How self-tapping screws are made. How are screws made?
The name self-tapping screw comes from two words - “myself” and “cut”. It is not for nothing that the fastening element that we will now consider was given the name self-tapping screw. But this is so: when you rotate and press on it, it itself cuts into the plane and cuts a thread in it. This process occurs thanks to the incredible density of steel grades ST08KP and ST10KP.
In general, the production of these hardware products occurs in several stages. Let's take a closer look at how self-tapping screws are made.
The first stage is the production of a blank, the so-called blank for the future screw. At this stage, the main components and parameters of the screw are formed: head, tip and length of the rod. The diameter of the screw depends on the thickness of the wire used.
The second stage is cutting the thread onto the rod. Both the production of blanks and thread cutting are carried out by special automatic machines. The blanks are poured into a special container of the machine and, using a vibrating conveyor, are fed individually into the thread cutting compartment. It is worth noting that the working parts of the machine feed blanks in one direction relative to the working elements - flat dies. The dies fit tightly into the screw shaft and move perpendicular to the axis. The dimensions of the dies exactly correspond to the thread parameters of the screws.
Thanks to its sharp tip and hard surface, which is processed at high temperatures (hardening), the self-tapping screw is able to drill through both soft and hard materials. Moreover, so that the screw rod can be screwed into dense surfaces, its sharp end is made in the form of a drill. The self-tapping screw, when rotated, forms a hole that exactly coincides with its diameter. It should be noted that the sharp shape of the tip is formed at the initial stage of production, and threading at the next stage.
The most important process in the formation of a self-tapping screw is hardening under high temperatures. The hardening process is influenced by two factors: the quality of the steel and the creation of stable conditions during the technological process. As we have already said, the process of producing self-tapping screws is completely mechanized. High-tech equipment and the latest technologies are used for production. But, even with all of the above, it is not always possible to achieve a high-quality product at the end.
The final stage is the formation of a corrosion-resistant surface. The most common methods are oxidation, phosphating, and galvanic galvanizing.
Despite the economic crisis, the construction market is experiencing stable growth. Residents of our country are constantly building and repairing something, so fastening materials are very popular. Beginning entrepreneurs who want to start the production of self-tapping screws as a business can be sure that such an activity will generate high income.
Registration of activities
To open the production of self-tapping screws in Russia, you must first complete all the necessary documents. If you are planning to create a large enterprise that will produce a wide range of products in large volumes, you should register an LLC. This will allow you to sell products by bank transfer to legal entities, as well as enter into agreements with suppliers of raw materials.
This type of activity is not licensed, so you will not have to obtain any permits. To make your products competitive, it is advisable to undergo certification. For mini-production of self-tapping screws, it is enough to register as an individual entrepreneur.
Premises and location
The success of a business largely depends on the location where it is located. Some companies are more attractive to potential buyers because they are easy to reach. But not in our case.You should not rent a building in the city center for a self-tapping screw production plant. After all, these are not buns that passers-by buy. Such products are purchased in tons, so sales volumes do not depend on where your enterprise is located - in the center or on the outskirts. The most important thing is that there are good access roads leading to it. The buyer will pick up quality goods at an affordable price from anywhere, so when choosing a premises, be guided by the rental price.
Choose an inexpensive, convenient room that meets all requirements. This could be a former garage for tractors or other special equipment. For it you will pay approximately 5 thousand per month. Agree that this is ridiculous money for a business, even a small one. Remove all the trash from there, install electricity and you can start choosing a production line.
Equipment
In order for the product to be of high quality, you need to purchase machines for the production of self-tapping screws. Such equipment is offered by different manufacturers. The choice of certain models largely depends on the self-tapping screw production technology that you are going to use in your enterprise.
Scheme: production of self-tapping screws
The technological process includes the following stages:
- Manufacturing of blanks;
- Thread cutting;
- To expand the product range, units for surface hardening and anti-corrosion treatment should be added to the line for the production of self-tapping screws.
The basic set of equipment for the production of self-tapping screws consists of the following units:
- Drawing machine;
- Unit for forming a workpiece;
- Thread cutting machine.
If you are going to compete with large industrial enterprises, you should purchase an electroplating line, a drying centrifuge and a hardening furnace to improve the quality of products.
The cost of equipment varies over a wide price range. There is no point in buying an expensive high-performance line until all sales issues have been resolved. If you have limited financial resources, you can purchase used equipment.
You will have to spend a lot of money to equip your enterprise, since all the machines are quite expensive. High-performance equipment pays for itself much faster. This should be taken into account when developing a business plan.
