Bolts are a necessary component of everything from construction to the everyday devices we use in our lives. But ever wonder how these minuscule but powerful components are put together? Bolts are made by a fascinating process that involves forging and stamping to produce these dependable and robust fasteners.
The two main processes used to make bolts are forging and stamping. Every technique has specific steps and benefits of its own. Forging is the process of molding metal into the required shape using heat and pressure; stamping, on the other hand, involves cutting and shaping metal sheets into bolt shapes using strong presses. Gaining knowledge about these procedures helps us appreciate the nuts and bolts that keep our world together.
The decision between forging and stamping is frequently influenced by the bolts’ unique specifications, including size, strength, and intended application. Both techniques guarantee the bolts’ strength and ability to withstand high loads. This post will walk you through the stamping and forging procedures step-by-step, emphasizing the complexities involved in creating these commonplace but essential parts.
| Step | Description |
| 1. Raw Material | Bolts start with steel rods, which are cut to the desired length. |
| 2. Heating | The steel rods are heated until they become soft and malleable. |
| 3. Stamping | The heated rod is placed in a die and a punch presses it into shape, forming the bolt head. |
| 4. Forging | In forging, the steel is hammered or pressed into shape, making it stronger. |
| 5. Threading | The bolt is then threaded by rolling or cutting to ensure it screws in properly. |
| 6. Finishing | The bolts are cleaned, coated, or plated to prevent rust and improve durability. |
Types of bolts
Every bolt has the same shape: they are made of metal rods that vary in length, with a full or partial thread at one end and a consistent-shaped head at the other. Structures, parts, and products are fixed with the help of hardware and nuts.
Head shapes vary. There are:
- Multifaceted. This is the most common type, having a hexagon shape. This type of head can be hemispherical, with a conical headrest, with a spherical or enlarged supporting surface, with a relief groove (including a centering belt), with a slotted headrest.
- Cylindrical (terminal) with a slot for a screwdriver, two flats (including those at partial height), an internal hexagon (used for “secret” installation).
- Semi -spoke with turnkey slots and grooves under the screwdriver.
- Slotted – triangular shaped slots are placed along the outer contour.
- Semicircular with square head.
Hardware is additionally fitted with notches, holes in the head, or rods to enhance performance. A unique washer guarantees increased dependability.
Although titanium and non-ferrous alloys can also be utilized, carbon steel is the most commonly used material in the production of bolts due to their high demand.
The two main techniques used to create bolts, which are crucial fasteners in machinery and construction, are stamping and forging. Using precise dies, stamping produces uniform, effective bolts for mass production by cutting and shaping the metal. But in forging, the metal is heated and hammered into shape, producing incredibly robust and long-lasting bolts. For bolts to satisfy the various requirements of contemporary engineering and construction, both procedures are essential.
Purpose and type of connection
The application determines the kind of bolt connection to use:
- Flanged suitable for pressure vessels.
- Shoe – for heavy tracked vehicles.
- Connecting rod – in heavy structures.
- Impact – in parts that are subject to various types of loads (cyclic, static, dynamic).
Cold formed bolts
Bolts made of carbon steel are made by cold stamping. The workpiece is a unique wire rod that undergoes a 30-hour heat treatment in an oven. The additional processing step is carried out in a sulfuric acid-filled vat. The metal surface gets rid of rust when it is exposed to an acidic environment. Following a thorough washing with water, the blanks are treated with phosphate, a unique chemical compound that prevents corrosion in the finished product.
A unique lubricant is applied to the blank before it is pressed. The ideal temperature range for stamping is + 18–20 °C. There are multiple stages to the entire process. The wire rod is first lengthened and straightened on a rolling mill, after which it is sliced into pieces with a small margin that are the necessary length to form the head.
The blank is fed through a press to create a perfectly round cylinder. A head of the matching type is then stamped on different presses. The following is how the hexagon is made:
- A small protrusion is made.
- Internal pressing is performed.
- The next form is rounding the blank.
- 6 faces are created.
The thread cutting step starts when the head forms. A beveled edge is produced by a sharpening machine, ensuring precise cutting device entry and simpler nut mounting. A die (die) is a specialized tool used to create thread.
External threads are obtained on the rod during mass production, following its passage through the rollers. Hard alloy plates are also frequently utilized in devices that cut threads. As much as 300 pieces of hardware can be processed in a minute.
Every batch is calibrated, which involves choosing a few parts and verifying their specifications. A micrometer is used to measure the rod’s length, a calibre is used to measure the head’s width, and a ring calibre is used to check that the thread is correctly positioned.
Bolts are made by stamping and forging, two processes that guarantee the robustness and dependability of these crucial fasteners. Smaller, less important bolts are stamped, which is a process that involves cutting and shaping metal sheets. Bolts are produced swiftly and in large quantities using this economical and efficient method. It does not, however, provide the same degree of strength as forging.
In contrast, forging is the process of heating the metal until it becomes pliable and then using compressive forces to shape it. Bolts made with this technique are incredibly robust and long-lasting, which makes them perfect for uses where high strength is required. The bolt’s overall integrity and performance are improved by the forging process, which aligns the metal’s internal grain structure.
In the production of bolts, stamping and forging both have important roles to play, each with unique benefits based on the demands of the application. For heavy-duty applications where dependability is crucial, forged bolts are essential, even though stamped bolts are good for daily use. Knowing these production procedures makes it easier to choose the best kind of bolt for any building or remodeling project while maintaining efficiency and safety.
The decision between stamped and forged bolts ultimately comes down to the particular requirements of the project. One can make an informed choice by taking into account variables like load requirements, environmental conditions, and budget. This information improves the longevity and safety of the newly constructed or renovated structures in addition to improving the quality of the construction work itself.
