Self-tapping screws production

2 Optional equipment

In the production of nails, in addition to the main apparatus, it is recommended to purchase a tumbling machine. Such a device provides cleaning of the resulting nails from cutting, rust and sharp edges. In addition, such a device effectively polishes products.

Drum for tumbling nails

The tumbling machine consists of a loading device, a drum for tumbling, a drum designed for screening sawdust and a vibrating sieve. Cleaning of manufactured products is carried out using sawdust

When choosing a tumbling device, you need to pay attention to the ranges of diameters of the processed products, the permissible length of the workpiece, productivity, sawdust consumption, weight and dimensions

A machine can also act as an auxiliary equipment, which provides sharpening of a cut-off knife. If you plan to produce not only a smooth look of nails, but also all kinds of fasteners that require circular and screw knurling, you need to purchase a rolling unit.

2.1 How to avoid manufacturing defects?

If the products are crooked, then there is a need to align the straightening rollers. This must be done in such a way that the wire fed to the knife is in a horizontal position. It is also recommended to periodically lubricate the internal feed rollers to prevent chip clogging.

When a large number of bent products are received, the bevel angles of the chopping knives change by 10 degrees up or down.

If the workpiece kinks under the head, this may be due to the clamping jaws moving away from the center of the wire feed. In such cases, it is necessary to fine-tune the clamping dies or replace them with new ones. The reason for the incorrect operation of the machine may be the clogging of the ram box.

Automatic nail making machine in a small workshop

To prevent blockages, it is necessary to lay out a small soft piece of rag in the places where the clamping dies touch. If the nails are of different lengths, then the feed cutter must be adjusted so that the sharpening angle is 80 degrees. You can also apply a stronger tension to the spring that takes the knife away or completely replace it.

In this case, it is necessary to adjust them so that their rotation is easy and the bending of the feeding wire is not too strong.

If the head of the made nail is knocked down, then you need to make sure that the plane of the bed and the die box are in the same vertical position. It is also necessary to check the gaskets under the top bar and add them if necessary. If the backlash is not eliminated after this, then the strips should be replaced with new ones.

Self-tapping screw production technology

Technological processes in the production of self-tapping screws begins with the selection of a suitable steel, it can be carbon, brass, stainless. Raw materials are purchased at specialized metal rolling mills, in the form of a rod or wire. The production of self-tapping screws is similar to the production of nails, but the process differs in some nuances and equipment requirements. The manufacture of self-tapping screws requires specially prepared equipment, it occurs in stages:

• A blank is created from a metal wire of the required diameter. The length of the workpiece must correspond to the finished product; cold heading equipment is used to make the head.
• Before threading, the self-tapping blanks go into the hopper, where they are prepared for transfer to the machine on which the thread is applied.
• The parameters of strength, endurance of self-tapping screws, in accordance with the declared indicators, are achieved by hardening in a furnace. The temperature reaches over 900 degrees, then the stress of the metal is released in the furnace with a lower temperature.
• The anti-corrosion properties of an almost finished product are achieved by immersing them in special baths, the galvanic coating is applied in stages, and at the end it is treated with electrolyte from zinc anodes to fix the result.

In the production of screws, a centrifuge machine is used for drying, after which you can see the finished product. The size of production affects only the throughput of the machines and machine tools used, control over the quality of products, the production process, can be carried out by one person.

Chinese and domestic machine tools

Russian manufacturers are trying to match their Chinese counterparts in the development of this equipment.

You will find interesting offers in PJSC Kupra, LLC Avto, CJSC Monolit, LLC Technoservice Krasnaya Zarya and LLC SAMSTAL. Chinese devices - Candid and INNOR also managed to establish themselves with our customers.

For example, for novice businessmen, you can offer a budget Chinese model, it even fits in the garage. The work process is semi-automatic, so you will have to hire an operator. The number of products made per minute is only 25. But this machine also has advantages:

• cost about $ 3000;
• the settings provide for the manufacture of different products: self-tapping screws, screws, bolts.

However, prices for Chinese, fully automatic, cold-heading and thread rolling machines can go up to $ 150,000.