Technological process
A self-tapping screw is a fastener consisting of a rod with an external thread and a head. It is worth noting that the technology and equipment for the production of nails and self-tapping screws are almost the same, but there are still some differences.The production process consists of the following stages:
- Wire cutting to size;
- Applying threads and forming a cap;
- Hardening process;
- Washing;
- Anti-corrosion treatment.
Low-carbon wire that has undergone heat treatment is used as a raw material for the manufacture of self-tapping screws. If you are interested in the production of self-tapping screws, a video on this topic can be found in this article.
Staff
Since the production line is automatic, it does not require many workers to operate it. Operators oversee pre-set equipment, supply supplies, and remove finished products. When drawing up a business plan for the production of self-tapping screws, at the first stage you can provide two workers. In addition to the salary of 15–20 thousand rubles, the costs of their training should be taken into account. You also need to hire an accountant. The salary of such a specialist is in the range of 25–30 thousand rubles.
Business plan
To be profitable, you should not miss the following important points:
- Purchase of equipment;
- Selection of premises;
- Purchase of raw materials;
- Choice of assortment;
- Hiring employees;
- Search for sales markets.
Before you start work, prepare all the necessary documents.
Income and expenses
- Rental of premises – 5 thousand rubles;
- Salary – 40 thousand rubles;
- Raw materials – 15 thousand rubles;
- Electricity bills – 10 thousand rubles.
Raw materials
As a rule, there are no problems with the purchase of raw materials. Suppliers offer blanks or wire in reels at affordable prices. They typically deliver the raw materials directly to the facility, allowing you to save on shipping costs. The choice of raw materials largely depends on technology and equipment.
To reduce the cost of products, you can purchase raw materials directly from manufacturers at low wholesale prices. Steel or brass wire costs approximately 12.5 thousand rubles per 1 ton. One reel will yield 500 thousand self-tapping screws.
Range
In order for your business to generate high income, you need to constantly expand your product range. It will not be possible to achieve much variety, since self-tapping screws can differ only in the type of head, length and thread.
Produce different fastener models in small quantities. Over time, you will be able to decide which screws are in demand in your region.
Production of self-tapping screws Production of self-tapping screws
Sales of products
To receive a stable monthly income, you need to find potential buyers. Sales of fasteners must be continuous. To achieve this, you need to produce a wide range of products. This could be the production of roofing screws, nails, anchors, etc. Focus on the most popular types of products. In the future, you can adjust your business depending on the season.
The best option is a contract for the supply of products with. For large-scale construction, large volumes of such products are purchased. Sometimes one object covers the monthly productivity of the enterprise. Also, pay attention to . For example, a small furniture workshop consumes several tens of thousands of screws per month.
First of all, try to establish contacts with construction supermarkets, which will be happy to expand their range. In any city there are markets or markets, where you should start. To conclude contracts for large deliveries, you will have to work hard. To attract customers, you will have to slightly reduce product prices.
Conclusion
Now you know how to make self-tapping screws and make money from it. This is a simple, promising and fairly profitable business. Since all the equipment is automated, the main problems can arise only with the sale of products. But they are easily solved in the process of work. Read about others on our website.
A self-tapping screw is a standardized type of fastener that makes it possible to connect various parts by cutting threads in parallel. This method is quite convenient when it comes to working with polymer, wood, and metal elements. Self-tapping screws are widely used in the construction industry, during the manufacture of household appliances and at a number of stages of assembly on mechanical engineering lines. This is one promising species. At fairly low prices, product turnover is always significant, which allows for stable profits.
Opening your own business to produce self-tapping screws today is a promising and quite profitable direction. To implement this task you will need to go through only a few steps. First, novice entrepreneurs need to familiarize themselves with the existing technology for producing ready-made self-tapping screws. After this, evaluate the machines offered on the market and select the most appropriate types of equipment in terms of the tasks and cost. At the same time, it is important to look for possible clients in advance so that investments in the business pay off and the equipment begins to make a profit. In parallel with the search for distribution channels, you can prepare.
How are self-tapping screws made?
The technological line for the production of self-tapping screws includes a number of key sections. Typically, the raw material is wire of a standardized diameter. It is fed to a machine that forms the semi-finished product automatically. The cut is formed in accordance with the predetermined length of the product. The next stage is the cold heading process, the result of which is the pressing of the screw head.
Using a conveyor, the workpieces are sent to a machine that will select threads on the workpiece. After this, the finished self-tapping screw goes through the stage of heat treatment and washing. The penultimate stage of the production process is chemical treatment, after which an anti-corrosion coating appears on the surface of the product. The screw is then dried and also subjected to quality control.
