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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
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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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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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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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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Volume of Bolt: Volume of Head: Length of wire required: using 13.5 wire
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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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