Therefore, before starting a manufacturing business, research the market thoroughly. Identify the positions that are in demand and think about how you want to organize the processes for the manufacture of self-tapping screws. The need to purchase equipment of limited specialization or organize a full-fledged production line will depend on this.

The construction market is now on the rise, but even during the economic crisis, the demand for such products will remain, because repair work is carried out regardless of the economic situation in the country. We recommend that you look at existing manufacturers of self-tapping screws and conduct competitive intelligence.

22.01.2020

Necessary equipment

The price of production equipment for self-tapping screws is high, so it is necessary to carefully study the design, performance. There are many models on the market, the price range varies from destination, country of origin, speed of production. The most common device is a line for the production of self-tapping screws, where metal blanking, threading and making a cap, drying and galvanic processing are carried out.

Self-tapping line

Machine performance is matched to production needs

There are various automatic models that produce from 30 to 300 screws per minute, it is important to understand that the price of the device depends on this indicator. Control over the quality of products, the technical condition of the equipment is carried out by trained operators

The number of people in production depends on the size of the line and the work plan.

Drawing machine

Carries out the preparation of rods at the initial stage of the process. Production begins with a furnace with die holes through which the wire passes and decreases in diameter. Drum-type raw material is used for the process, as it is easy to install in the seats. For long-term use and compliance with temperature conditions, the equipment is cooled with a cutting fluid.

Cold heading equipment

The main work of a cold heading machine for self-tapping screws is the manufacture of hats and special holes on them for working with a tool.Before processing, the raw material is divided into a uniform number of products, then the self-tapping head is formed.

Cold heading machine

Cold heading equipment requires adjustment, technical maintenance. Correct alignment of all systems will allow you to achieve a high-quality self-tapping screw at the exit, which is convenient for the client. The equipment controls the supply of raw materials automatically, then after the work, it dumps it into a hopper or basket.

Thread rolling machine

The equipment is equipped with a small conveyor with fixing elements. Further, the workpiece is processed with dies on both sides. The knurling elements are adjusted according to the available stroke, this happens when changing the type of part. The pitch, shape and number of turns on the product completely depend on the element used, the correct setting. Each variety requires a separate, removable tool.

Hardening equipment

After the above processes, the product looks finished, but is not applicable to use. Self-tapping machines are not capable of working with solid products, so hardening occurs at the end of the process. The hardening furnace is adjusted at a temperature of about 900 degrees, after the process, the products are placed in a furnace with a low degree.

Hardening furnace

Due to the temperature drop, the metal relieves stress, is less prone to kinks. After hardening, washing is carried out to clean the finished product from traces of dirt and carbon deposits, and also cooling takes place.

Electroplating equipment

Electroplating is necessary for anti-corrosion properties, increased mechanical parameters of self-tapping screws. The process is carried out using several baths with different solutions, the processing of the part in which is carried out sequentially. The initial stage is immersion in a bath with a degreaser, then phosphate solution is applied, then oxide solution, etc. After all treatments, water is rinsed, zinc coating is applied under electrical influence.

Drying and packaging machines

A drum with a centrifuge is used to dry the finished product; the work is done according to the principle of a washing machine. For packaging, bags are used with the possibility of packaging several dozen pieces. In the wholesale trade, packaging is carried out in boxes or other metal containers.

Features and service

AG4116 can be called one of the most popular conveyors. The work uses steel wire with a diameter of 0.8–8.0 mm. It is sold in reels from 5 to 1000 kg. This version weighs about a ton, has dimensions of 195x116x106 cm, and is equipped with a three-phase asynchronous squirrel-cage motor (4A112M4U3). The device's performance reaches up to 500 units. products per minute. Also on this installation, you can use galvanized metal threads. It is noticeably strong and resilient.

Azov cars also have excellent performance:

• length, width and height of the structure - 150x190x110 cm;
• weight - 2900 kg;
• electric motor - 5.5 kW;
• volumes per minute - 525 pcs.

This machine for the production of nails produces construction hardware with a circumference of 0.5 cm and a length of up to 15 cm. A distinctive feature of this mechanism is the adjustment of the longitudinal size of the rod. For its full functioning, as for most conveyors, a voltage of 380 V is required.

