SWEDISH COLLEGE OF ENGINEERING AND

TECHNOLOGY WAH CANTT TAXILA

Course Teacher:Dr Zaheer ul Hassan

CEP Title: Manufacturing of Screws and Nuts

GROUP NO: A8
NAME UET REG NO:
M.Saeed : 012
Muzaffar Niaz : 015
Mudassir Hayat: 041
DEPARTMENT OF MECHANICAL ENGINEERING

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 Report 1

Topic proposal
“Manufacturing of Screws and Nuts”

1.1 Introduction:
A nut is a type of fastener with a threaded hole. Nuts are almost always used in
conjunction with a mating bolt to fasten multiple parts together. A screw and a bolt (see
Differentiation between bolt and screw below) are similar types of fastener typically made of
metal, and characterized by a helical ridge, known as a male thread (external thread).

Manufacturing processes:

In principle, the following manufacturing processes are differentiated: On the one hand there
is forming without cutting and on the other, machining. With forming without cutting there is
a further differentiation between cold and hot forming. The following diagram is intended to
make the production processes clearer: Fig. N: Overview of the various production processes.

Cold forming (cold extrusion):

In modern fastening technology the majority of fasteners are made using the cold forming
procedure. In this procedure, the fastener is formed, usually in multistage processes, by
pressure forging, cold extrusion and reducing, or a combination of these procedures.

The term solid or cold forming was coined for this type of production. This procedure is
usually used for large quantities, because, from an economic aspect, it is the most rational
method.

The choice of the suitable forming machine depends on the size of the fastener and on the
degree of forming. The greater the degree of forming, the more forming stages are required.
Sharp-edged transitions or thin profiles are unfavourable for cold forming and lead to
increased tool wear. A decisive role for the quality of the final product is played by the choice
and the quality of the input material (wire).

Screw manufacturers usually receive the wire coiled on rolls that often weigh over 1000 kg.

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The wire is normally phosphate treated to enable the wire to be worked perfectly and to
minimise tool wear.

The designer of a screw or a fastener tries during development to harmonise the advantages
and disadvantages of the different materials with the requirements specified for the fastener.
With the materials differences are made, along with corrosion-resistant steels, between
unalloyed and alloyed steels. For example, if increased strengths are required, it is absolutely
essential to subject the parts after pressing to a heat treatment process in order to be able to
influence the mechanical properties specifically.

Diagram of the stages for a hexagon head screw:

Wire Descaling Intermediate Finishing Calibrating Round die sectionupsettingthread rolling

Nuts are usually produced with the cold or hot forming procedure as well. The choice of one or
the other proce- dure depends on the one hand on the size and on the other on the required
quantities.
Diagram of the stages for a hexagonal nut:

Advantages of cold forming:

• Optimal use of material
• Very high output
• High dimensional accuracy and surface quality
• Increase of strength properties through strain hardening
• Run of the chamfers in press parts in accordance with the load

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 Hot forming:

This production method is used mainly to manufacture large diameters starting with approx. M27,
and longer pieces starting from approx. 300 mm. In addition, parts are possible that cannot be
produced using cold forming because of the very small volumes, or because of a very high degree
of forming.

With this procedure, the input material (usually bars) is heated wholly or partially to forging
temperature. This heating up enables even complicated geometries or very high degrees of forming
to be realised. A typical feature for a hot-formed component is the raw surface structure. Strain
hardening is not carried out during hot forming!

Advantages of hot forming:

• Enables production of complicated geometries

• Low production runs
• Large diameters and lengths

Machining:

During turning, the required contour of

component is cut from the input material using a
turning tool. The diameter of the input material
depends on the largest
diameter of the component. Usually, bars with a length of up to 6 m are used. In contrast to cold
or hot forming, the chamfer course of the input material is destroyed.

