually on transfer-

type machines, as well as by specially designed thread rolling equipment.

When the threads are rolled in the special threading machines, however,
it is done as a secondary operation. The blank to be threaded is transferred
automatically in the headers, and either automatically or manually on the
thread rolling machines, between dies having thread-shaped ridges. Pressure
between two dies having these ridges displaces the metal to form a thread
of the required shape and pitch.
Where a partially threaded length is specified, it is best to allow the pro
ducer to determine the diameter of the unthreaded section, unless this diam
eter must be the same the outside diameter of the thread. Assuming this
as

to be the case, to roll-thread a part, the three operational steps shown in

Fig. 18 are required.
However, if the unthreaded section is unimportant in its end use, either
of two alternatives may be used to save the cost of the extruding operation
as well as raw material— either an undersized unextruded section ( approxi

mately pitch diameter size ) , shown at the top of Fig. 19, or thread the part
up to the head, as shown at the bottom of Fig. 19.
HEAD
r— MIN DIA APPROX. EQUAL
TO MIN P D. OF THREAD

FULL THREAD TO HEAD

Fig. 19
 This high-speed, thread-rolling machine handles 60 to 600 blanks per minute.

As shown here, designing for secondary operations often results in the

elimination of an operation, with resultant savings in cost.

THREAD CUTTING
Because thread cutting is usually more expensive than thread rolling, it
is generally used only when some feature of the part makes rolling imprac
tical. An example of this is a long, partially-threaded rod where the un
threaded portion of the shank must have the same outside diameter as the
threads, and the blank is too long to be extruded down preliminary to the
threading operation. Another example is a part with a thread length too long
to be accommodated by the available thread-rolling equipment.
TRIMMING
In a trimming operation, which can
be performed in the header, or as
a secondary operation, the head is
formed in a die to impart the proper
shape, and the excess metal is sheared
off. A wide variety of standard and
special shapes, some of which are
shown in
Fig. 20, right, can be
achieved economically from the
headed parts by trimming.

TURNING
Same as Box Milling. Fig. 20

49
 Application No. 41

FORMER PART

I
5/16-18 UNC 2A

REDESIGNED PART

I
MIN FULL THD
7 1/8

An Example of Rolled-Thread Economy

By cold heading this bolt from smaller
sized steel wire and eliminating cutting of
the threads, the customer now saves about
20 per cent of its cost.
The bolt, originally designed to be
formed by cold heading, was made from
5/16" wire, and the 5/16"— 18 thread was
nil on 1" of the shank end.
The bolt was redesigned, to be made
from .272" diameter steel wire, so that the
thread, when rolled in the shank end, now
is the required 5/16"— 18 thread. Approxi
mately 20 per cent of the original cost is
saved. The rolled thread, in addition, is
stronger and more wear-resistant than was
the cut thread.

Application No. 42

HIGH PRODUCTION RATE

and costs are less
Here the stud for a kitchen cabinet as
sembly had insufficient head to act as stop
for automatic hammering.
A cold-headed collar nail with annular
threads solved the problem. The cold-
headed part cost only 66 per cent of the
screw machine cost, saving 34 per cent!
The annular threads assured greater hold
ing power, production rate was much
higher— in addition to the savings in time
and money.

DESIGNING FOR AUTOMATIC

FEED MECHANISMS
When any reasonably large quantity is involved,
most secondary opera
tions will include a slide-rail feed mechanism to deliver the headed blanks
to the tools that perform the operations. This feed mechanism consists of a
hopper into which the headed blanks are loaded to be fed to the slide-rails
which, in turn, deliver the blanks by gravity to the secondary work station.

50
There are many variations, but the basic design considerations— balance and
upset size— are the same as for the typical feed mechanism shown in Fig. 21.

SECONDARY
OPERATION WORK
STATION

First, let us consider balance of the headed blanks or, to be more exact,
unbalance. A short part with a relatively large head will cause feeding
trouble, because the shank will not readily enter the slide-rails from the
hopper— the head end tends to topple the shank from between the rails, as
illustrated in Fig. 22.
Not too much can be done about this condition unless the "A" to "B"
relationship can be brought to the proper unbalance, either by decreasing
the head size or by lengthening the shank.
Another type of feed problem exists
where a secondary operation is to be per
formed upon one specific end of a stud
with a collar on it. In Fig. 23, the stud is

being fed down the rails in such a position

that the %"-long end will be pointed.
However, the fact that the opposite end
of the stud is only %" shorter makes it
difficult to insure that the correct end al Fig. 22

ways will be pointed downward.

If realized in the design stage, this can
easily be corrected in one of two ways:
One, make both ends of the stud the same
length, so that it will make no difference
which end is pointed in the secondary op
eration; or, increase the length difference
between the two ends so that the unbal
anced condition will be more pronounced,
and the hopper mechanism will more Fig. 23

readily reject parts incorrectly entering

the rails.
51
 It is important that there is enough difference between the diameter of the
head and that of the shank to permit the part to "rest" on the slide-rails of the
feed mechanism. If the rails must be brought too closely together, any vari
ation in shank size may cause binding. Conversely, if there is too much of a

gap between the rail, small heads will drop through.

Referring to Fig. 24, below, D is shank diameter, A is head diameter, and
E is the overhang of the head beyond the shank. E is determined by using the
A-D = E. Dimensions of E less than these shown in Table F can
formula

cause feed trouble, to make the secondary operations more costly.

In summation, it is apparent that if a part can pass down the slide-rails to
the secondary operation without difficulty, production costs will be com
paratively lower, due to efficient feeding. Maintaining the proper unbalance
and providing a part that has sufficient "resting" surface are the important
factors.

A
A-D
Size of Shank D =F
Inches
2
,E , -° E
Inches

Up tO 5/32 032

1 P
5/32to y, .048

V, to Vz .064.093

Yz and Over .125

7/ /// Y/, %
TABLE F
WEED
rEED RAILS—'
RAH
MINIMUM EDGE OVERHANG
OF HEAD BEYOND SHANK Fig. 24

COLD-FORMING IS SIMPLIFIED . . . COSTS LESS

Application No. 43 Application No. 44

HEX-HEAD PULL SWITCH ARMATURE

Round heads aren•t easy, but making metal
BRASS DOWEL STUD FOR BATTERY
"flow" into so large and thin a hex-head as Headed blank is cold-formed; straight knurl
this so smoothly and cleanly is one of the is roll-formed. Note how much metal is
rare accomplishments achieved by cold- cleanly "upset" to form the wide head.
forming.
 H EADING MATERIALS

Important in the design of any engineered part is the selection of the material
from which it is to be made. Choice of material, physical dimensions, and
processing methods are closely related, and only by being constantly aware
of this relation can the designer arrive at the best compromise between serv
iceability and economy.
Basically, the proper material is the one that best performs the required
service at the lowest cost. In service, each part in an assembly must fulfill
certain specific functions. These may be as simple as a space filler, or they may
be as complex as a highly stressed part in a jet engine. These requirements
must be satisfied before the part can function as it was intended. Thus, it is
end use requirements that dictate selection of the material.
It will
usually be found that several different analyses of a basic material
will satisfy the same combination of service requirements. However, these
different analyses may vary quite widely in their processing properties, avail
ability, and cost. When exact material analyses, processing operations, and
treatments to be used are specified, the designer closely limits the manufac
turer's flexibility, and production costs may be increased substantially. Pro
viding there is a clear understanding as to what the end service requirements
are,responsibility for final choice of raw material and manufacturing
method is best left with the producer.
Based on the fundamental premise— that end usage of the part governs
material selection— a system of twenty material grades is offered for the
designer's convenience. This system includes seven steels, three stainless
steels, four copper alloys, three aluminum alloys, and three nickel alloys.
Practically any combination of end properties can be satisfied with at least
one of these twenty grades. These grades are based solely on end properties
that can be expected, not on the raw materials used to arrive at those proper
ties.
A discussion of each of the twenty grades follows. Also included at the
end of this chapter is a table which shows at a glance the end service
properties offered by the different grades.

