Fastener Manufacturing and Manufacturing Practices

New Flat Die Thread Rolling Technology

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Reprint from China Fastener World Magazine, Vol. 189

One of the delights of being an independent consultant is the wide assortment of people I meet and projects I get to review. Over the last ten years the two problems that I am most commonly approached about include skills development and thread rolling. In fact, I have written many articles in the last ten years and the one that I most frequently have inquiries about years later is related to problems in thread rolling. This is truly a step in the fastener manufacturing process that is ripe for innovation.

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Thread Rolling Machines

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Reprint from China Fastener World Magazine, Vol. 189

I started my career in the fastener industry between my third and fourth year of university. Although it’s been thirty- four years now, I can remember almost like yesterday the first time I got to walk around a fastener manufacturing plant. Of course we started in the heading department and seeing headers paying off wire and spitting out parts was very exciting, but it was the rolling operation that really left a lasting impression on me.

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Common Problems Faced by Manufacturing in Nut Processing

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Reprint from China Fastener World Magazine, Vol. 188

Nuts, like screws and bolts, are, generally, a high volume commodity. As such, the most predominant method of manufacturing them starts
with cold forming a blank. However, lower volume or large size nuts more often use hot forging or screw machining techniques. For the purposes of this article, we will limit our discussion to the cold forming manufacturing method.

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Multi-station Parts Forming: How Does a Parts Former Differ from a Nut Former?

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Reprint from China Fastener World Magazine, Vol. 187

What do Multi-station Formers Do?
Prior to considering the machine itself, we should first consider what consumers and manufacturers want from these machines. The answer to this question is pretty simple, consumers want quality parts, suited for the intended purpose at a reasonable price and manufacturers want to provide such parts with the most efficient processes or methods available. In other words, as parts become more complex and sophisticated they usually
become more challenging to manufacture. The manufacturer is motivated to remain competitive, and, therefore, must evolve their manufacturing capabilities to be as efficient as possible. Let us consider for example a high volume trimmed hex head part.

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Where Does Cold Heading Wire & Rod Come From? Part 3 – Wire Processing

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From Fasteners Technology International, October 2014

In recent years, there has been a strong resurgence of interest in the wine and spirits industry. One of the advantageous traits of many wines and other spirits is their ability, or in some cases necessity, to age in the bottle or a wooden barrel. This “aging” time transforms the wine or spirit from a drink that may be initially quite nondescript or even “nasty” to one that is of fine quality and enjoyed by the consuming practitioner.

In much the same way, hot rolled rod looks to all but the trained eye like a product ready to go into a cold header and be made into bolts. Like wine though, at this stage looks can be deceiving and a variety of unpleasant surprises may be in store for fastener manufacturers that would consider
using hot rolled rod straight from the mill.

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Where Does Cold Heading Wire & Rod Come From? Part 2 – Hot Rolling

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From Fasteners Technology International, August 2014

In the June/July 2014 issue of this magazine, we began this three-part series tracing the origins of cold heading wire and rod. In Part I, we looked at the steel-making process and how the CHQ wire and rod used in North America today mostly starts out as a combination of smelted or processed iron ore and steel sources melted in electric arc furnaces, refined and continuously cast into intermediate steel products known as billets or blooms.

It is from this point that we pick up the process. In this, Part II, of this series, we will explore how these intermediate products are transformed from a long, usually square or rectangular section of steel, to the “round” coiled rod we associate with raw material for cold heading.

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The Basics of Fastener Sorting

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From Link Magazine, Summer 2014

Over twenty-five years ago when I first started working in the fastener industry PPAP, ISO9000, and zero defects were not yet commonplace ideas. In fact, when I first started, sorting was all manual and reserved pretty much only for salvaging parts that a customer returned with a major problem. Today, it is a very different story. A large percentage of fasteners made or sold in the U.S. are sorted, with some companies serving certain industries or customers adopting the philosophy of sorting 100% of their
parts.

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Where Does Cold Heading Wire & Rod Come From? Part 1 – Steel Making

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From Fasteners Technology International, June 2014

Although our human nature is innately curious, we often simply don’t have the time to fully explore our world and accept many everyday occurrences at face value. For example, when we flip on a light switch we rarely, if ever, consider how that electricity was generated or delivered to our home. In a similar fashion, those of us who manufacturer fasteners rarely give much thought to how the raw materials we start with are transformed into a product that we can successfully cold head.

This article is the first of a three part series that looks at the origins and processes of cold heading quality wire and rod. Part one explores how steel is created today from both scrap and elemental sources and continuously cast into intermediate steel products. Part two will explore how these intermediate products are “broken down” and hot rolled to form coiled bar and rod. Part three will explore how hot rolled product is further processed into wire and rod that can be introduced and used in a cold header.

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Basics of Austempering — A Thermal Hardening Process for Fasteners over HRC40

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From Fasteners Technology International, February 2014

What do many lawn mower blades and automotive spring steel clips have in common? When considering their applications, probably very little, but in their product realization, they likely have both employed Austempering (a heat treating process) as their method for strengthening and toughening. Although over 75 years old, Austempering is a heat treating process that has really only become practically viable and commercially employed in the last 40 years. Austempering will likely never supplant conventional quench and tempering processes for the majority of threaded fastener applications, yet some of the advantages are so compelling that there will always be interest and activity in expanding the current application field. At hardness levels above 40 HRC, Austempered parts demonstrate improved mechanical properties such as toughness, ductility and strength over their quench and tempered counterparts of comparable hardness. Austempered parts undergo significantly less distortion, which reduces the subsequent cost of post heat treatment remediation.

Since this technology has direct application for the fastener industry, both now and well into the future, it is advisable for practitioners of the industry to have an understanding of the basics and enough information to consider what future possibilities might be waiting out there. The goal of this article is to provide a simplified explanation of this complex process and to explain some of its more compelling advantages.

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Heat Treating Basics – A Primer

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From Fastener Technology International, February 2013

A couple of years ago, I took up Sporting Clays, which is a shotgun shooting sport where the target, a four inch round clay disc, is presented to you in two different ways over a course composed of maybe 10 to 15 different stations. Although I am still “developing” my skills, I have found this to be a fun and challenging sport. I have enjoyed it so much that for my birthday last year my wife presented me with a year’s subscription to one of the sport’s magazines. This too I have enjoyed, but it quickly showed me, with no lack of frustration on my part, how very little I really know about the sport. I couldn’t tell you what the different target presentations are intended to represent, how competition is properly scored and for that matter what much of the terminology means.

In much the same way, when I was confronted early in my career with the process of heat treating fasteners, all but a few basic concepts that I remembered from my beginning Engineering Materials class were unknown and cloudy. As I gained more experience, asked questions, learned how parts were manufactured, saw the process and participated in the industry’s technical community, I gained clarity and understanding. However, for those not normally engaged in technical activities or those new to the industry, I imagine that much about heat treating is shrouded in mystery. Why does one heat treat a fastener? How does it work? What is some of the important terminology? This article is intended to help give some simple answers to these questions and unwrap the mystery for those that have no reason or need to hold a metallurgy or engineering degree, but desire to know a little more about fasteners.

For the purposes of this article I will limit our discussion to basic carbon steel and carbon alloy fasteners. This covers the vast majority of fasteners, but certainly not all. Many specialty and highly engineered fasteners utilize more exotic materials that have special and unique metallurgy and often complicated mechanisms to improve physical properties. The bottom line is that this topic can be studied to great depths and there is much to know, even at the simplest level. This article will only touch on the most basic of these concepts.

 

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