博萨培训-螺钉生产

1、Fastener Manufacture ProcessWelcome to Bossard SeminarSurface TreatmentHeat TreatmentThread RollingCold Head/Hot ForgingRaw MaterialPackingInspectionFastener Manufacture Process如资料为不锈钢,到此步骤即可.Raw Material.Raw MaterialDesignated area for different types of steel.Types of steel indicated by colourRaw

2、Material.Tags showing:- The manufacturer- The heat number- The dimension- The weight- The Carbon contentRaw Material.Wire Material Control:- Wire diameter- General aspect- Hardness- Hardenability- UTS- DecarbonRaw Material.Raw Material.Phosphating bathRaw MaterialBaths controlRegular cleaning.Phosph

3、ated wires.Wire calibrationRaw Material.普通螺钉三角头自攻螺钉.Cold Heading/Hot Forging.Hex Head Cap Screw Forging Sequence 4 StnCUT OFF STN1ST STN2ND STN3RD STN4TH STNCold Heading.Cold Heading.Cold Heading.Cold Heading.In process controlCold Heading.Hot Forging.Hot forgingBars heatingHot Forging.Hot ForgingOv

4、er 25 mm Diameter.Thread Rolling.THREADS ROLLINGA PROCESS OF FORMING THREADS WITHOUT REMOVING THE MATERIALFLAT THREAD ROLLINGPLANETRYY THREAD ROLLINGCIRCULAR THREAD ROLLINGSEGMENTAL CIRCULAR THREAD ROLLINGThread Rolling.1 Flat rolling dies2 Segmental rotary rolling dies 3 Two rolls one supporting le

5、dge4 Three rolls Thread Rolling.FLAT THREAD ROLLINGSTATIONARY DIEMOVING DIEBEFOREAFTERFor moderate production, CG 1,2,4 (partly),5,9,10 & 11,1290 % products from catalogueThread Rolling.CIRCULAR THREAD ROLLINGCIRCULAR ROLLING DIE 2 NOS.Low production rate, suitable for Odd head shape CG 4 (e.g. BN 2

6、53,256,276,278,258 & above M24 & critical auto parts)Thread Rolling.Thread rolling after heat treatmentHorizontal thread rolling is mainly used to form thread after heattreatment, process is very precise but slow and not fit for large quantitiesThread Rolling.SEGMENTAL CIRCULAR THREAD ROLLINGCIRCULA

7、R ROLLING DIE 2 NOS.STATIONARY DIEROTATING DIE3 TO 4 PIECES AT A TIMEFor M/c screws, CG 5Thread Rolling.Planetary Thread rolling.Thread rolling Set up thread rolling:5 samples are checked by QC.In-process control5 samples/15 mn (No record)Recorded values: every 1 hour (min-max).Heat Treatment.LPSHEA

8、T TREATMENTA COMBINATION OF HEATING & COOLING OPERATIONS TO OBTAIN DESIRED PROPERTIESHARDENING HEATING & QUENCHINGTEMPERINGHeat Treatment.HEATINGHEATING THE MATERIAL ABOVE AUSTENISATION TEMPERATURE & SOAKING AS PER CROSS SECTIONQUENCHINGRAPID COOLING OF AUSTENISED MATL.?IMMERSING IN OIL OR WATERMART

9、ENSITIC TRANSFORMATION RESULTING INTO INTERNAL STRESSESHeat TreatmentFor 8.8 and above 820 to 900 Degree C.LPSTEMPERINGHeating Hardened material to specific temp. much below austenisation temp. for specific desired properties?Immediately after QuenchingREDUCES INTERNAL STRESSES & ALSO REDUCES HARDNE

10、SSHEAT TREATMENT PROCESS FOR 8.8 & ABOVE45010 Degree C.Fasteners of various grades made out of different steelsAt room temp. the Material is in Pearlite (Lamellar)/Spherodised & ferrite formQuenching Fast CoolingHard Martensite (accicular) Structure, Brittle, not suitable for useTemperingTempered Ma

11、rtensite Structure, product suitable for useFurnace Having three zones, Controlled atmosphere of endo Gas available from gas generator,cracked gas (LPG: Air: 1:10)Heating to austenising temp. of 820 to 900 degree C, temp. controllers provided123Austenitic Structure as a result of heatingHEAT TREATME

12、NT PROCESS FLOW CHART.LPSDEGREASING & WASHINGHEATING IN FURNACEOIL QUENCHINGDEGREASING & WASHINGTEMPERINGQUENCHING IN CUTTING OIL FOR THERMAL BLACK & RUST PREVENTIVE OILDRY MATERIALPLATING LINEPHOSPHATINGAll Other CoatingsHEAT TREATMENT PROCESS FLOW CHART.Heat TreatmentHeat Treatment Equipment.Heati

13、ng for quenchingHeat Treatment.Heat TreatmentQuenching (Oil or Water)TemperingHeat Treatment.Heat treatment:Long or large bolts must be carefully handled.Heat TreatmentIn process control:Tensile testProof loadHardnessHeat Treatment.Surface Coating.Against CorrosionSurface CoatingZinc Plating Process

14、电镀工艺Mechanical Plating Process机械镀锌工艺Dacromet Coating Process达克罗工艺HDG Process热浸锌工艺最小M6,也有M4的最小M12,附着力最好.DacrometGeometOrDeltatoneZinc PlatedHDGMechanical PlatingSurface Coating.Zinc Plating + PassivationElectroplated Coatings1Electroplating ProcessZinc platingZincPassivation (yellow, blue.)2Chemical

15、ProcessCr(III)Cr(VI).Electroplated Coatings.1432Coatingprocess:Dacromet coating of fasteners2 Sand- blasting3 Dip- Spin coating4 curing at 340C1 DegreasingLPS.MECHANICAL PLATINGPlating Barrel.Glass Beads- Impact MediaMECHANICAL PLATING.MECHANICAL PLATINGSMALL DRYING UNITLARGE DRYING UNIT.PHOTOGRAPHS

16、 OF HOT DIP GALVANIZING PLANT.Bars are shot blasted prior to hot dip galvanization.Pre-heating prior to HDG(80 to 120).HDG Low Temperature (2 to 3 mn) 450 C +/- 5 C.Thread tolerance 6az before HDG (undersized thread)Thread tolerance 6hafter HDGCapacity HDG: 800 mm max.Spinning after hot dip galvanization (2 sides)Thickness: 60 to 80 micronsHDG bath.Cooling into water+ passivation Cr 3+ (Appro