53
 TABLE G

MATERIAL GRADE SYSTEM

OF
INDUSTRIAL FASTENERS INSTITUTE
CARBON AND ALLOY STEELS
Grade S O-Steel
Grade S 1— Low carbon steel
Grade S 2— Low carbon steel
Grade S 3— Medium carbon steel
Grade S 5— Medium carbon steel, quenched and tempered
Grade S 8— Low alloy steel, quenched and tempered
Grade S 10— Low carbon steel, annealed

STAINLESS STEELS
Grade SS 1— Stainless steel, 12% chromium
Grade SS 2— Stainless steel, 17% chromium
Grade SS 3— Stainless Steel, 18%, chromium, 8% nickel

COPPER AND COPPER ALLOYS

Grade C 1— Copper
Grade C 2— Commercial bronze
Grade C 3— Heading brass
Grade C 4— Silicon bronze

ALUMINUM AND ALUMINUM ALLOYS

Grade A 1— Aluminum
Grade A 2— Aluminum, 17S

Grade A 3— Aluminum, 24S

NICKEL AND NICKEL ALLOYS

Grade N 1-Nickel
Grade N2-Monel
Grade N 3— Inconel

54
CARBON AND ALLOY STEELS
In the heading industry, all carbon with carbon content too low to
steels

permit a marked response to heat treatment are considered low carbon steels.
These steels are easily headed, have relatively good strength properties that
can be substantially improved by cold working, and they can be case hard
ened, to provide a wear-resistant surface.
Medium carbon steels respond to a quench-and-temper heat treatment.
Heat treated medium carbon steel (IFI Grade
S5) represents the most
strength per dollar of cost attainable from any known metal. Medium carbon
steels are fairly easily cold worked but, as the carbon content increases, their

headability decreases.
Alloy with small quantities of alloying elements,
steels are manufactured
such as silicon, molybdenum, nickel, vanadium, chromium and boron, added
to improve hardenability, strength, toughness, resistance to loss of strength
at high temperatures, or to offset brittleness at low temperatures. Depending
upon the alloy selected, any of these properties, simply or combined, may be
achieved. After heat treatment, alloy steels offer a much greater factor of
safety and uniformity than carbon steels. However, the allovs make them
more expensive, and more difficult to process.
The seven carbon and low alloy steels in the IFI grade system are as

follows:

IFI GRADE SO-STEEL

This grade is used to make parts for which there are no physical require
ments. It may be case hardened if wear resistance or surface hardness are
required.

Application No. 45

COLD HEADING
cuts cost 40 per cent
This insert screw, which is imbedded in a
die cast plastic part, was formerly cut in
a screw machine. With cold heading the
savings in material (besides faster speed)
reduced the cost 40 per cent!
The part is also stronger as the flow lines
of the material are not cut in threading and
knurling processes. Threading and knurl
ing are natural low-cost adjuncts to cold-
heading operations as all are performed in
one machine without additional handling
of parts. Threading and knurling were
performed in one pass through knurling
and roll-threading dies separated by a
spacer.

55
 Application No. 46

GREATER STRENGTH, FINER FINISH

AND CLOSER TOLERANCES
by cold heading
Producing this automotive clutch-release
bolt by cold heading instead of forging
increased the strength, improved the finish
and resulted in a part with closer toler
ances. The process calls for bending, flat
tening an end section and pressing four
ears. This work was done by a bolt heading
machine.

IFI GRADE SI-LOW CARBON STEEL

This is a low carbon steel with a tensile strength of 55,000 psi. Cold work
ing hardens and strengthens it.
If the upset is unusually large, a stress relief heat treatment is usually
necessary to reduce the brittleness caused by the large amount of cold work.
The producer normally will stress relieve when necessary to produce a satis

factory part. However, end usage may require the part be stress relieved, even
though the production process does not. In this case, it is recommended the
designer add the words "Stress Relieved" after the grade number. Hot headed
parts usually do not require stress relief, nor do any parts that will be heat
treated following the heading operation.
This grade is suitable for case hardening where wear resistance or surface
hardness is required.

IFI GRADE S2-LOW CARBON STEEL

This is low carbon steel, similar to IFI Grade
but with recognition of
S 1,

the higher physical properties in the smaller diameters and lengths attained
by cold working in heading.
As with IFI
Grade SI, the producer will stress relieve where necessary to
produce a satisfactory part. If the part's application requires stress relief, it
is recommended that the designer add "Stress Relieved" after the grade
number.
This grade is suitable for case hardening where wear resistance or surface
hardness is required.

IFI GRADE S3-MEDIUM CARBON STEEL

This grade is on the low side of the medium carbon steel area, and is for
use in the cold headed condition. It has a minimum tensile strength of
90,000 psi, and cold working is depended upon to induce this high strength
without subsequent heat treatment.

56
IFI GRADE S5-MEDIUM CARBON STEEL, QUENCHED AND
TEMPERED
This grade is a medium carbon steel, quenched and tempered to produce
high strength properties. Its minimum tensile strength ranges from 120,000
to 90,000 psi, depending on the size of the part. When strength alone is the
prime consideration in the design, this grade will usually be found the most
economical to use. Its relatively high hardness level also permits its use when
the part is subject to wear in combination with high stress.

IFI GRADE S8-ALLOY STEEL, QUENCHED AND TEMPERED

This is a low alloy quenched and tempered to produce a tensile
steel,

strength of 150,000 psi. Although its strength is somewhat superior to that of

IFI Grade S5, this advantage of extra strength is offset by added material
cost as well processing. Therefore, this grade is used only
as more difficult
when some other property, such as toughness, high hardness, or resistance to
loss of strength in elevated temperatures, is required.

IFI GRADE S10-LOW CARBON STEEL, ANNEALED

This is a low carbon steel, annealed to reduce its hardness level below
Rockwell B60. It is suited for small rivets, special pins, or other parts that
must be soft enough to be staked, bent, riveted, or deformed in some other
manner during assembly.

STAINLESS STEELS
Stainless steels may be broadly defined as ferrous alloys containing from
12 to 30 per cent of chromium and 0 to 20 per cent of nickel. This basic
analysis is further modified by the addition of carbon and other alloying
elements, which contribute specific effects, either to control mechanical
properties or to improve corrosion resistance.
The outstanding characteristic of stainless steels is their ability to form
on their surface a thin, invisible film of chromium oxide, which acts as a

Application No. 47

COLD HEADING .093

saves 85 per cent r 'i IO

o
i i
The manufacturer's problem here was to i j
produce a less costly stainless steel fluted
pin which was costing 819.20 per M by the
screw machine method.
////
////i
Ki
*
////

CM
By using the cold-forming method, the
fluted pin was manufactured at a cost of
82.95 per M. providing a cost reduction of
85%— another example of sensational sav
1
i

ings which are being achieved through the

IO
cold-headed process in the production of o
small parts and fasteners.

57
 Application No. 48

,1
Application No. 48 CD
-
COLD HEADED SHELVING SPACER
ro •I
costs 34 per cent less
This part made by the screw machine .v.4. . 3/* . m+
method was very costly and the manufac
turer was seeking a method of making FORMER PART
these stainless steel shelving spacers in
large quantities at lower costs and to closer
£t
\ / J.

"i
tolerances.
With the cold-heading process, double / \ ro
1

heading was used. The savings in scrap

alone amounted to $4.50 per M. The total 5/16 3/4 5/16
savings in cost was 34 per cent of the
original method. REDESIGNED PART

protection against corrosion of the underlying metal. Stainless steels also

have exceptional resistance to scaling and oxidation at high temperatures,
due also to this protective film. This film possesses remarkable stability, tough
ness, and ability to adhere at all temperature ranges. In general, stainless
steels have high strength properties, which may or may not be improved by
heat treatment, depending upon the analysis.

IFI GRADE SSI-STAINLESS STEEL, 12% CHROMIUM

This is a chromium stainless steel of the martensitic type. It has a tensile

strength in the annealed condition of 80,000 psi, and it may be heat treated
to higher strength characteristics. It is magnetic in all conditions of heat
treatment, has good heading qualities, and offers good corrosion resistance in
mild atmospheres, although for maximum corrosion resistance it must be
annealed.

IFI GRADE SS2-STAINLESS STEEL, 17* CHROMIUM

This is a chromium stainless steel with a tensile strength in the annealed
condition of 75,000 psi. It hardens during cold working, but will not respond
to heat treatment. It is magnetic, and has excellent heading qualities— both
cold and hot. It is widely used where corrosion resistance requirements are
not too severe, although for maximum corrosion resistance it must be an
nealed.

IFI GRADE SS3-STAINLESS STEEL, 18% CHROMIUM, 8% NICKEL

This grade is commonly referred to as "18-8 Stainless." It has a tensile
strength in the annealed condition of 75,000 psi and it retains good strength
characteristics at elevated temperatures. Its corrosion resistance is superior
in comparison with other stainless steels, but it also must be annealed for
best performance under severe corrosive conditions. It is non-magnetic in
the annealed state, but may be slightly magnetic in the as-fabricated state.

58
It hot forges well, but work hardens rapidly when cold worked. It will not
respond to normal heat treatments.

COPPER AND COPPER ALLOYS

Copper ranks next to steel in commercial importance. Copper alloyed
with zinc ( brass ) , and copper alloyed with some hardening element such as
tin, silicon, manganese, etc. (bronzes), are its most extensively used alloys.
Copper and its alloys possess excellent heading properties, toughness, re
siliency to withstand shock, excellent corrosion resistance in most atmos
pheres, good electrical and thermal conductivity, are non-magnetic, and will
take and maintain a fine, highly-polished finish. None of the brasses or
bronzes can be heat treated, although their hardness and strength properties
can be improved considerably by cold working. To eliminate embrittlement
and increase corrosion resistance in the presence of high stress, it often is
necessary to stress relieve parts after cold heading.

IFI GRADE Cl-COPPER

This grade is equivalent to commercially pure copper (99.92 % ). Its prin

cipal useful characteristic is its high electrical conductivity which, volume for
volume, is second only to silver. It is red in color, has good corrosion resist
ance, excellent toughness, and good heading qualities— both cold and hot.
It has an as-fabricated tensile strength of 32,000 psi.
IFI GRADE C2-COMMERCIAL HRONZE
Although it is commonly known as commercial bronze because of its
bronze color, this alloy actually is a brass, composed of 90 per cent copper
and 10 per cent zinc. It has a tensile strength of 45,000 psi, reasonably good
electrical conductivity, is readily cold worked, but hot forges with difficulty,
and it possesses good corrosion resistance. Like copper, it is not subject to
"season cracking," a spontaneous failure of stressed material after consid
erable time in a corrosive environment, prevalent in brasses with less than
80 per cent copper content.

