Pogled unutar procesa proizvodnje vijaka

Bolstering strength and reliability is paramount in engineering, and the production of screws plays a crucial role in realizing these attributes. Often produced through techniques such as cold forming, hot forging, and machining, the ways in which screws are manufactured significantly affect their functionalities and efficiency in applications. Understanding this production process is crucial for engineers, manufacturers, and builders alike.

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Screw Production Process: A Step-by-Step Guide

Now, let’s take a closer look at one of these screw production processes in action. As mentioned, we primarily use cold forming at Wilson-Garner, so we will take a cold-formed screw as an example.

The screw we will examine here is a hex flange screw with a diameter of 1, made from alloy steel. Here are the seven steps we take to produce it, along with images from the production process. Note that this part requires several additional steps in the manufacturing process due to its shape and diameter.

1. Cutting

Our team takes steel rods and cuts them to length.

2. Extrusion

This is our first hit. By striking each piece of cut material (one at a time) within a large press, we reduce the diameter at one end to the specified thread diameter. This is where the threads will form in the next step.

The other end (with a larger diameter) is where the head of the screw will be. During this step, there is a slight increase in diameter to prepare for the next hit.

3. Upsizing

This is our second hit, where we again strike the material within the press (also one at a time). The goal here is to increase the head end of the screw to prepare it for the final hit that will shape it. Typically, material does not flow well enough to be formed in just one strike.

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4. Head Shaping

This is our third hit, also performed one at a time in the press. The hexagon, flange, inconsistencies, and markings of the head are all formed during this stage.

5. Trimming

This is our fourth and final hit. It is performed in a trimming press, one at a time. At this point, the flange is trimmed to make it flat and round.

6. Thread Rolling

During this phase, we roll the threads of the screw. While some manufacturers may opt to cut threads, at Wilson-Garner, we adhere to rolling threads. Rolled threads are typically sturdier, more precise, and waste fewer resources.

The threads are added using a thread rolling die, again one at a time. This is a very intense part of the screw production process.

Once all the threads are rolled, the screw is dimensionally complete and ready for final dimensional inspection. At this point, our team ensures all dimensions are within tolerance.

7. Finishing

During this phase, we send the screw (and all other items in the order) to a partner for heat treatment, blasting, and zinc plating. We do not perform finishing or zinc plating in-house at Wilson-Garner.

After the screws have undergone heat treatment, blasting, and zinc plating, we return them, and they are nearly complete. However, before they are ready for packaging and delivery, we roll the threads again. This step is conducted to remove any scratches or bumps that may have occurred during heat treatment or zinc plating, and to ensure the threads measure correctly.

From there, the screws undergo final inspection to ensure everything is as it should be. Then it's time for packing and shipment!

Looking for a Quality Screw Manufacturer? Choose Wilson-Garner.

Wilson-Garner is your reliable source for high-quality, custom fasteners in limited runs. Our manufacturing and testing processes ensure you receive the precise fasteners you need, every time. If you require a screw, bolt, or nut produced to your specifications, please contact us! We would love to discuss how we can assist you.