Self-tapping screws that meet the standards are packaged and sent to a warehouse, from where they are distributed among customers at direct or retail prices. Once certain results are achieved and the first contacts with construction companies appear, you can establish. This will allow you to expand the range of materials and get your first customers through established business contacts.
Machines for the production of self-tapping screws - price
In essence, the process of producing self-tapping screws takes place in a fairly compact area, since the production line is relatively small. Several configuration options can be distinguished. The quality, and therefore the price, of finished self-tapping screws depends on the type of equipment used.
The cold heading machine is an equipment that can be divided into two main groups, which use a semi- or fully protective casing. They have different performance indicators, a general control system, and the ability to use automated control systems. The simplest models are created with a focus on the manufacture of one specific type of product. Machines that belong to the category of the middle and high price segment make it possible to produce a wider range of self-tapping screws. The price can fluctuate quite a lot.
A thread rolling machine will allow you to create thread rolling using a special replaceable die. Depending on the model, it becomes possible to change the set thread pitch. A heat-hardening oven is needed to increase the strength of the self-tapping screw, which on the Brinell scale can be about 55 units or more. The process itself involves heating to 1 thousand degrees Celsius for 1 minute with further cooling in a quenching environment.
The galvanic line is used to form a special anti-corrosion coating on the surface of the self-tapping screw. There are a variety of options:
- phosphating;
- oxidation;
- zinc coating, etc..
This element of the production line consists of several baths in which electrochemical reactions take place. At the final stage, a centrifuge is needed, which will dry the finished product with hot air immediately after washing. The price may vary greatly, depending on the quality of the equipment for the self-tapping screw production line, the production location, power and other factors. The minimum cost for creating a mini-factory will be 200-250 thousand rubles. Compare this to other options for starting your own.
If we take the simplest option for organizing the production of self-tapping screws, then you can get by with a drawing machine, which are available for 60-75 thousand rubles, a cold heading machine (80 thousand rubles) and a thread rolling machine (100 thousand rubles). Equipment of a full-fledged line with galvanic coating and a centrifuge will cost 1 million rubles.
Advice: Refrain from purchasing expensive, high-performance equipment until you have established sales lines for finished products. In some cases, it makes sense to buy used equipment. The latter option should be approached with caution, since there is no guarantee that such elements of the self-tapping screw production line will work long enough. Quite often, entrepreneurs pay attention to machines manufactured by KONNAR and Fob. Both of these manufacturers are known for the low cost of their machines.
Wire for the production of self-tapping screws - price
To make self-tapping screws, you need to choose suitable raw materials. Each specific type of fastener has corresponding requirements in GOST. The characteristics of metals differ in hardness, ductility, chemical composition, etc. As a rule, stainless and high-carbon steel and brass are used to create self-tapping screws.
It should be noted that wire for producing self-tapping screws, supplied in ready-made reels, is more preferable due to a number of technical nuances. When choosing a material, it is important to know what your customers intend to use the screws for. For fastening metal, wood and drywall, the requirements may differ in many ways. Will it be a self-tapping screw for indoor use or will it be in contact with a fairly aggressive environment?
Advice: agree with clients to carry out wholesale supplies of raw materials. This will significantly reduce costs when changing the reference point of the production line from one type of self-tapping screws to another. At the same time, bulk purchases of raw materials are usually somewhat cheaper.
Many people are interested in how much raw materials cost using standard technology for producing self-tapping screws. As a rule, this value is 2.5 thousand rubles per ton. Each ton of wire makes it possible to produce about 500 thousand medium-sized fasteners.
To produce self-tapping screws, it is quite easy to organize a small workshop on your own. In addition, there are a number of proposals on the market for opening a business that will allow even inexperienced beginning entrepreneurs to open their own business with minimal risks. The price of the equipment may vary, but on average, to create your own workshop for the production of self-tapping screws you will need 0.25-1 million rubles.
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The construction industry continues to develop quite strongly, so the production of self-tapping screws is a profitable direction. There is a much greater demand for them than for the same nails, due to their more durable fasteners. An additional advantage is that the production of self-tapping screws in mini-factories is not a new thing, and large companies already have a certain degree of confidence in this area. Having accumulated some capital, you can try yourself as a pioneer. Choose an existing option and gain a foothold in a new niche. As a rule, this carries certain risks, but the profits can also be quite significant.
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A self-tapping screw is a fastening element that is used in construction, furniture manufacturing, and repairs. This is a universal fastener, since there are self-tapping screws for almost all types of work and any materials.
Technology for manufacturing screws and self-tapping screws
While choosing the length and diameter of the self-tapping screw is not difficult (to do this you need to know the thickness of the elements being connected), then with the material from which the self-tapping screw itself is made, things are more complicated.