IFI GRADE C3-HEADING BRASS

This is a brass containing from 65 to 70 per cent copper and 35 to 30
per cent zinc. It has a tensile strength of 45,000 psi, good corrosion resist
ance, pleasing yellow color, and reasonably good electrical conductivity.
This is the most widely used brass in the heading industry, possibly because
it offers the most favorable compromise between economy and useful service
characteristics.

IFI GRADE C4-SILICON BRONZE

Silicon bronze contains about 96 per cent copper, 1.5 to 3.75 per cent
silicon, and one or more other elements, such as zinc, manganese, tin or

59
 Application No. 49

ONE-PIECE COLD HEADED PART

replaces two-piece assembly
By making this hose clamp adjusting screw
in one piece in a cold-heading machine the
material and assembly costs were greatly
reduced.
The cold heading machine forms the
head with a flange. After the head is
slotted, the flange is forced up around the
top in an operation similar to the trim
ming performed on a bolt head. The
screwdriver shield is now an integral part
of the piece. The obvious result is savings
in time and money.

iron. It has a tensile strength, as-fabricated, of 70,000 psi and, as-annealed,

of 56,000 psi. Its electrical conductivity is not as good as other copper alloys,
although its corrosion resistance is exceptionally good in most atmospheres.
It has good heading qualities— both cold and hot— depending upon the par
ticular type or analysis used.

ALUMINUM AND ALUMINUM ALLOYS

On a volume basis, aluminum,because of its light weight, is the leading
non-ferrous metal in use today. Light weight is its most important property,
being about one-third that of steel and three-tenths that of copper. Pure alu
minum has relatively low strength, but it may be strengthened considerably
by alloying. Many of its alloys may be further improved by heat treatment
as well as by cold working. Its electrical conductivity is excellent. It ranks

closely behind copper in thermal conductivity but, because of its relatively

low melting point, it is not suitable for high temperature applications. Alu
minum and its alloys possess good corrosion resistance in general, although
they are subject to attack in some atmospheres. Aluminum has good heading
qualities, is non-magnetic, and will take and maintain a highly polished finish.

IFI GRADE Al-ALUMINUM

This pure aluminum ( 99.0
is commercially minimum . Because of its
r/°

low strength— 13,000 psi— not very widely used. However, its very soft
is
it

ness makes suitable for headed parts that must be staked, riveted, peened,
it

or otherwise formed in assembly. has excellent cold and hot heading

It

properties.

IFI GRADE A2-ALUMINUM, 17S OR EQUIVALENT

This grade an aluminum alloy with the principal alloying elements
is

being copper, manganese and magnesium. can be heat treated, and in its
It

60
 Application No. 50

THIS ALUMINUM PART

v[-
was produced at a savings of
89 per cent
This valve stem for a pressure release as
sembly was previously made by the screw
.375
machine method. in
CM
By using the cold-heading method cM K>
at
and employing two high-speed operations .138 IO
(heading and re-heading) the savings was
89 per cent of the former screw-machined .320
cost. This provided the customer with a
1
part simple and quick to assemble and in
expensive to purchase.
N^ '

T4 condition, it has a tensile strength of 62,000 psi. It has very good cold and
hot heading qualities.

IFI GRADE A3-ALUMINUM, 24S OR EQUIVALENT

This aluminum alloy is a modification of IFI Grade A2, with the alloying
elements slightly increased. In T4 condition it has a tensile strength of 68,000
psi, and this increase in strength is obtained without sacrificing its good
heading qualities.

NICKEL AND NICKEL ALLOYS

In many respects, the properties of nickel resemble those of iron, except
that nickel has excellent corrosion resistance in practically all corrosive en
vironments. In general, the properties of nickel and its alloys are superior
to those of other non-ferrous alloys, but their higher cost limits their use to
those applications suited to their special high-grade properties. The com
bination of its high strength and good heat resistance make nickel and its
alloys some of the best materials for use in elevated temperatures. Nickel
is magnetic up to about 660 F, but above this temperature it becomes non
magnetic. Nickel is relatively scarce and sometimes difficult to obtain.

IFI GRADE Nl-NICKEL

This pure nickel (99.4% minimum), and has a tensile
is commercially

strength of 68,000 psi. Because of its purity, it does not respond effectively
to heat treatment. It has good cold heading and excellent hot forging
properties.

IFI GRADE N2-MONEL

This is a nickel alloy, commercially known as Monel, composed of ap
proximately 67 per cent nickel, 30 per cent copper, and small quantities of

61
 Application No. 51

nr\ £h
DOUBLE HEADED PART PRODUCED
BY COLD HEADING
265 .117
saves 41 per cent
The problem here was in manufacturing
a double-headed
low cost.
part in large quantities at
"t?
By using the cold-heading method this
mounting screw with collar and slotted
head was produced faster, more economi
cally (with a savings of 41 % ) and in large
quantities. \f
FORMER REDESIGNED
PART PART

iron and manganese. It has an annealed tensile strength of 75,000

psi, is
slightly magnetic at room temperature, but loses its magnetism when heated.

IFI GRADE N3-INCONEL

This is a nickel alloy, commercially known as Inconel, composed of ap
proximately 77 per cent nickel, 15 per cent chromium, and 7 per cent iron,
with a tensile strength in the annealed condition of 80,000 psi. It is an out
standing material for parts that must retain their strength and resist oxidation
at temperatures ranging up to 1600 F. It is non-magnetic, has excellent hot
forging properties, but is difficult to cold head.

SPECIFYING THE MATERIAL

It is recommended the designer give first consideration to selection of one
of the grades listed in the material grade system. If the end requirements for
the part are not fully satisfied by one of these grades, the designer may

Application No. 52

COLD HEADING
saves $1 2.35 per thousand
In this case a steel stud formerly made by
screw machining cost $15.00 per M. By
using the cold-heading method the cost
was reduced to $2.65 per M— a clear cut
savings of 84 per cent ($12.35). Another
case where cold heading has proven to be
the most versatile and economical method
of producing fasteners and small parts.

02
specify the IFI grade number most nearly corresponding to that needed,
then qualify it by listing those special or slightly different properties needed.
When the service requirements are of such a special nature that none of these
grades will approximate what is needed, it is recommended the producer be
consulted for his opinion. The manufacturers have expert heading engineers
available to advise and help the customer select the most efficient and eco
nomical material for any application.

Cold-headed parts which are produced at great savings.

63
 O
TA--

GRADES OF MATERIALS AND TYPICAL PROPERTIES OF FINISHED PARTS

TOPICAL OOI- OEEL OARDN-S

GRAO GENERAL AISI CHEMICAL OELOO OELOO -OER
D-IGNAOEL D-C-POEL ANALOS- COMPOSIOEL Min. Min. ELQUIELMENTS
Fir Riliruci Only p.s.i. p.s.l. O-EEL ROCKWEEL

&
CAR-EL AELOO OEELS

0
IFI GRADE Steel 1010 No Requirements

S to
0)
(Similar SAE Grade 10O
10-
1108
11O

CCC C CC
1120

1
IFI GRADE Steel, Low Carbon 1O0 55,000 2- Max. -95 Max.

S to
1)
(Similar SAE Grade 10O
10-
11O

£
CC CCC
1120

S
2
IFI GRADE Steel, Low Carbon 10O

6
in
CC
in. length and under 10-
C1020

to
Up in. Dia. 69,000 55,000 2O Max. B100 Max.

¥t
Over in. in. Dia. 64,000 52,000 2O Max. -100 Max.

to to
Over in. VA in. Dia. 55,000 2- Max. -95 Max.

