Vocational Training on

Screw Manufacturing
at
SAMRATH FASTENERS

submitted by:
Ankur Thangry – CO17114
Introduction
 SCREWS ARE GENERALLY MADE FROM LOW TO MEDIUM CARBON STEEL
WIRE.
 BUT OTHER TOUGH AND INEXPENSIVE METALS MAY BE SUBSTITUTED,
SUCH AS STAINLESS STEEL, BRASS, NICKEL ALLOYS, OR ALUMINIUM
ALLOY.
 HE COLD HEADING MACHINE CUTS A LENGTH OF WIRE AND MAKES TWO
BLOWS ON THE END, FORMING A HEAD.
 IF A FINISH IS APPLIED TO THE SCREW, IT MUST BE OF A COMPATIBLE
MAKEUP.
 STEEL MAY BE COATED OR PLATED WITH ZINC, CADMIUM, NICKEL, OR
CHROMIUM FOR EXTRA PROTECTION.
 MACHINING IS ONLY USED ON UNIQUE DESIGNS OR WITH SCREWS TOO
SMALL TO BE MADE ANY OTHER WAY.
 THE MACHINING PROCESS IS EXACT, BUT TOO TIME CONSUMING,
WASTEFUL, AND EXPENSIVE.
COLD HEADING

 Wire is fed from a mechanical coil through a prestraightening machine.

 The straightened wire flows directly into a machine that automatically cuts the
wire at a designated length and die cuts the head of the screw blank into a
preprogrammed shape.
 The heading machine utilizes either an open or closed die that either requires one
punch or two punches to create the screw head.
 On average, the cold heading machine produces 100 to 550 screw blanks per
minute.
 Heading is a metalworking process which incorporates the forging, extruding and
upsetting process.
 This process typically produces a near net shape work piece, which means the
final product is almost finished although it can sometimes create the final product
less plating or heat treating.
 An important consideration in heading is the tendency for the wire to buckle if its
unsupported length to diameter ratio is too high.
 This ratio usually is limited to less than 3:1 but with appropriate dies, it can be
higher.
THREAD ROLLING

 Once cold headed, the screw blanks are automatically fed to the thread- cutting
dies from a vibrating hopper.
 The hopper guides the screw blanks down a chute to the dies, while making sure
they are in the correct feed position.
 The blank is then cut using one of three techniques.
 In the reciprocating die, two flat dies are used to cut the screw thread.
 One die is stationary, while the other moves in a reciprocating manner, and the
screw blank is rolled between the two.
 When a centerless cylindrical die is used, the screw blank is rolled between two to
three round dies in order to create the finished thread.
 When a centerless cylindrical die is used, the screw blank is rolled between two to
three round dies in order to create the finished thread.
 The final method of thread rolling is the planetary rotary die process.
 It holds the screw blank stationary, while several die-cutting machines roll around
the blank.
 All three methods create higher quality screws than the machine-cut variety.
 This is because the thread is not literally cut into the blank during the thread-
rolling process, rather it is impressed into the blank.
 Thus, no metal material is lost, and weakness in the metal is avoided. The threads
are also more precisely positioned.
 The more productive of the thread- rolling techniques is by far the planetary
rotary die, which creates screws at a speed of 60 to 2,000 parts per minute
HEADING MACHINES

 Heading machines produce screws, semi-tubular and fully tubular rivets, bolts,
special fasteners.
 Parts with very complex shapes starting from drawn wire in coils can also be
formed .
 The 2-die, 4-blow machines are particularly suitable for components whose heads
have a very large volume or components where two dies are sufficient, but at least
three blows are needed, such as Allen screws or trimmed components
 An advantage of these machines is the third blow can often be used as an
introductory punch if parts with large heads and a short shank have to be
transformed.
HEADING MACHINES
1. H15-63-BP BY EDISON
 Wire Diameter : 2.3¬5.0
 Screw Length : 6mm¬63mm
 Production : 130¬150 pcs/min
 Add on Equipment's : Sensor , Light Stand , Conveyor