What are they made of?
Based on the material used, self-tapping screws are divided into: Self-tapping screws made of carbon steel;
Stainless steel self-tapping screws;
Brass self-tapping screws.
The harder the material that will be attached, the stronger the self-tapping screw should be. The most durable are self-tapping screws for metal and plastic. They are hardened for greater strength. To avoid corrosion, self-tapping screws are covered with protective coatings so that the self-tapping screw can work in conditions of high humidity. Self-tapping screws are protected by phosphating or galvanizing.
The materials from which self-tapping screws are made are the most important factor when choosing them for construction or installation work.
The main stages of manufacturing a self-tapping screw Manufacturing the base (blanks). The material is cut to a specified length.
Sending workpieces to the bunker. Thread cutting, head making.
Heat treatment (hardening of products) in a special oven.
Washing, applying a protective layer.
It is not for nothing that the self-tapping screw is called this way. It can cut threads in both soft and high-hardness materials. This self-tapping ability is manifested because its surface undergoes a special heat treatment. In addition, self-tapping screws have sharp ends for better penetration into parts that need to be fastened. To protect against corrosion, the following are used: mechanical protection, electrochemical protection, coating with a protective oxide layer (phosphating), coating with a protective layer of another metal (nickel plating, galvanizing with various application technologies, brass coating). When manufacturing a self-tapping screw, strictly defined steel characteristics and strictly defined metal hardening technology are required.
We buy self-tapping screws wholesale
There is no doubt that it is much cheaper to buy self-tapping screws from a wholesale supplier. Many companies offer self-tapping screws in bulk, among them Metizsnab. Be careful when purchasing fasteners; bulk purchases prevent you from overpaying.
How self-tapping screws are made
The name self-tapping screw comes from two words - “myself” and “cut”.
It is not for nothing that the fastening element that we will now consider was given the name self-tapping screw. But this is so: when you rotate and press on it, it itself cuts into the plane and cuts a thread in it. This process occurs thanks to the incredible density of steel grades ST08KP and ST10KP.
In general, the production of these hardware products occurs in several stages. Let's take a closer look at how self-tapping screws are made.
The first stage is the production of a blank, the so-called blank for the future screw. At this stage, the main components and parameters of the screw are formed: head, tip and length of the rod. The diameter of the screw depends on the thickness of the wire used.
The second stage is cutting the thread onto the rod. Both the production of blanks and thread cutting are carried out by special automatic machines. The blanks are poured into a special container of the machine and, using a vibrating conveyor, are fed individually into the thread cutting compartment. It is worth noting that the working parts of the machine feed blanks in one direction relative to the working elements - flat dies. The dies fit tightly into the screw shaft and move perpendicular to the axis. The dimensions of the dies exactly correspond to the thread parameters of the screws.
Thanks to its sharp tip and hard surface, which is processed at high temperatures (hardening), the self-tapping screw is able to drill through both soft and hard materials. Moreover, so that the screw rod can be screwed into dense surfaces, its sharp end is made in the form of a drill. The self-tapping screw, when rotated, forms a hole that exactly coincides with its diameter. It should be noted that the sharp shape of the tip is formed at the initial stage of production, and threading at the next stage.
The most important process in the formation of a self-tapping screw is hardening under high temperatures.
How self-tapping screws are made
The hardening process is influenced by two factors: the quality of the steel and the creation of stable conditions during the technological process. As we have already said, the process of producing self-tapping screws is completely mechanized. High-tech equipment and the latest technologies are used for production. But, even with all of the above, it is not always possible to achieve a high-quality product at the end.
The final stage is the formation of a corrosion-resistant surface. The most common methods are oxidation, phosphating, and galvanic galvanizing.
Based on materials from http://www.ru.all.biz.
When we talk about a screw, does everyone know what it is? The word screw comes from the German Schraube. In fact, it is a screw that can easily be screwed into any soft material, forming a thread there “on its own.” A typical material of this kind is wood.
Why is a screw able to be screwed into soft materials? First of all, due to the threads, which cover a significant part of the screw shaft. This thread is different from the threads found on screws and bolts. It is not surprising, since the latter are screwed not into wood, but into metal. The thread on the screw is slightly higher. It has a significant cutting pitch and is applied to the threaded section of the screw in the form of a conical shape, which tapers towards the end of the screw. By the way, the thread on a screw can be cut either along its entire length or only along its part.