Vi !4 3A 6
in
Over in. length
All diameters 55,000 2- Max. -95 Max.

to
2)
(Similar SAE Grade

3
IFI GRADE Steel, Medium C1030

S to
3)
(Similar SAE Grade Carbon— Cold C10O

to
Up Vi" Dia. Worked 110,000 O,000 2--269 -9-1O

to
Over W *h" Dia. 100,000 80,000 207-269 -9-1O Stress Relieved
Over H" Dia. 90,000 70,000 -7-269 -9OO
C

5
IFI GRADE Steel, Medium C10O .30% Min.

S to
5)
(Similar SAE Grade Carbon— Quenched C1038 Mn .30% Min.
C

Up to Dia.
V and Tempered 1O0 .048% Max. 120,000 O,000 2O-302 C23-32 Min. Tempering Temp,

to
PS

1*
is

Over V," Dia. C1O5 .058% Max. 1O,000 78,000 2O-302 C2-32 800°F.

to
1"
Over \Vi" Dia 105,000 74,000 223-2O C19-30

to
Over Vfi" 3" Dia. 90,000 55,0- -3-2O
 O
TA-- (Continued)

GRADES OF MATERIALS AND TYPICAL PROPERTIES OF FINISHED PARTS

TOPICAL OOI- OEEL HARDNESS

GRAO GENERAL AISI CHEMICAL OELOO OELOO OOER
D-IGNAOEL D-C-POEL ANALOS- COMPOSIOEL MIn. MIn. ELQUIELMENTS
Farlataraaca
Oili M.I. p.s.i. O-EEL ROCKWEEL

8
IFI GRADE Steel, Alloy 8635 .O0% Max. Min. Tempering Temp.

S to
PS

8)
(Similar SAE Grade Quenched and 8640 .O0% Max. 800°F.

to
Dia. O- 30-O2

Up
Wi" Tempered O0,-0 120,0- C3-38 Min. as Quenched
Hardness Re 47

S
10
IFI GRADE Steel, Low Carbon 1006 -60 Max. (Note: Hardness measured
of

Annealed 1008 on side shank)

CCC
1O0

OA--SS OEELS

1
C
of

IFI GRADE SS Stainless Steel, O0 .O% Max. Strength properties

Annealed 12% Chromium O6 Mn 1.00% Max. 80,000 -,000 160O90 O4-88 "As-Fabricated" condition

Si
1.00% Max. are variable but usually

8)
Cr 11.-13.5% higher than "Annealed"
If

condition. maximum

2
is

IFI GRADE SS Stainless Steel, corrosion resistance

Annealed 1- Chromium 430 75,000 O,0- 154 Min. -2 Min. desired then "Annealed"
condition should be
specified.

3
IFI GRADE SS Stainless Steel, 302
Annealed -% Chromium 305 75,000 30,000 154 Min. -2 Min.
8% Ockel

&
COPPER COPPER AELOOS

C
1
IFI GRADE
%

Commercially Pure Cu 99.92% 32,000 10,000 Elect. Cond. IACS®

to

As-Fabricated Copper 68°F. 101% (Applies

Electrolytic Tough Pitch
Copper)

C
2
IFI GRADE Commercial Cu90% 45,000 30,0- Elect. Cond. 44%
-ronze Znl0%

C
3
to

IFI GRADE Heading -rass Cu 63-70% 45,000 20,000 Elect. Cond. 2- 28%
-alance Zinc
and Others
 H
TA-- (Concluded)

GRADES OF MATERIALS AND TYPICAL PROPERTIES OF FINISHED PARTS

TOPICAL OOI- OEEL HARDN-S

GRAO GENERAL AISI CHEMICAL OELOO OELOO OOER
D-IGNAOEL D-C-POEL ANALOS- COMPOSIOEL Mln. Mln. ELQUIELMENTS
Fir IiIiiiici Illy p.s.i. p.s.i. O-EEL ROCKWEEL

4
C
IFI GRADE Silicon -ronze Cu 9-96% Elect. Cond. 7O2%

Si
As-Fabricated 1.-3.75% 70,000 O,0-
Annealed Zn 1.5 Max. 5O000 25,000

&
ALUM-UM ALUM-UM AELOOS

Al

1
A
IFI GRADE Aluminum (2S) 99.0% Min. 13,000 5,000 Elect. Cond. 5-
-0- Condition Others (An, Fe,
Cu, Mn) 1.0%
Max.

2
A
IFI GRADE 17S-T4 Condition Cu 4.0% -,000 40,000 Elect. Cond. 30%
35
Mg 0.5%
Mn 0.5%

Al
-alance

3
A
IFI GRADE ELS-T4 Condition Cu 4.5% 68,000 4O000 Elect. Cond. 30%
Mn 0.6%
Mg 1.5%

Al
-alance

&
NICKEL NICKEL AELOOS

N
1
IFI GRADE Ockel
O 99.4% 68,0- 20,000 O6 Min.

N
2
IFI GRADE Monel O6-;Cu30% -1 Min.
Annealed Fe 1.4%; 75,000 O,000
Mnl%

N
3
IFI GRADE Inconel O7- -5 Min.
Cr

Annealed O%
Fe- 80,000 25,000
 D RAWINGS AND SPECIFICATIONS
When the headed part has been designed, the designer alone knows what is
expected— the size, shape, material, the why, where and how the part will be
used. Before his design can be converted into a reality, his ideas must be
passed on to others responsible for bringing the part through the many
stages of production.
The drawings and specifications form this common ground of understand
ing between designer and producer. The drawing illustrates the part; it
shows the shape, dimensions, tolerances, and all the special features that can
be indicated diagrammatically. The specifications supplement the drawing
by describing the material, properties, treatments, coatings, and any other
requirements that cannot conveniently be shown on the drawing.
Sometimes parts become unnecessarily expensive due to incomplete or
ambiguous drawings and specifications. For this reason, a brief discussion
of good drafting practice is considered advisable.

DRAWINGS
All drawings should be clear, complete and legible. As many properly
dimensioned views as are required to show every detail of the part should
be included. It should never be necessary to calculate, scale, assume, or guess
any dimension, tolerance, or other feature important enough to require con
trol in manufacture.
Most headed parts are relatively small, so the drawing also may be small.
Use of standard 8%" x 11" (letter size) sheets is recommended wherever
possible. When drawings are too large, they become difficult to handle, re
quiring folding for more convenient use, thus introducing the possibility of
overlooking some pertinent note or other detail.
Wherever possible, each part should be detailed on a separate sheet; com
bining parts on the same drawing invites errors in manufacture. Each draw
ing should be properly identified with a number and a date, and each sub
sequent revision dated. Attention to these details will avoid many potential
sources of error.

SPECIFICATIONS
Specifications need not be long; if possible, it is advisable to incorporate
them into the drawing. Only vital factors should be included because, in
cold and hot heading, in other manufacturing processes, each additional
as

requirement multiplies production difficulties, and adds to the cost. A good

67
 specification, therefore, includes only such items as are necessary to assure
end usefulness.
Often it is necessary to refer to existing standards and specifications when
noting material, properties, test procedures, treatments, or other characteris
tics. When such reference is made, special care should be taken to note the
source of the specification, so the producer can readily obtain a copy. This
will not only avoid chances of error, but it will be a real time-saver, permitting
the producer to process the inquiry or order more quickly.
DIMENSIONS
Any surfaces or points having definite relation to each other, or which
control the location of other component or mating parts in the assembly
should be dimensioned.
Decimal dimensioning is preferable for dimensions which must be held
to close limits. Other dimensions, not critical to the proper functioning of
the part, may be shown in either decimals or fractions, to suit individual
preferences.

no!
good!
3/16 1/2 2 1/2
3/16 .J/2.

Fig. 25

When dimensioning longitudinally, it is good practice to leave one di

mension open, as shown in Fig. 25. This dimension may be either one section,
or the overall length; usually, it is the dimension of least critical importance.
The open dimension then is flexible, and accommodates accumulated toler

la
ances of the other dimensions. BASE LINE IS LARGEST
DIAMETER OF UPSET
BASE LINES
It is good dimensioning

practice to establish a base

< y- \
line for each plane of view.

Fig. 26

COLD-FORMING SPEEDS PRODUCTION . . . CUTS COSTS

Application No. 53 Application No. 54

r— £

PIN FOR WINDOW FRAME

The diameter of wire (lock used is thai of SPECIAL EYE BOLT
the SMALLER end. Note the great amount of By producing this part by cold forging, the
metal successfully made to "flow*• into the cost was reduced 50 per cent. Cold forging
head. saves time, and it•s simpler too!
This base line then serves as a datum from which to originate all dimensions
in that plane, the primary purpose being to avoid an accumulation of toler
ances by chain dimensioning.
For headed parts, the most convenient base line from which to dimen
sion surfaces and points perpendicular to the axis of the part is the largest
diameter of the upset. Fig. 26 shows how this base line is established in rela
tion to variously shaped parts. When the upset is a collar, or some other type
with sides parallel to the axis, the edge adjacent to the long end of the part is
usually chosen.

CENTER LINE
The majority of upset parts are concentric (symmetrical) about a lon
gitudinal center line, and consequently this best serves as the base line from
which to dimension surfaces or points parallel to

I
4 it.
Diameters are shown straddling the center
} line, but not referenced directly to it. Offsets as
shown in Fig. 27, and other non-symmetrical
.3/4. sections, should be tied in with the main center
Fig. 27 line.

TOLERANCES
The final cost of a part often is measured in
terms of tolerances; therefore they should be to *
490
realistic. Specifying tolerances closer than the
application demands can be a costly practice.
Actually, the only justifiable tolerances are those
which, if exceeded, render the part unusable. »r
8 +1
.010+. u>
Tolerance limits are shown in three different 500'

ways, each of which is acceptable. ( Fig. 28 ) The

first method places the maximum limit above the 1 1

dimension line, and the minimum limit below. CD

O
The second method gives the calculated or nom 1- q
■
inal size, followed by the tolerance plus or minus, .490+021 °- o
CO
o
in
M
with the plus value above the minus. The third to

method gives the preferred dimension followed Fig. 28

CONCENTRIC WITH CTR LINE WITHIN

by a unilateral tolerance, either plus or minus, .005 FULL INDICATOR READING-
but not both.
It is occasionally necessary to require control
of concentricity to allow proper fit of the headed
part into an assembly. Concentricity is a three- Fig. 29

dimensional function and, such, is difficult to show diagrammatically. The

as

recommended method (Fig. 29) for indicating concentricity limits is by

69
means of anote referenced directly to the applicable surface, and specifying
the total dial indicator reading. One-half of this reading gives the amount ot
concentricity. Requirements for concentricity and eccentricity should
specify not only the point at which the reading is taken but the line to which
the readings are related.