2. 248 E 2 Die 4 Punch Heading Machine

 Min. wire diameter: 4mm steel, 4mm titanium
 Max. wire diameter: 12.5mm steel, 10mm titanium
 Max. shank length: 82mm
THREAD ROLLING MACHINES
 Thread rollers come in a variety of types and sizes, but they all use a mechanism
where hardened steel dies are matched and set to penetrate with force in order to
reshape the material surface of a round diameter into a thread form. A cylindrical
work piece or blank is fed into the machine (manually or automatically) and the
dies rotate (cylindrical dies) or reciprocate (flat dies) in order to produce threads
in a “chipless” forming process. Every thread form, shape, and size has a unique
set of dies which are typically ground from heat treated tool steel and procured,
rather than made in-house.
 A horizontal two die process is suitable for both infeed and thru-feed rolling.
EXAMPLES OF THREAD ROLLING MACHINES
1. 6R-65 BY EDISON
 Size Range : 5.5
 Screw Length : 65
 Production Speed: 150~180~210pcs/min
 Add on Equipment: Metal Pieces Separating Machine 
o Feeding Size: 6.5x105 
o Rolling Wheel Size: 45x600
o Gear Motor: 60W 1:10
o Machine Weight: approx. 32KG
2. TX-6R BY TAISHIN
 The machines are designed for precise machining of all types of screw thread
conforming to the Metric, BSW, UNC, UNF, Japanese system, American system
HEAT TREATED FASTENERS

 High-strength or heat-treated fasteners are often required to handle the tensile,

shear or combination loads on the bolted joints in demanding applications.
 Structural anchor bolts are made of carbon or fully heat- treated medium alloys.
 Heat-treated fasteners are also essential in engine, vehicle and hydraulic
applications where bolts and fasteners are under high stresses.
 Environmental considerations such as temperature and corrosive media are an
additional factor that will impact a project.
HEAT TREATMENT PROCESS
 Heat treatment includes a wide range of processes.
 Some heat treatments like annealing soften a metal, while others harden and
strengthen.
 Annealing heat treatments are used to relieve residual stress, remove cold work
and dissolve the alloying element or segregation and provide a more
homogeneous material.
Quench & Temper Hardening Process
 In the quench and temper hardening process, steel fasteners are first heated up to a
temperature where their structure is converted into austenite.
 then quenched or rapidly cooled in water, oil or air to crystal structures that
transform to martensite.
 Next, the martensitic steel fasteners are heated at an intermediate tempering
temperature to change the martensite to ferrite, with a very fine dispersion of
cementite.
 Steels cooled slowly from austenitizing temperatures, as well as nonhardenable,
low carbon grade steels, form a softer, coarser pearlite structure of ferrite and iron
carbides (cementite)
 The cooling rate has to be fast enough to avoid the formation of pearlite.
Case Hardening Process
 Case hardening is a process for hardening a surface or “case” layer of low carbon
and alloy steels.
 The steel is first carburized, or carbonitrided, to increase the carbon content in the
outer layer
 The martensitic steel fasteners are heated at an intermediate tempering
temperature to change the martensite to ferrite, with a very fine dispersion of
cementite.
 Steels cooled slowly from austenitizing temperatures, as well as nonhardenable,
low carbon grade steels, form a softer, coarser pearlite structure of ferrite and iron
carbides
 The cooling rate has to be fast enough to avoid the formation of pearlite.
PHOSPHATE CONVERSION COATING

 Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as
a foundation for subsequent coatings or painting.

 It serves as a conversion coating in which a dilute solution of phosphoric acid and

phosphate salts is applied via spraying or immersion and chemically reacts with
the surface of the part being coated to form a layer of insoluble, crystalline
phosphates.

 Phosphate conversion coatings can also be used on aluminium, zinc, cadmium,

silver and tin.
THANK YOU