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FOR

FASTENER MANUFACTURE
BY
MANGESH R. WARAY

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DEFINITION
Metal forging process used for rapidly
producing enlarged (upset) sections on a
piece of rod or wire held in a die

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PROCESS CHARACTERISTICS
Extrusions without draft
Range of Tolerance: IT6 to 15
Normal range: IT9 to 12
Finished workpieces have improved
Grain structure
Mechanical properties
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PROCESS CHARACTERISTICS
High productivity
Full quality control
Process monitoring & methods of SPC
High material yield
Reduced material cycle
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PROCESS CHARACTERISTICS
Finished surfaces are smooth with
uniform accuracy
All ductile metals

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COLD FORGING TECHNIQUES

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STAGES IN COLD FORGING

Billet/preform production - by cropping,
shearing or machining
Upsetting to form a cheese
Annealing to restore maximum ductility
Lubrication
Cold forging
Finish machining
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SINGLE DIE HEADING PROCESS

Cut off, the wire is sheared off in pieces
with same cubic volume as the final
fastener blank shape
Preform, a blow is delivered to the
fastener blank, transforming it into a
fastener preform, or cone blow
Finish blow, a second blow reforms the
one or preform into the final fastener
geometry
Eject, or kick out
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STAGES IN FASTENER Mfg.

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SHAPES SUITABLE
Ideal parts geometry results in:
Smooth & uniform fibre structure
generally parallel with the die walls
Uniform & even distribution of forging
stresses around the die
Maximum die life without
catastrophic failure

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MATERIALS
Low carbon steel
Low carbon alloy steel.
Non-ferrous - Al, Cu, Mg, Pb, Ti, Zn, Sn,
Ni & their alloys

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ADVANATAGES
Precision cold forging of materials offers
the net/near net shape production of simple
or complex geometry parts
High accuracy gives savings on account of
material & energy (no finish machining
needed)
CAD can be used to optimize strength to
weight ratio
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ADVANTAGES
Yield & break strength increased
Harder surface & more favorable
material structure
Results in smoother surface, suitable for
surface treatment, such as zinc plating

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PRECAUTIONS TO BE TAKEN
WHILE SELECTING MATERIAL

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PRECAUTIONS TO BE TAKEN WHILE

SELECTING MATERIAL
The bolt plating material is usually the
limiting factor on maximum service
temperature
Carbon steel & alloy steel are unsatisfactory
(become brittle) at temperatures below -65 F
(-54 0C)
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PRECAUTIONS TO BE TAKEN WHILE

SELECTING MATERIAL
Series 400 SS contains only 12 % Cr &may
corrode in some environments
Contact of dissimilar materials can create
galvanic corrosion, a major problem
Hydrogen embrittlement is a problem with
most common methods of plating, unless
special procedures are used
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DIE DESIGN
FOR

COLD FORGING

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RULE 1
Limit of length of
unsupported stock
that can be upset in
one blow without
injurious buckling
is not more than 3
times the diameter
of the bar
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RULE 2
Length of the stock more than 3 times bar
diameter can be successfully upset in one
blow, provided the diameter of the upset
made is not more than 1.5 times bar diameter

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RULE 3
In an upset
requiring more than
3d in length when
the diameter of the
upset is 1.5d, the
amount of
unsupported stock
beyond the face of
the die must not
exceed 1d of the bar
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MATERIALS FOR DIE BLOCKS

Heat resistant
Adequate strength
Low wear rate
Machinability
Typical material: Carbide

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GOVERNING FACTORS FOR

MACHINE SELECTION

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 Volume of the stock required in

the finished forging

Size of the stock used
Maximum dimension of the
finished forging
Number of blows necessary to
complete the forging
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DESIGN OF BOLT (CASE STUDY)

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Material Class: 8.8

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Material class 8.8 stands for

8 x 8 = 64 640MPa yield strength
800MPa ultimate tensile strength
Carbon steel with additives (e.g.
Boron, Mn, Cr) quenched & tempered

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STAGES IN MANUFACTURING A
FASTENER

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Volume of Bolt:

4130 mm3

Volume of Head:

2945.24 mm3

Length of wire required:

29 mm

using 13.5 wire

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Why 13.5 & not 7.9 wire?

Extrusion ratio with 13.5 =
with 7.9 =
Permissible limit

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24.29%
90.1%
70 %

Why 13.5 & not 7.9 wire?

Upset ratio with 13.5 =
with 7.9 =
Permissible limit

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70.84%
90%
70 %

Company visited
Mini Nuts
Bangalore

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CONCLUSION
To conclude we can say that this is a
very cost effective process as compared
to other manufacturing processes for
fasteners, as.

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THANK YOU

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