THREADS
Screw threads are classified and distinguished from each other by the
number of threads per inch of length applied to a specific diameter. Screw
threads are highly standardized dimensionally and the available selection
of thread series and classes of thread fit is so extensive that very seldom should
it be necessary for the designer to deviate from a recognized standard.
The majority of all threaded items are sup
plied with one of two thread series— coarse
thread series (UNC or NC), and fine thread
series (UNF or NF). The coarse thread series is PICTORIAL

the more popular for general use.

Classes of threads are distinguished from
each other by the amount of tolerance, or the
f SCHEMATIC
amount of tolerance plus allowance, as applied
to the pitch diameter. Class 2A, applied to ex
ternal threads, and Class 2B, applied to internal SIMPLIFIED
threads, are the recognized standards for normal Fig. 30

production of threaded parts. Class 2A maximum

dimensions are less than basic by the amount of an allowance. This allowance
provides a definite clearance between the external and internal threads, thus
minimizing galling and seizure sometimes encountered in assembly and use.
An additional advantage is that this allowance supplies a space to take care
of average plating applied to external threads. ( Class 2 provides no allowance
with basic dimensions being used for maximum external and minimum in
ternal thread dimensions. )

SIMPLIFIED PRODUCTION . . . SAVES SCRAP

Application No. 55 Application No. 56

1 r°95

.005x45•

TERMINAL FOR LIGHT SWITCH STUD FOR TYPEWRITER RIBBONS

 There are three recognized conventions for illustrating screw threads on
drawings : pictorial, schematic and simplified. ( Fig. 30 ) Permanency of the
drawings, general workmanship, drafting time, clarity of intent, etc., in
fluence the choice of which to use.
The thread is designated on the drawing by a note indicating in order:
the diameter ( or screw number ) , the number of threads per inch, the thread
series symbol, and the class of fit.
All threads are normally considered right-hand and single lead, unless
specifically noted otherwise. For left-hand threads, the letters LH should
follow the class symbol. If double or triple lead, the words DOUBLE or
TRIPLE should precede the pitch diameter limits. For plated Class 2A ex
ternal threads, the pitch diameter limits should be noted and followed by the
words BEFORE PLATING, and the basic diameter should be specified as the
maximum diameter followed by the words AFTER PLATING. Examples of
thread designations are shown in Fig. 31.
Thread length preferably from the end of the part to the
is dimensioned
last usable thread, i.e., the partial threads in the runout should be outside the
length specified. (Fig. 32) If, for some reason,
the number of partial threads must be controlled,
then the overall thread length (to the last
5/16-24 UNF 2A
RD. .2843-2806

1/2-13 UNC 2A
P.D. .4485-4435
'
BEF. PLT6.
P.D. .4500 MAX. AFTER PLT6.
5/8-
PD
II UNC 2A DOUBLE
56 44-5589
\ 3/8-16 UNC 2A LH-*
Fig. 31

scratch ) should be dimensioned in addition to the length of complete thread.

On parts where the thread length must be as close to the head or shoulder
aspracticable, the maximum allowable distance from the head or shoulder to
the first full thread may be dimensioned instead of the thread length. ( Fig. 33 )
A recommended maximum distance from the un
derside of the head to the first complete thread-
is 2V-2 threads for sizes up to 1" in diameter, and
2>Y>threads for sizes larger than 1". If a definite Fig. 32 1/4 MIN

length of unthreaded or unscored body is a criti FULL THREAD

cal functional requirement, it should be dimen

sioned on the drawing as shown in Fig. 34.
The length of partial threads is dependent

upon the method used to produce them, produc .2 1/2 MAX

PARTIAL THDS. Fig. 33
tion efficiency, and the life of the threading tools.
Thus, for maximum economy, the designer should
avoid being unnecessarily restrictive when di-"
mensioning thread runout. In general practice,
1/4 Mil
an allowance up to 3 threads is recommended. FULL SHAANK Fig. 34

71
 When thread length is designated as minimum only, the producer assumes
he is permitted to supply as much thread beyond this minimum as suits his
method of manufacture. A maximum dimension only for thread length should
be avoided, unless accompanied by other data. Specifying a range, such as
V/z" to 2", gives the producer more latitude, and may result in low costs.
(Fig. 35)

Fig. 35
1.1/4 TO 1 3/4
FILLETS FULL THREAD

There are two methods of dimensioning fillets, each considered accept

able practice. The first is to show at every corner or bend the allowable fillet
radius. While more time-consuming, this method is more accurate, and
eliminates the possibility of later question during inspection or acceptance.
The second method is the use of a gen
eral footnote to the effect that comers may
1/16 MIN. RAD. SHARP-
be rounded, not to exceed "X" approximate
radius. Both methods are shown in Fig. 36.
A combination of the two systems ac

tually is preferable. Any corner or bend of a CORNERS MAY BE ROUNDED

1/16 MAX. UNLESS NOTED
critical nature should be specifically shown
Fig. 36
and dimensioned; all others may be covered
by a footnote. The actual drawing of
rounded corners is not necessary, so long as it is noted whether they are,
"
r corners.
or are not, sharp *f3JL 0RILL CTSK B0TH
ENDS FOR BURR REMOVAL

DRILLED HOLES

s
Holes to be drilled in the part Fig. 37
should have the diameter given, fol .125 DRILL
FULL LGTH.
lowed by the word denoting the opera
tion. For counterbores the diameter
and depth should be shown. When
countersinks are required to smooth CTBRr~BOTH ENDS
3/16 DlA x i/8 DEEP
the edge of a drilled hole and remove
possible burrs simply note "Counter
sink for burr removal." ( Fig. 37 ) Func <&
tional countersinks should show the in
cluded angle and surface diameter 2.760
2 750
either by dimensions or notes.
Fig. 38
The location of drilled holes, whether through the upset or through the
shank, is generally dimensioned from the largest diameter in the upset closest
to the hole. (Fig. 38)
KNURLING
Knurling is used for one of two reasons— to provide a definite grip or bite
when assembling into a mating part, or to offer a roughened surface to fa
cilitate gripping with fingers or wrench. Usually simple indication of the style
of knurl desired is satisfactory when knurling for the latter purpose. A func
tional knurl, however, on which proper assembly may be dependent, is a
critical requirement and, as such, it should be dimensioned adequately, as
shown in Fig. 39.
The drawing should show, in addi •STRAIGHT KNURL
tion to the type of knurl desired, any APPROX. 16 TEETH

two of the following three character

istics: diameter before knurling, diam ■'

eter after knurling, or the approximate K -1

UJ tc
t- 3
number of teeth. It is important the u. z
< K
exact number of teeth not be specified, CJ in
C»J o
as it may add to production difficulty IS (0

and possibly to the cost. Fi9- 39

POINTS
Whenever a point is not required, it is best to omit

it,
and the drawing
should show the part with squared end.
a

required, the greatest

If

point POINT
is
a

economy results from permitting the

producer the option of style and di
mensions. To do this, merely show
a

Fig. 40
chamfered point with the note "Point"
referenced to it, as shown in Fig. 40.
Special points, when required,
nr
E3DtE3X)
should be dimensioned carefully and
completely. Length, diameter, in
cluded angle, and any other important
requirements should be shown. See
Fig. 41.

Fig. 41

IDENTIFICATION
Identification marks should be on
top of the head or upset, and may be of
any shape, form, or lettering desired.
3
Raised markings are preferred. (Fig. RAISED MARKING
LOCATION OPTIONAL
42) Fig. 42

73
GENERAL NOTES
Notes are supplementary to dimensioning, and are used to indicate in
formation relative to the illustrated part. Usual drafting practice is to place all
general notes above or to the left of the title block.
Suggested information which might be given by general notes is as
follows :
( 1 ) Material: The grade of material or the part's end properties, with addi
tional data when necessary, such as hardness range, tensile strength,
surface hardness ( if case hardened ) , or any other special property re
quired to assure proper functioning of the part.
(2) Coatings and Finishes: The type and thickness of coating, if protective;
and the type alone, if decorative. If the part is to be plated, another note
to the effect that dimensions should be met before or after plating is
necessary. Usual practice is to meet dimensional requirements after
plating. For the most economical plating, specify "Commercial Plating."
(3) Acceptable tolerances where none are specified on the drawing.
(4) Acceptable fillet radii where none are specified on the drawing.
( 5 ) End use of the part. A short description indicating how and where the
part will be used is of tremendous help to the producer. Knowing the
end use of the part, he often is able to suggest slight changes in the
design, to make possible new savings without sacrifice of end usefulness.

Cold-headed parts showing a variety of shapes and sizes.