Some prototypes of this technique vibrate strongly when turned on.

Therefore, it is important to place it correctly on the floor.

An easier approach is to use washers that dampen vibration. If this is not done, the constant vibration will loosen the bolts and the nailer will eventually become unusable.

The maintenance procedure also includes the lubrication of the operating elements: there is a lubrication chart on the panel, which indicates all the places for filling with specialized oil.This must be done so that the moving links of the apparatus do not jam.

Advantages and Disadvantages of Nail Press Machine

Pressing machines have higher productivity, but require frequent replacement of dies and jaws. High loads on the forming elements of machine tools lead to their rapid wear.

Pressing machines are arranged in a similar way, but instead of a hammer, a stamp is installed in them, which forms the head of the nail by gradual pressure. The stamp is driven by a curly washer or an eccentric. In the opposite direction, the wire is fed forcibly (in contrast to impact machines, where it occurs under the action of a spring). This design increases productivity by almost 2 times. In pressing machines, production waste is about 3% of the weight of the wire used. These are "petals" and marriage.

Machine tools for the production of self-tapping screws at home

The range of machines is wide enough. You can pick them up at an affordable price with little productivity. Alternatively, you can purchase equipment that will produce a large number of hardware per shift.

The cheapest equipment for the production of self-tapping screws

The most interesting machine for home business is the Candid model AS3016. This is a semi-automatic machine for the production of hardware screws screws screws. Its price starts at $ 3000. But in such cases, you will have to sacrifice productivity, which is only 25 pieces. per minute

Please note that the machine is semi-automatic, which means that some operations must be performed by the machine operator. But if you are new to this industry and are just starting to get to know the market of screws and self-tapping screws, then you should think about purchasing a budget model such as the Hangzhou Candid AS3016

Industrial business equipment retains its value very well. By investing in it, you preserve your capital for years - after all, it is an asset that brings money. Figuratively speaking, a machine for printing money. And when you have already established a sales market, you can cash out your assets and switch to more expensive machines with significantly higher productivity.

Chinese machines and domestic

In the production of screws and bolts, the process is divided into two main operations:

1. Specialized cold heading machines form workpieces with different types of "heads"

Thread rolling machines roll threads onto blanks at a speed of 60 pieces per minute.

Such equipment is manufactured in Ukraine, China and Taiwan. On the territory of the Russian Federation, there are only a few manufacturers producing such equipment. Therefore, the purchase of a machine is a rather expensive operation: you need to pay not only for the purchase itself, but also for the delivery.

The market leaders in the production of machine tools are:

• LianTeng (Taiwan);
• FOB (Taiwan);
• Candid (China);
• INNOR (China);
• KUPRA (Ukraine: PJSC "Odessa plant for the production of press-forging machines");
• SAMSTAL (Russia, Samara: SAMSTAL LLC).

These machines differ in the productivity of products per minute. The simplest machines produce about 60 pieces per minute, while others have the ability to produce up to 250 pieces per minute. Some models can be customized to produce other products. This is a significant plus, since you can expand your product range over time, and there is no need to spend on buying specialized equipment.

The price of the most inexpensive models of automatic machines with a productivity of more than 50 pieces / min. starts at $ 13,000.

Popular models of automatic wire nails

It is better to purchase time-tested equipment that has already passed the test in real working conditions. The only exception to this rule is the possibility of buying a device from a trusted manufacturer, who has released a new model of the machine with improved performance.

Currently, the following unit models are used for the production of nails:

1. AB4118 is a single-impact wire-nailing machine that produces hardware with a diameter of 2.5 to 6.3 mm.

The length of the nails made by the machine can be from 32 to 200 mm. The equipment makes it possible to manufacture hardware not only from round wire.

With AB4118 it is possible to produce square and screw profile nails. The mass of the device is 4720 kg, the engine power is 11 kW. Cost after repair (used) 280,000 rubles.

2. K09.117.02 - a high-performance device for the manufacture of nails.

The length of the manufactured products ranges from 13 to 150 mm. The maximum wire diameter is 5 mm. Power - 5.5 kW. Weight - 2900 kg. Price (used) 230,000 rubles.