Since the sizes of screws are quite varied, a natural question arises on what this depends on. The sizes of screws closely correlate with their purpose. So, to attach nameplates to finished products, a very small screw, popularly called a “bug,” is widely used. Its dimensions: diameter - 4 mm, length - 8 mm. Another screw, called a travel screw, has a length of 170 mm and a diameter of 24 mm. And this is understandable, since it is used to attach the railway rail to the sleepers. The heads of such screws also have different shapes, determined by the installation conditions themselves, the appearance of the product and the requirements for the structure being mounted.
The head shapes are shown in Fig. 1.
About the types of heads and slots of screws
Among the types of heads we highlight: countersunk, countersunk double, countersunk truncated, countersunk "horn" type, semicircular head, semicircular head with a press washer, narrow cylindrical head, trapezoidal head, hexagonal head, hexagonal head with a press washer.
The countersunk head is recessed in the material of the element being fixed. At the same time, the surface of the material was and remains smooth. The countersunk double head is a reinforced version of the countersunk head. It is able to withstand significant loads, even with the impact method of installation in solid materials.
Countersunk truncated head makes it possible to press the element being fixed to the base material with high efficiency. This is achieved due to the fact that the length of the thread of the fastening element is increased; a lower platform is formed on the head, which is perpendicular to the action of the pullout load.
Concealed horn type head remarkable in that it very effectively ensures high-quality pressing of drywall to the base material. It is the specially curved shape of the head, which has the appearance of a “horn,” that ensures optimal perception of the pullout load. The semicircular head, thanks to the wide bearing surface, effectively holds the element being fixed. The use of such a head is justified when there is no particular need to keep the surface of the element being fixed flat.
Another type of head - with a press washer - represents an increased bearing surface of the head and a reduced height. Due to the expanded bearing surface, a head of this type is ideal for reliably fastening sheet materials.
Narrow cylindrical head provides an important, in some cases, minimum load-bearing surface. During installation, this ensures that it is completely recessed into the element being fixed. It is widely used in fastening elements that are fixed both in the base material and in the element being fastened using threads that perform the main function of fastening. The trapezoidal head has an increased bearing surface, and locking notches are located on its inner side.
One of the most famous and oldest types of fastener heads is hex head. As a rule, it is standardized to fit the existing key sizes, and in order to install it using a power tool, special hexagonal sockets are used.
The functions of a hex head with a press washer are the same as those of a simple hex head, but its bearing surface is still larger.
In order to mount a screw using tools, using a screwdriver or a hexagon, slots are pre-formed in the screw head, which can be straight, cross-shaped, combined, in the form of a six-pointed star, in the form of a hexagon or in the form of an internal hexagon.
Traditionally, for the manufacture of screws, a material such as ST 08 KP or ST 10 KP steel is used.
Screw manufacturing technology
At the first stage of the manufacturing process, a blank or base for the screw is formed. In this case, a device similar to a nailer is used everywhere. Thanks to this device, the screw head and its tip are formed. The diameter of the future screw is determined by the wire used.
At the second stage of manufacturing a screw, threads are cut on its shaft. And this process is carried out using special machines. In this case, the blanks of future screws are poured into a hopper, where, thanks to a vibrating conveyor and an anchor mechanism, they arrive one by one into the area where thread cutting is carried out. At the same time, the screw blanks are strictly oriented in relation to the working elements, i.e. to flat dies, moved towards and parallel to each other, and perpendicular to the axis of the screw, which are pressed tightly against the screw shaft. At the same time, depending on where they are manufactured, dies are produced based on the basic parameters of the thread.
This scheme makes it possible to produce screws with a diameter of 10-12 mm, but screws with larger diameters are usually produced using the hot stamping method. An example of such a product is a travel screw, the dimensions of which we talked about just above.
Self-tapping screw manufacturing technology
As you know, the self-tapping screw has this name because it is capable of cutting threads anywhere, in wood, plastic, metal and concrete, etc. This is due to the fact that its surface has powerful strength, obtained through heat treatment, i.e. hardening The end of the self-tapping screw is often made in the form of a drill. Thus, its optimal screwing into the structures being fastened is achieved, as well as drilling a hole of the required diameter.
At the first stage During manufacturing, the formation of a drill is ensured even during the process of forming the blank.
At the second stage, similar to the thread formed on a screw, the formation of a self-tapping thread is ensured.
At the third stage The finished self-tapping screw is surface hardened. This is perhaps the most important stage in the manufacture of self-tapping screws, since it is important to strictly adhere to all technological methods to ensure that the necessary technical parameters are obtained.
At the fourth, final stage, self-tapping screws are protected from possible corrosion using methods such as phosphating, oxidation, galvanizing with yellow or white zinc.