 OSV 3NIH0VW 00
3H0*oni« . Vd
1viH31vn ui savite to
«30NV«3101~2C/I SS31NH0310N
SM3NH03 AVH39 030ND0II9i/f XVNOVH SS31NH0310*
a3av3dHi anoNids
Nl S3H3N1
11V SN0ISN3H10 ldVd ON Qfr£2l
NM0- QM0ON
-0AfldV
31V0- X681

2/1CI- 3NHV3
Od S»>»- SC»».3U0i3fl SNIlVId
Od OOS».XVN M31JV 6NUVH

1vius1vn til 30»UD Sfi zax diHS ONianma oo

ONUVId 133OdlO3031iSOd 2000
C '3NI2 NIH SS3NM31H1 ovoag is 'i3xnvnMiN on
11V SN0iSN3ma01 39 13ftU31JV SNUVId
S33NVH3101
S«3NdOO
^3C/I SS31NH
AVM 38 a30NH0H
0310N
KTN»l/t WWa SSa1Nd0310M aaaaia n3NVd nog
11* SN01SN3HI0 Nl S3H0NI
NM0AS- QMQON
0AttdV-IB
31V0- Z6St?

3131dWOD SONIMVRQ JO SlRVd WOJ SONIQV3H

hei omi se|duioxe eAoqo srd ej8|duor3 s6uiMrad ijj^m teraodioaui
||o jo ei^j nsoijodueuiur>ore deui||no ui eijj 6ujdecred -rejdnip

Si
Some of the shapes made by hot heading.

70
 Effect of electroplating on
dimensions
It must not be assumed that specifying .0002" of cadmium plating, for in
stance, means that on round parts an allowance of .0004" for plating on the
diameter is all that is required. In the electroplating process, the metal does
not deposit uniformily upon all the areas of the part being plated. The
variation in rate of deposit upon the various areas of the part is influenced
by many factors, some of which are listed below:

(1) The "throwing" characteristics of the bath. This quality is difficult to

define, but it is related to the inability of the process to plate recessed
areas as heavily as the more exposed areas.

(2) The geometric design of the part.

(3) The operating conditions of the plating bath.
(4) In rack-plating, the arrangement and distribution of the parts to be
plated.
(5 ) The current density at which the plating is done.
Although an experienced plater knows the gen-
— electrooepositeo eral effect of all the factors involved, it is difficult,
J
I
even for him, to predict with accuracy the resulting
product on a strange item. Here are some of the
metal things he takes into consideration:
(1) Plating builds up most heavily at sharp cor
ners, as illustrated in Fig. 43.
Fig. 43
Therefore he recommends rounded or broken
corners, or chamfers, when
heavy electro-
ELECTRODEPOSITED plated deposits are required on a part.
METAL
(2) Plated thickness is greater near the ends and
base metal — ' edges
dges of
ot a piece; it is least in the center, as
Fig. 44 shown in Fig. 44.

(3) Plated thickness will be least in recessed areas,

ELECTRODEPOSITED as shown in Fig. 45. It may be impossible to
METAL
plate folded-over clips and similar items in the
folded-over area.

(4) In bulk plating, there will be a variation of

100 per cent in plated thickness from high to

BASE METAL low, measured on the same points of each

Fig. 45 piece.

77
 (5) In rack plating, with special precautions, the variations can be kept
lower, but it may be very expensive to keep it below 100 per cent. An
extreme example, because of the length of the bolt, of what happens
when a bolt is plated is shown in the case of %"— 16 x 6" hex head bolts,
plated to a minimum of .0002". The range of plated thicknesses shown
in Fig. 46, below, are taken from various pieces in a one-barrel lot.

\
.0006-0010
.0002- .0003 -.00045-0007
£.
-a: 00035-0006 .0003- .0005 0006-.00I0-
Fig. 46

(6) In the specific case of external threads, the plating is thickest at the top
of the thread and tapers down to the root, causing a slight change in the
thread's angle. On internal threads, the plate is heaviest at the root diam
eter of the thread and tapers down to the major diameter of the thread,
altering the angle of the thread slightly, but in the opposite direction
from the alteration of a plated bolt.
( 7 ) A unit thickness of plating on the wall or flank
of the thread increases the pitch diameter by
PLATING four times that thickness, i.e., .0002" of plate
CHANGE IN DIMENSION IN
THICKNESS
,— DIRECTION IN WHICH P. D increases the pitch diameter by .0008". A study
IS MEASURED
of the geometry of this situation, as indicated
in Fig. 47, left, shows the reason for this: If,
however, the plating thickness is specified as
a minimum thickness, the allowance on pitch
diameter should be six times the minimum
Fig. 47
thickness, or .0012", to allow for plating thick
ness variations.

78

CLOSER TOLERANCES FASTER PRODUCTION

Application No. 57 Application No. 58

+. 010
.1SS

TERMINAL FOR BATTERY ELECTRIC RAZOR CONTACT PINS

Close tolerance must be maintained on Used to make electrical contact from razor
knurled shank to avoid splitting carbon into to cord. Close tolerances are very important
which it is driven. Knurl prevents part from and tenon must be held concentric with
turning when nut is tightened on threaded shank.
(8) Plating builds up more rapidly at the mouth of the threaded hole of
nuts, rather than in the interior. Where heavy plating is required on a
nut, the mouth of the hole should be counterbored, or very substantially
chamfered, to avoid excessive build-up on the first few threads.
The foregoing review of the facts that require consideration in deciding
what effect plating will have on the fit of a bolt and a nut shows that it is
almost impossible to make a positive answer in a critical case. The final
answer can be obtained only by some trial-and-error experimentation. Ob
viously, this is not practical in all cases; for most classes of fits, where platings
called for (up to about .00025"), an allowance on the pitch diameter of six
times the minimum plating thickness will suffice.
When making the allowance, considerable thought must be given to an
adjustment of the threading tolerance because, as pointed out previously,
the plater cannot be expected to hit an exact thickness on every piece. There
fore, he must have tolerances within which to work. The machining tolerances
must be so selected that any parts receiving the thinnest permissible plate,
and any parts receiving a deposit twice as thick, will both be acceptable with
respect to the final fit.
Some of the more widely used platings, coatings and finishes, together
with their characteristics and common uses are shown in Table I, next page.

PRODUCTION IS SIMPLIFIED COSTS ARE SLASHED

Application No. 59 Application No. 60

SPECIAL HEX HD SHOULDER BOLT SPECIAL HEX TAPER HEAD BOLT

This special hex head shoulder bolt when The cost of making this special hex taper
formed of steel by the cold-heading process head bolt by the cold-heading process is
saved 50 per cent. In addition to saving slashed. Once again, an out-moded and
time and money, the process simplifies high-cost process was replaced by cold
 TABLE I
PLATINGS, COATINGS AND FINISHES FOR COLD AND HOT HEADED PARTS

Corrosion
Finish Color Characteristics and Uses
Resistance

Bluing Blue Very slight Thin, clear, blue oxide film produced by
heat treating

Brass Brass Fair Electroplated alloy of copper and zinc on

steel for color matching of brass products

Bright Polish Bright None Degreasing, descaling, barrel tumbling of

all metals

Cadmium Bright silver Excellent Electroplated coating cathodic to steel for

best corrosion protection. Lustrous, eye
appealing, good electrical conductivity.
Thickness to ASTM, Army, Navy
specifications

Copper (Electroplated) Copper Fair Good appearance for color matching; used
under nickel to increase corrosion
resistance of base metal

Copper (Wash) Copper Slight Immersion coating of thin copper film

Cronak Bronze to olive Excellent Dip process after electroplating of cadmium

drab, irridescent and zinc, greatly increasing their
corrosion resistance

Dichromate Dip Rainbow Excellent Same as Cronak

Ebonol Jet black Slight on steel Non-soiling jet black finish for steel,
"C," "S," "Z" Satin or waxed Good on copper copper, brass. Also jet black on
and zinc electroplated copper and brass

Hot Dipped Galvanize Silver gray Excellent Good rust resistance for steel. Not
recommended for small threaded items

Hot Dipped Tin Bright silver gray Good Heavy coating, excellent soldering base

Japanning Various colors Excellent Baked enamel finish for color match

Acid Resistant Lacquering Transparent Good Baked acid-resistant coating

Nickel Bright silver Good Bright, eye appealing, electroplated

hard coating

Phosphate Coating Dull gray Good, excellent Chemical process for rustproofing steel;
with oil dip undercoat bond for paint

Parkerizing Dull gray Good, excellent Chemical process for rustproofing steel ;
with oil dip undercoat bond for paint

Passivating (Neutralizing) No change Nitric acid neutralization of stainless steel

for removal of foreign material and
forming chromate oxide film

Tin (Electroplated) Silver gray matte or Good Coating for parts contacting food
bright burnished