3. K09.117.01 - automatic wire-nailing machine for hardware from 13 to 120 mm long.

The diameter of the nail is from 2.0 to 4.2 mm. The device has a high performance with a total power of 5.5 kW. Power supply is carried out from a three-phase current network with a voltage of 380 V. You can buy a used unit for 180,000 rubles.

4. AG4116 - one-impact model for the release of nails from 13 to 250 mm long. Cost (new) 950,000 rubles and used 180,000 rubles.

For the manufacture of hardware, a nail wire with a cross section of 2.0 - 4.2 mm is used. Productivity is at least 350 pcs / min.

5. ASG 4.02 - allows to manufacture metalware up to 120 mm long. Engine power - 5.5 kW.

With this power, it is possible to obtain a productivity of nails up to 525 pcs / min. The mass of the device is 2650 kg. The average price is 420,000 rubles.

6. Z94-2C - a model of a wire-nailing device for hardware with a diameter of 1.2 - 2.8 mm. Cost from 280,000 rubles.

The productivity of the device with a rated power of 2.2 kW is at least 350 pcs / min. The length of the manufactured products is from 16 to 50 mm.

7. THA 40/120 S-E - Czech machine for making nails, distinguished by high productivity and product quality.

You can get products up to 120 mm long with a wire diameter of 40 mm.

8. Z4-x - a Chinese 3 kW unit produces hardware up to 100 mm in length, in quantities up to 300 pcs / min. Weight 1430 kg.

9. E127LYHIA is a China-made wire and nail machine. The equipment allows us to produce high quality products.

The machine also features low operating noise. The length of the manufactured hardware is from 40 to 110 mm. Engine power - 4 kW. Check the cost with the seller.

How to choose the right machine

The choice of a wire nail machine depends on many factors, but first of all, you should pay attention to the following characteristics:

The listed selection criteria are the main ones, therefore, before purchasing a machine, you should find out all its characteristics and correlate them with the requirements that will be imposed on the equipment at the enterprise.

Conclusion

The main step on the way to opening your own business for the production of hardware is the choice of a high-quality and suitable machine in terms of power. After purchase, you will need to correctly install and connect it.

It will also be necessary to purchase auxiliary devices and tools, and, of course, consumables, thanks to the use of which it will be possible to obtain products of the highest quality.

Price list for Chinese cold heading and thread rolling machines

Approximate average prices on the Internet for automatic equipment for the production of self-tapping screws, screws, bolts and nuts. The price list contains brief technical characteristics.

Approximate prices for thread rolling equipment.

* Note. All of the above equipment can be purchased on FOB terms.

A visual overview of 3D models of houses and cottages in a section for the analysis of the layout of the rooms.

The best machines for the production of self-tapping screws

Domestic and foreign companies are engaged in the manufacture of machine tools. The models differ from each other in technical characteristics, which in turn affects the performance and price of the device.

The simplest automatic machines produce about 60 parts per minute, and more advanced ones up to 250 pieces / min. Moments like these can have a huge impact on the payback period of the equipment.

Some models can be configured for the production of other products, in the future this will help expand the range of products without spending money on the purchase of additional machines.

Market leaders in the production of machine tools for fasteners include:

• Taiwanese companies LianTeng and FOB;
• in China, these are Candid and INNOR;
• representative of the Ukrainian market - KUPRA;
• Russian manufacturer Samstal LLC.

It is economically profitable to buy equipment in the above countries, it is always possible to combine a production line using machines from several manufacturers.

As for the cost, here you need to proceed from the requests of entrepreneurs. If we are talking about a small enterprise and new equipment, then according to the estimates of professionals, at the initial stage at least 700,000 rubles will be spent on the purchase.

On average, if we assume the purchase of machines from used to new and multifunctional options, then the run-up will be approximately from 300 thousand to 2 million rubles.

Diagram of a nailing machine with a description of the principle of operation

Schematic representation of the percussion apparatus.

Wire nails are produced on impact and press machines. The most common percussion machines, which form a nail with a blow with two hammers.

The wire is passed between two rows of rollers a, a. Further, it enters the feeder A (formed by the dog b and the spring c pressing it), which oscillates with an amplitude equal to the length of the nail with a margin for forming the cap. To increase / decrease the amplitude, the crank pin e serves.

