Fasteners Manufacturing Process Explained
A fastener is a simple piece of hardware that is universally used to non-permanently affix joints to two or more other items. In most cases, fasteners are utilized to create joint fixtures that are not permanent. The joints can be dismantled or removed with no harm or damage to the individual components. Conversely, an example of a permanent fixture is to create a joint by welding.
The purpose of fasteners is to hold standard fixtures in place on many items, from chairs to automobile parts. There is a diverse range of applications for fasteners. Fasteners are widely used in clothing, such as fashion hijab magnetic snaps. Fasteners are even used to regularly on things such as boxes, envelopes, or even novelty items such as a bread clip. But how exactly are fasteners manufactured?
This article will discuss the intricate process of manufacturing quality fasteners by Intact360, a well-known fasteners manufacturers India.
Processing and Inspecting Raw Materials
Initially, the fastener must begin as a concept and raw material. The manufacturer must choose the specific raw materials according to the specific use. The raw materials are then inspected and placed in a proper storage location. The storage location is essential to ensure appropriate coverage and prevent rust formation.
Manufacturing and CNC Machining
Next, unthreaded fasteners are created through the casting and forging process. At this stage, it is also possible for sintering and rapid prototyping to occur.
After all of the necessary parts have been forged and cast, it is time to pass through the CNC machine. The CNC machine cuts the unthreaded fastener into the dimensions desired. Here, the part undergoes a pointing, facing, and grooving process.
The fasteners then undergo a heat treatment process to make them more reliable and more durable. The heat treatment process consists of hardening and tempering to create a permanent part.
The process begins with hardening. The fastener is heated up to a temperature of around 850-900 degrees C. The part is then placed in the cooling media to be quenched.
Next, the fastener is re-heated to make the hardened bolt a more malleable. The re-heating process ensures that the fastener loses the undesirable brittleness, which happens during the hardening stage.
Finishing and Thread Rolling
The next step in the process is to give the fastener a surface finish. In most cases, a grinding process will create a smoother surface according to the part's specifications.
After the finishing is complete, the thread is rolled with two separate dies. One of these dies is stationary, while the other is moving. The moving die exerts pressure on the part to form the threads.
Hot Dip Galvanizing Process
A hot dip galvanizing process typically involves the following steps: A steel coil is first subjected to a degreasing process to ensure that the surface is free of oil and grease. The coil is then coated with a pickling solution.
The purpose of pickling is to remove the oxide layer on the metal surface. The pickling solution is a mixture of water, sulfuric acid, nitric acid, sodium hydroxide and other agents. There are different types of pickling baths depending on the metal being pickled.
The pickling solution is heated to a temperature of 160°F to 180°F (71°C to 82°C) to facilitate the pickling process. The pickling bath is agitated, and the pickling solution is circulated with the aid of a pump.
Coating and Inspection
The final steps in the manufacturing process are the final coating and inspection. After the threads are rolled, the bolts and fasteners are then coated to deter any rust or corrosion. An example of such a coating is a geomet coating, which is tested with a Salt Spray Test to ensure that the part lasts according to the specified number of hours listed.
Finally, upon completion of the manufacturing process, the fasteners must undergo a thorough inspection and quality spot check.
From concept to completion, the fasteners are then ready to be shipped for sale or use.
Uses of Fasteners
The vast majority of fasteners are used to join parts together. Construction, manufacturing, and repair operations of all types rely on fasteners to keep machines and other devices in working order.
The ability to repair or replace damaged or worn parts is critical to keeping these operations moving forward. Therefore, being able to find and purchase replacement fasteners quickly, and at a reasonable price, is a top priority.
Fasteners are used on a wide variety of products including cars, aerospace parts, and construction equipment. In addition to all of the uses in industry, fasteners are also used in building construction and other applications. The most common type of fastener is a screw.
Screws are available in various types, including wood screws, drywall screws, sheet-metal screws, and self-tapping screws. Also popular are nails and staples, which are used extensively in the woodworking and home construction. The head of a nail or staple is known as the nail head.
Other types of fasteners include snaps, rivets, bolts, nails, pins, staples, screws, nuts, and studs. Fasteners are used to hold objects together; they are often used in conjunction with other types of fasteners.
The most common fasteners are nails, screws, bolts, rivets, and brackets. Nails and screws are common fasteners. These may be long or short, but the length is determined by the application.
It is estimated that there are more than 1 billion fasteners in use in the United States. The most common fasteners are nails, screws, and bolts.