Tin (Wash) Silver gray Fair A light immersion coating of tin

Zinc (Electroplated) Silver gray Excellent Electroplated, with high resistance

to corrosion

Bright zinc High lustrous Excellent Electroplated, with high resistance

silver gray to corrosion

80
 APPENDIX

HARDNESS CONVERSION TABLE

MATERIAL WEIGHT CONVERSION TABLE

DIMENSIONS OF COARSE THREAD SERIES

DIMENSIONS OF FINE THREAD SERIES

CORROSION GUIDE

VOLUME FORMULAE

FRACTIONS AND DECIMAL EQUIVALENTS

81
 HARDNESS CONVERSION TABLE

BRINELL ROCKWELL
TENSILE
STRENGTH
Oia. in mm. C Scale 160 Kg. B Scale 100 Kg.
Hardness 1000 p.s.i.
3000 Kg. Load Lead 120 Deg. Load Vu in.
Number
10 mm. Ball Diamond Cone Diamond Ball

2.75 495 51.0 253

2.80 477 49.6 243
2.85 461 48.5 235
2.90 444 47.1 225
2.95 429 45.7 217

3.00 415 44.5 210

3.05 401 43.1 202
3.10 388 41.8 195
3.15 375 40.4 188
3.20 363 39.1 182

3.25 352 37.9 (110.0) 176

3.30 341 36.6 (109.0) 170
3.35 331 35.5 (108.5) 166
3.40 321 34.3 (108.0) 160
3.45 311 33.1 (107.5) 155

3.50 302 32.1 (107.0) 150

3.55 293 30.9 (106.0) 145
3.60 285 29.9 (105.5) 141
3.65 277 28.8 (104.5) 137
3.70 269 27.6 (104.0) 133

3.75 262 26.6 (103.0) 129

3.80 255 25.4 (102.0) 126
3.85 248 24.2 (101.0) 122
3.90 241 22.8 100.0 118
3.95 235 21.7 99.0 115

4.00 229 20.5 98.2 111

4.05 233 (18.8) 97.3 108
4.10 217 (17.5) 96.4 105
4.15 212 (16.0) 95.5 102
4.20 207 (15.2) 94.6 100

4.25 201 (13.8) 93.8 98

4.30 197 (12.7) 92.8 95
4.35 192 (11.5) 91.9 93
4.40 187 (10.0) 90.7 90
4.50 179 (8.0) 89.0 87

4.60 170 (5.4) 86.8 83

4.70 163 (3.3) 85.0 79
4.80 156 (0.9) 82.9 76
4.90 149 80.8 73
5.00 143 78.7 71

5.10 137 76.4 67

5.20 131 74.0 65
5.30 126 72.0 63
5.40 121 69.8 60
5.50 116 67.6 58

5.60 111 65.7 56

5.70 107 64 55
5.80 103 61 53
5.90 99.2 59 51
6.00 95.5 56 49

82
 MATERIAL WEIGHT CONVERSION TABLE

POUNDS CONVERSION
MATERIAL IFI GRADE NO.
Per Cu. In. FACTOR

Carbon and Alloy Steels S 0 to S 10 Inclusive 0.283 1.000

Stainless Steel (12% Cr) SSI 0.279 0.986

Stainless Steel (17% Cr) SS2 0.277 0.980

Stainless Steel (18-8) SS3 0.286 1.011

Copper CI 0.323 1.141

Commercial Bronze C2 0.318 1.124

Cold Heading Brass C3 0.306 1.082

Silicon Bronze C4 0.312 1.102

Aluminum (2S) Al 0.098 0.346

Duralumin (17S) A2 0.101 0.357

Superduralumin (24S) A3 0.100 0.353

Nickel Nl 0.322 1.138

Monel N2 0.319 1.127

Inconel N3 0.307 1.085

Titanium Alloy (4AL. 4MN) 0.163 0.576

83
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85
 CORROSION GUIDE AND RESISTANCE
OF TYPICAL MATERIALS TO VARIOUS EXPOSURES

MATERIALS & IFI GRADES

BRASS STAINLESS STEELS

TYPE OF & NAVAL
SILICON MONEL
EXPOSURE OR BRONZE
BRONZE
ATMOSPHERE
Type Type
410,430 302
IFI Grade IFI Grade IFI Grade IFI Grades IFI Grade
C3 C 4 N 2 SS1, SS 2 SS 3

Acetate solvents, pure E E E E

Acetic acid vapors NG G F NG G
Acetone E E E E

Acetylene NG G E E
Alcohols E E E E
Alums G G NG F

Ammonia gas NG E E
Ammonium hydroxide NG NG F E E
Ammonium phosphate (ammoniacal) NG NG G E E

Ammonium sulfate F G G E
Asphalt E E G E
Benzine E E E E

Borax G E E E
Boric acid G E F G
Butane, butylene, butadiene E E E E

Cane sugar liquors E E G E

Carbon dioxide G G E E
(wet and aqueous solution)
Carbon disulfide NG F G E

Carbon tetrachloride E E E E
Chlorine (wet) NG F F NG NG
Chromic acid NG NG F F G

Citric acid G G F G
Coke oven gas F G E E
Copper sulfate NG F F E E

Creosote G E E E
Ethers E E E E
Formaldehyde G E E E

Freon E E E E
Gasoline (refined) E E E E
Glucose E E E E

Glycerine or glycerol E E E E
Hydrochloric acid NG F F NG NG
Hydrofluoric acid F E NG NG

Hydrogen E E E E
Hydrogen peroxide NG F G E E
Hydrogen sulfide NG F F G
(wet and aqueous solution)

Lacquers and lacquer solvents E E E E

Magnesium chloride G E F G
Magnesium sulfate G E E E E

86
 CORROSION GUIDE AND RESISTANCE
OF TYPICAL MATERIALS TO VARIOUS EXPOSURES

MATERIALS & IFI GRADES

BRASS STAINLESS STEELS

TYPE OF SILICON
& NAVAL MONEL
EXPOSURE OR BRONZE
BRONZE
ATMOSPHERE
Type Type
410, 430 302
IFI Grade IFI Grade IFI Grade IFI Grades IFI Grade
C 3 C 4 N 2 SS 1, SS 2 SS3

Mercuric chloride NG NG NG NG NG
Mercury NG NG G E
Milk F F F E

Natural gas G E E E
Nitric acid NG NG NG G
Oxalic acid F G E G

Oxygen E E E E
Petroleum oils (refined) E E E E
Phosphoric acid, 50, 85 percent NG G G NG NG

Picric acid NG NG NG E
Potassium chloride F G E G
Propane E E E E

Rosin (light) NG NG G E
Shellac G E E E
Soda ash (sodium carbonate) G G E E

Sodium chloride F G E G
Sodium cyanide NG NG G E
Sodium hydroxide NG F E E

Sodium phosphate (alkaline) F G E E

Sodium phosphate (acid) F G E NG G
Sodium silicate F G E E

Sodium sulfate G E E E
Sludge acid NG G G NG NG
Sulfate liquors NG NG G E

Sulfur NG F F E
Sulfur dioxide (wet) NG G NG NG G
Sulfuric acid 10 percent NG G G NG NG

Sulfuric acid 95 percent NG NG NG G G

Tar G E E G E
Tartaric acid F G G F G

Trichloroethylene E E E E E
Turpentine F E E G E
Varnish G G E E E

Vegetable oils G G E E E
Vinegar F G G F G
Water (fresh) F G E E E

Water (salt) F G E F G
Zinc chloride NG G E NG NG

Key: NG-NoGood F— Fair G-Good E— Excellent

87
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FRACTIONS AND DECIMAL EQUIVALENTS

.015625 £^.515625
.03125

O
.046875 ©-.546875
.0625 ^^.5625
.078125 .578125
.09375 ^-.59375
I09375 ©-.609375
125 ^^.625
140625
15625
171875 .671875
1875 .6875
.203125 .703125
.21875 .71875
.234375
.25
.265625 .765625
.28125 .78125
.296875 .796875
.3125 .8125
.328125 .828125
.34375 r.84375
.359375 ©-.859375
.375 ^-.875
.890625
.90625
.921875
.9375
.453125 .953125
.46875 .96875
.484375 .984375
.5 I.
 SPONSORS
This publication has been made possible through the cooperation of the
members of the Industrial Fasteners Institute and suppliers of machinery
and raw materials essential to the manufacture of industrial fasteners.

INSTITUTE MEMBERS
American-Monarch Corporation, Cleveland 5, Ohio

Anti-Corrosive Metal Products Co., Inc., Castleton-on-Hudson, New York

The Atlas Bolt & Screw Co., Cleveland 10, Ohio

Automatic Products Company, Detroit 8, Michigan

Bayonne Bolt Corporation, Bayonne, New Jersey

Bethlehem Steel Company, Bethlehem, Pennsylvania

Buffalo Bolt Company, North Tonawanda, New York

The Champion Rivet Company, Cleveland 5, Ohio

Chandler Products Corporation, Cleveland 17, Ohio

Clark Bros. Bolt Company, Milldale, Connecticut

Cobb and Drew, Inc., Plymouth, Massachusetts

La Consolidada, S.A., Mexico 2, D. F.