Thread production:

Where screws are mass-produced, the thread is usually formed or rolled. In this procedure, the
screw is rolled between two rolling dies (flat dies), one of which is fixed and the other running,
and this creates the thread (see the diagram). With this type of thread production it is possible to fit
several hundred screws per minute with a thread.
The thread is usually applied before hardening and tempering. If special requirements mean
that the thread is applied after the heat treatment process, the thread is referred to as “finally
rolled”.

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Other methods for making threads:
Plunge cutting:
Tool rolls that are driven at the same speed rotate in the same direction. The workpiece rotates
without being axi- ally displaced. This method can be used to make threads with very high pitch
accuracy.

Continuous method:

The thread pitch is generated by inclining the roller axes by the pitch angle. The workpiece is given an
axial thrust and moves by one thread pitch in an axial direction, with a full rotation. Overlength
threads can be made in this way.

Thread cutting:

In this procedure the thread is made by means of a tap or a screw stock. With screws, this
procedure is mainly used for very low production runs or with machined parts as well.

However, things are different when a female thread is made. In this case the thread is usually cut
with a screw tap or taper tap.

4.1 Heat treatment

Hardening and tempering:

The combination “hardening” and subsequent “tempering” is referred to as hardening
and tempering.

DIN EN ISO 898 Part 1 prescribes hardening and

tempering for screws from strength class 8.8, and
DIN EN 20898 Part 2 prescribes it for nuts in strength class 05 and 8 (>M16), and from
strength class 10.

Hardening:

The screw is heated to a specific temperature among other things in dependence on its carbon
content and kept at this temperature for a long period. This changes the microstructure. A great
increase in hardness is achieved through the subsequent quenching (water, oil, etc.).
Annealing:
The glass-hard and therefore brittle material cannot be used in practice in this condition. The
material must be heated up again to a minimum temperature specified in the standard, in order to
reduce the distortions in the
microstructure. It is true that this measure reduces the hard- ness that was reached beforehand (but this
is much higher than the values of the untreated material), but greater ductility is achieved. This
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 procedure is an important aid for manufacturers to make screws that satisfy the requirements demanded
by users.

Case hardening:

This procedure is used among other things for tapping screws, thread grooving and self-drilling
screws. In this case, very hard surfaces are decisive, so that these screws are able to make their own
thread automatically. The screw core, in contrast, is soft.

Steels with a carbon content of 0.05% to 0.2% are used for these types of screws. The steels are
heated and kept for a long time in an atmosphere that gives off carbon (e.g. methane). The carbon
diffuses into the surface zones and in this way increases the local carbon content. This process is
known as carburisation. Finally, the material is quenched and in this way hardened in the surface
zones. This has the advantage that the surface is very hard, but sufficient ductility remains in the
core of the screw.

Stress relief annealing:

There are a number of different annealing procedures which have different effects in each case
on the micro- structure and the states of stresses in the material. One very important procedure in
the context of fasteners is stress relief annealing (heating to approx. 600°C and maintaining this
temperature for a long period). The strain hardening created on cold forming can be reversed by
stress relief annealing. This is particularly important for screws in strength classes 4.6 and 5.6,
because here there has to be a large elongation of the screw.
Tempering:
Tempering is the thermal treatment of high strength com- ponents (strengths ≥1000
MPa or hardnesses ≥320 HV) with the aim of minimising the risk of hydrogen embrittle- ment.
Tempering must be carried out at the latest 4 hours after the conclusion of the galvanic surface
treatment. The minimum temperature depends on the strength classes or on the materials that are
used.

References:

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• https://www.wuerth-
industrie.com/web/media/en/pictures/wuerthindustrie/technikportal/dinokapitel/Kapit
el_04_DINO_techn_Teil.pdf
• http://www.madehow.com/Volume-3/Screw.html
• https://www.duplexfastener.com/fasteners-nut-washer-screws-bolts-manufacturing-
process.html
• https://www.expometals.net/en-gb/hall/screws-and-bolts-making-machines