Fasteners Manufacturing By Rupal Jyotishi

Fasteners Manufacturing

Rupal Jyotishi…

Fasteners Manufacturing By Rupal Jyotishi

Manufacturing process flowchart

Wire Drawing Forming Threading Heat

Treatment FinishingPackaging

& Dispatch

Bolt forming

Fasteners Manufacturing By Rupal Jyotishi

Manufacturing process flowchartNut forming

Wire Drawing Forming Tapping Heat

Treatment FinishingPackaging

& Dispatch

Fasteners Manufacturing By Rupal Jyotishi

Module 1.1Raw Material Handling

Note:- “Before starting this we need to identify few areas...”& for this I designed a “Level 1 –Technique” _write me on rupaljyotishi@gmail.com to get a copy of “Level 1-Tech” ..

Fasteners Manufacturing By Rupal Jyotishi

Fastener Material..• There is no one fastener material that is right for every environment. Selecting

right material from vast array of material is important from technical and commercial perspective.

• Apart from the cost and availability, careful consideration may need to be given to strength, temperature , corrosion, vibration, fatigue and many other variables.

Fasteners Manufacturing By Rupal Jyotishi

Terms Used to describe the Strength of Fastener Material Are:-

1. Tensile strength 2. Yield stress 3. Proof load stress4. Ultimate tensile stress5. Fatigue strength 6. Tensional strength 7. Hardness8. Ductility9. Toughness

Fasteners Manufacturing By Rupal Jyotishi

Mechanical Properties…

• Tensile Strength:- is an expression of the maximum capacity of a particular material to stretch under tensile load , prior to failure.

Its normally expressed in :- Pound/Tons - inch terms Kilo Newton – metric terms

• Yield Stress:- is an expression of the theoretical point of stress (pressure) beyond which the material losses its elasticity and becomes permanently stretched.

Its normally expressed in :- ibf/ in2 - inch term N/ mm2 - metric terms

Fasteners Manufacturing By Rupal Jyotishi

• Proof Load Stress:- is an expression of the minimum stress a material must achieve, prior to permanent elongation and, the stress which would be applied to test and re-measure a specific fastener to prove it had not permanently stretched and that it will carry the required load.

Its normally expressed in :- ibf/ in2 N/ mm2Approximately between 80% and 90% of the theoretical yield stress.

• Ultimate Tensile strength:- is the theoretical minimum point at which the material will fracture. It is expressed in the same terms as yield stress and proof load stress.

These properties used to calculate the Proof Load and Breaking load for each diameter of each grade or class of product.

Its normally expressed in :- Pounds force - inch terms Kilo Newton (KN)- metric terms

Mechanical Properties…(cont.)

Fasteners Manufacturing By Rupal Jyotishi

• Fatigue Strength:- is a maximum stress a fastener can withstand for a specified number of repeated cycles prior to its failure.

• Torsional Strength:- is a load usually expressed in terms torque, at which fasteners fails by being twisted of about its axis.

• Ductility:- is a measure of the degree of plastic deformation that has been sustained at fracture. In other words , it is the ability of material to deform before it fracture.

• Toughness:- is defined as a material’s ability to absorb impact or shock loading. Impact strength toughness is rarely a specification requirement.

Mechanical Properties…(cont.)

Fasteners Manufacturing By Rupal Jyotishi Stress-Strain………

Fasteners Manufacturing By Rupal Jyotishi Stress-Strain Diagram:-

Fasteners Manufacturing By Rupal Jyotishi

Material used in Fasteners Manufacturing

AlloyBrass

BronzeAluminumMagnesiumLow carbon

Stainless steel

Fasteners Manufacturing By Rupal Jyotishi Stainless steel….

• Stainless steel is a family of iron-based alloy that must contain at least 10.5% chromium . The presence of chromium creates an invisible surface film that resists oxidation and makes the material “passive” or corrosion resistant.

Stainless steel can be simply and logically divided into three classes on the basis of their microstructure:-

Austenitic :-* 300 series contains nickel * Not heat treatable * Strength through cold-working

Martensitic :-* 400 series contains no nickel* Responds to heat treat Ferritic :-* 400 series (430)contains no nickel* Not heat treatable * Strength through cold working

Fasteners Manufacturing By Rupal Jyotishi

Stainless Steel 302• Most common grade available in HQ (with Cu)• Excellent salt spray resistance• Strength as received 75 ksi (app. 517.10 Mpa)• Work hardenable to 110 ksi (app. 758.42 Mpa )• Becomes slightly magnetic when cold worked• Tendency to gall

Note:- 1 ksi=6.89 Mpa

• Common heat treatable grade used for high strength• Hardenable to range 35-45 HRC• Magnetic• Average corrosion resistance• High K factor• Similar corrosion resistance to heavy zinc plating

Stainless Steel 410

Fasteners Manufacturing By Rupal Jyotishi

Aluminum

• Common alloys are 2024,6061 and 380 (for casting)• Tensile strength range from 45 ksi to 75 ksi• Softness can cause some heading problems (build-up vs wear)• For grade 8 fasteners consideration needs to be given to under head bearing stress

to reduce embedment*• When used with stainless steel screws aluminum has a high probability of galling.• If aluminum is combined with stainless steel in a corrosive environment, the

aluminum will corrode due to galvanic action.

*(Embedment is a phenomenon in mechanical engineering in which the surfaces between mechanical members of a loaded joint embed)

Fasteners Manufacturing By Rupal Jyotishi

Magnesium

• Very good strength to weight ratio• Very low formability • High galling tendency• Tensile strength around 40ksi• Strongly attacked by galvanic corrosion.

Fasteners Manufacturing By Rupal Jyotishi Carbon Steel

Majority of fasteners manufactured are out of steel. Steel is readily available, less expensive, excellent workability, offers a wide range of attainable strength properties.

• Low carbon steel:-Contains less than 0.25% carbonSome are heat treatable (Generally boron based low carbon steels)Most commonly used AISI 1006-1022

• Medium Carbon Steel:-Carbon contains 0.25% to 0.60%Heat treatableMost commonly used AISI 1030,1035,1045 and 1541

• Alloy Steel:-Steel with one or more mix elements./ <2% carbon etc.Heat TreatableMost commonly used AISI 4037,4140,4135 and SCM435

Fasteners Manufacturing By Rupal Jyotishi

Processes of Material Handling..

Raw material handling in a fasteners industry contains several steps before going to next operation as input. The processes are:-

1. Pre-cleaning2. Phosphating3. Wire drawing4. Annealing 5. Storage by assigning color code

Fasteners Manufacturing By Rupal Jyotishi

Wire Process…

Input •CHQ wire•CHQ Bar

Pickling •H2SO4 & HCL •Hydro Lime

Drawing•By using drawing machine

Annealing•To remove internal stress /increase ductility/soften the material

Pickling & Coating •To remove scale (if any) and coating(phosphating) for corrosion resistance

Finished lots•Send to raw material inventory by assigning colour coding

Fasteners Manufacturing By Rupal Jyotishi

For detailed description of these processes, you can write an email to me on _ rupaljyotishi@gmail.com

1.Pre-cleaning2.Phosphating3.Wire drawing4.Annealing 5.Storage by assigning color code

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Fasteners Manufacturing By Rupal Jyotishi

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