Detroit-Diamond Screw Products Company, Wyandotte, Michigan

Dominion Fasteners, Limited, Hamilton, Ontario, Canada

Elastic Stop Nut Corporation of America, Union, New Jersey

Erie Bolt & Nut Co., Erie, Pennsylvania

Federal Screw Works, Detroit 10, Michigan

Fischer Special Manufacturing Co., Cincinnati 6, Ohio

Grip Nut Company, South Whitley, Indiana

Hackensack Bolt & Nut Co., Inc., Hackensack, New Jersey

The H. M. Harper Company, Morton Grove, Illinois

John Hassall, Inc., Westbury L. New York

I.,

Haydon Bolts, Inc., Philadelphia 24, Pennsylvania

Industrial Nut Corp., Sandusky, Ohio

90
Klincher Locknut Corporation, Indianapolis 18, Indiana

KSM Products, Inc., Merchantville 8, New Jersey

Lake Erie Screw Corporation, Cleveland 7, Ohio

The Lamson & Sessions Co., Cleveland 9, Ohio

The E. B. Lanman Company, East Chicago, Indiana

Lewis Bolt & Nut Company, Minneapolis 14, Minnesota

MacLean-Fogg Lock Nut Co., Chicago 40, Illinois

Marquette Bolt & Rivet Co., Chicago 17, Illinois

The Maryland Bolt and Nut Company, Baltimore 9, Maryland

National Machine Products Company, Utica, Michigan

The National Screw & Manufacturing Co., Cleveland 4, Ohio

Northwest Bolt & Nut Co., Seattle 7, Washington

The Nylok Corporation, Paramus, New Jersey

Pawtucket Manufacturing Co., Pawtucket, Rhode Island

Payne's Bolt Works Co., San Francisco 5, California

Pittsburgh Screw and Bolt Corporation, Pittsburgh 30, Pennsylvania

R. E. C. Corp., New Rochelle, New York

Republic Steel Corporation, Bolt and Nut Division, Cleveland 13, Ohio

Rhode Island Tool Co., Providence 1, Rhode Island

Ring Screw Works, Van Dyke, Michigan

P. L. Robertson Mfg. Co., Limited, Milton, Ontario, Canada

Russell, Burdsall & Ward Bolt and Nut Co., Port Chester, New York

St. Louis Screw & Bolt Co., St. Louis 15, Missouri

Security Locknut Corporation, Melrose Park, Illinois

Shakeproof, Division of Illinois Tool Works, Elgin, Illinois

Sheffield Division, Armco Steel Corporation, Kansas City 25, Mo.

Thomas Smith Co., Worchester 5, Massachusetts

Standard Nut and Bolt Co., Valley Falls, Rhode Island

The Steel Company of Canada, Limited, Toronto 3, Ontario, Canada

Sterling Bolt Company, Chicago 10, Illinois

91
Tinnerman Products, Inc., Cleveland 1, Ohio

Townsend Company, New Brighton, Pennsylvania

Tru-Fit Screw Products Corporation, Cleveland 7, Ohio

Wolverine Bolt Company, Detroit 13, Michigan

Zimmer-Lightbody Industries, Inc., Detroit 19, Michigan

SUPPLIERS
Wire and Wire Products

Keystone Steel & Wire Company, Peoria 7, Illinois

Machinery

National Machinery Company, Tiffin, Ohio

The Waterbury Farrel Foundry & Machine Co., Waterbury 20, Connecticut

92
 INDEX
A PAGE F PACE

Automatic Feed Mechanisms, Designing Facing 46

for use of 50-52 Feed Mechanisms, Automatic,
Designing for 50-52
Fillets 32,72
B
Fins 36
Bending 45
Flattening 46
Box Milling 45
Form Turning 46
Broaching 45
Fractions and Decimal Equivalents Table .... 89

c: G

Coatings and Finishes 74, 80 Grades of Materials and Typical Properties

45 (Tables) 64-66
Coining
Cold Heading Process 17-22 Grinding 46

Collars 38 Grooving 47

Corrosion Guide and Resistance of

Typical Materials Table 86-87 II
Counterboring 45, 72
Hardness Conversion Table 82
Countersinking 45, 72
Headers, Cold 17
Cupping 35
Cold Rod 21
Cut-Off 45
Open Die 19

Reheaders 21

D Single Blow, Double Blow 19

Solid Die 19
Design Recommendations, Summary . . . .40-41
Transfer 19
Designing for Secondary Operations 45-52
Heading
Designing Parts for Heading 25-41
Advantages 7, 11
Diameters of material for heading 26
Dies
Cold 17-22
Definition 9
Life of 14

Solid and open 19 Designing Parts for 25-41

Hot 23
Dimensioning, General Notes 74
Improves Quality 12
Dimensions of Coarse Thread Series Table. . .84
Processes 17-24
Dimensions of Fine Thread Series Table 85
Produces Better Parts 11
Dimpling 35
Reduces Costs 9, 1 1
Double Heads 38
Three Extra Benefits 13
Drawings and Specifications 67-75
Heading Materials 53-66
Drilled Holes 72
Aluminum and Aluminum Alloys 60
Drilling 46
Carbon and Alloy Steels 55

Copper and Copper Alloys 59

E
Nickel and Nickel Alloys 61

Electroplating, Effect on Dimensions 77-79 Stainless Steels 57

Extrusion 33-35 Hot Heading Process 23-24

93
 INDEX (Continued)

I PAGE T PACE

Identification 37, 73 Tables

Corrosion Guide 86-87
K 35
Cupping

Knurling 37, 47, 73 Dimensions of Coarse Thread Series 84

Dimensions of Fine Thread Series 85

Edge Overhang Dimensions 52

L
Fractions and Decimal Equivalents 89
Lengths of Headed Parts 29 Grades of Materials and Typical Properties
Lugs 36 of Finished Parts 64-66
Hardness Conversion 82

M Material Grade System 54

Material Weight Conversion 83

Machines and Processes 17-24
Plating, Coatings and Finishes 80
Material Grade System 54
Point Dimensions 33
Material Weight Conversion Table 83
Tolerances 30-31
Materials for Heading 53-66
Tapers 37
Milling 47
48
Tapping
Thread Cutting 49
P Thread Rolling 48
Threads
Piercing 47
Basic Dimensions 84-85
Platings, Coatings and Finishes Table 80
Dimensioning 70-72
Pointing 47
Illustrating 70-72
Points 32, 73
Plating, Allowances for 78
Polishing 47
Tolerances 29, 69
Properties of Materials ( Tables ) 64-66
Head 30
Length 31
R
Shank 29
Ribbing 35 Tables 30-31
Trimming 49

S Turning 49

Scrap Savings 44
U
Screw Threads 70-72, 84-85

Secondary Operations 45-52 Upset Dimensioning Nomograph 28

Shaving 47

Shoulders 32 V
Slotting 37, 47
Volume of Material in Upset 26-28
Specifications 67
Volume Formulae Illustrations 88
Specifying Material 62

Sponsors of Manual 90-93

W
Swaging 48
Swell Necks 37 Weights of Various Materials 83

94
 APPLICATION INDEX
APPL. NO. PRODUCT PACE APPL. NO. PRODUCT PAGE

1. Square-shouldered Tie Bolt 10 31. Spacer Stud for Auto Clutch 42

2. Spring Holder 11 32. Control Plug 42

3. Automobile Clutch Spacer Stud 12 33. Mounting Bolt for Air Conditioner 43

4. Door Latch Rivet 12 34. Aluminum Screw 43

5. Cold-headed Bolt 13 35. Gate Valve Stem 43

6. Hacksaw Blade Holder 14 36. Industrial Chain Pin 43

7. Mounting Bolt 15 37. Power Shaft 43

8. Throttle Lever 15 38. Oval Countersunk Head Bolt 43

9. Hinge Pin for Auto Door 16 39. Head Screw for Camera 46

10. Ridged-head Lock Screw 16 40. Regulator Lever Pin for Auto Heater . . .46

11. Knurled Shaft for Venetian Blind 16 41. Rolled-thread Bolt 50

12. Shaft for Nylon Rollers 18 42. Stud for Kitchen Cabinet .'~r 50

13. Adjusting Screw for Sewing Machine. ... 18 43. Hex-head Pull Switch Armature 52

14. Steel Mainspring Plunger 27 44. Brass Dowel Stud for Battery 52

15. Screw for Model Railroad Cars 27 45. Insert Screw 55

16. Locking Stud 33 46. Auto Clutch-release Bolt 56

17. Stud for Filing Cabinet 34 47. Fluted Drive Pin 57

18. Stud for Electrical Fixtures 34 48. Spacers for Shelving 58

19. TV Antenna Stud 35 49. Hose Clamp Adjusting Screw 60

20. Center Post for Auto Cigarette Lighter. .35 50. Valve Stem 61

21. Collared Stud 38 51. Mounting Screw 62

22. Steel Knob for Sewing Machine 38 52. Steel Stud 62

23. Folding Furniture Fastener 38 53. Lock Pin for Window Frame 68

24. Knurled and Threaded Stud 39 54. Special Eye Bolt 68

25. Post for Small Transformer 39 55. Terminal for Light Switch 70

26. Terminal for Auto Oil Condenser 39 56. Stud for Typewriter Ribbons 70

27. Knurled Head Bolt 42 57. Terminal for Battery 78

28. Shifter Interlock Lever 42 58. Electric Razor Contact Pins 78

29. Rubber Grommet Insert 42 59. Special Hex Head Shoulder Bolt 79

30. Part for Electric Sweeper 42 60. Special Hex Taper Head Bolt 79

95