Having passed the feeder, the wire is driven between the clamping cheeks w, w ', and w is static, the g' is affected by the downforce of the lever z, moved by the curly washer k (figure 14).

The cheeks are equipped with toothed grooves that allow you to fix the wire when riveting the head. Also in the cheeks there is a shape corresponding to the geometry of the bottom of the cap.

Behind the cheeks are knives p, p ', respectively, moved by levers o, o', which come into motion under the influence of washers c and c ', on the outer surface of which figured grooves are cut (figure 14).

The knives are pyramidal (figure 16). Cutout a serves to press the sharp end, blades b - cut off the excess. The remaining "petals" are removed during polishing.

A design feature in which the knives barely touch each other allows to avoid quick dullness of the knives. This design prevents the nail from being completely cut off.The final separation of the product from the wire takes place with the help of an ejector m, the movement of which is imparted by the levers y and the thrust f, which are actuated by the cam x.

The spring n, n 'strikes the protrusion of the hammer l, imparting an impulse to it. The hammer strikes the nail to form the head. A wooden spring (steel in some machines) is compressed with a cam m. (Figure 15, curve D).

The graph (figure 15) shows the order of individual working strokes of the machine for the production of nails. Curve A corresponds to the wire feeder that feeds the wire forward.

The strokes of the cheeks holding the wire are described by curve B (when the feeder moves the wire in the opposite direction, the cheeks do not fix it).

The working stroke of the scissors from the moment the wire is fixed is described by curve G.

The operation of the ejector separating the finished product is shown by curve B.

The sequence of the hammer is visible on curve D.

Then the feeder takes the extreme working point, the cheeks open, the working cycle starts from the beginning (curve B).

The difference between nominal and real productivity is about 20-40%. The reason for this is the downtime caused by the replacement and installation of the tool, refueling of the machines with new circles of wire, scrap, etc. When making nails, from 2.5% to 3.5% of the material is lost on the "petals". Losses for rejects reach up to 1%.

Wire for the production of self-tapping screws

For the manufacture of hardware in the form of self-tapping screws, wire from high-carbon and stainless steel or brass is used. Depending on the manufactured products and production volumes, the entrepreneur can purchase raw materials in the form of blanks or wire of a certain diameter.

There are many factories supplying these raw materials. You shouldn't have any problems finding suppliers

When choosing a supplier, you should pay attention to the price of raw materials, their quality and proximity to your workshop. The proximity of the supplier in relation to you will help to shorten the delivery time, as well as the cost of transportation

Application of hardware products

Self-tapping screws are used in different directions and areas. Production can be provided by more than one construction company or wholesale client. The main consumers of hardware products:

• Construction organizations, large and small teams.
• Manufacturing for the production of household and industrial appliances.
• Workshops for the manufacture of furniture, small workshops.
• Markets that represent construction products.
• Large trade organizations.

Factory for the manufacture of hardware products

The indicators of profitability of the hardware business always remain at a high level. The opening of production in a weakly competitive market will allow the equipment to be recouped in less than six months during the construction season. It is worth noting that the purchased equipment is not subject to wear and tear, so the investment will be profitable for many years. Construction work will always exist in the everyday life of mankind, repairs of various types of premises cannot be carried out without appropriate materials.

The first steps in organizing home production

Having registered your company and having decided on the productive capacity, you need to choose a room and calculate the initial investment.

The calculation of the initial investment directly depends on:

• volumes of manufactured products;
• the cost of the purchased equipment;
• purchase prices for raw materials.

Home production workshop

Next, you need to decide on the room. If you have sufficient capital, while you have the opportunity to rent a good premises, where the full production cycle will take place, then this will be much more convenient for you. You will be able to distinguish between home and work. However, at the initial stages, there is not always enough money for rent, so many people start making screws at home in the garage.These are quite suitable conditions for this business idea.

For the production of screws at home, a garage is suitable, which would have an area of ​​at least 18 m2. It must be equipped with a good ventilation and heating system. The production area must be well organized, and the general environment must comply with all labor protection rules.