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Flat head bolt process analysis and process
For the head-shaped bolt, it is essential to machine the screw diameter and thread before forming the head. If the head is formed first and then the rod is machined, it becomes difficult to secure the workpiece for subsequent operations, making the production process inefficient. To address this, a round steel blank with a working diameter of 25 mm was selected as the raw material. During hot forging, a significant amount of material is used for the head, and due to the high deformation ratio in the initial stage, it is necessary to perform two deformation steps to meet the production requirements. Therefore, the process includes two hot piercing operations and one flattening step.
The process flow begins with placing the rough mold into the upper mold box of the universal friction press. The larger end of the pre-machined blank is heated in a high-frequency furnace (the non-processed end remains unheated), and then the rough head is thickened using a thick emblem. However, re-heating after the thickening process consumes energy and reduces material utilization. To improve efficiency, a cold rolling expansion precision forming process is now used, which simultaneously forms the inner and outer rings and the groove. This method saves approximately 30% of the material compared to traditional processing.
The cold heading process results in denser material, refined grain structure, and aligned metal flow lines, significantly enhancing the bearing life and reliability. According to domestic users, the service life can be increased by over 50%. Luoyang Guotou Precision Machinery Co., Ltd. has independently developed the D56G CNC precision cold heading ring machine based on the D5M model. On August 7, 2001, the Henan Provincial Economic and Trade Commission organized an appraisal meeting for the D56G70 CNC precision cold heading machine in Luoyang. Experts at the meeting agreed that the machine features a novel design, advanced technical specifications, and high processing accuracy, making it suitable for machining ring parts such as bearing rings. The product reached the domestic leading level and was approved for small-scale production.
Currently, the D56G series includes three models: D56G6O, D56G7O, and D56G14O. It uses PLC control and allows users to select the inner and outer diameters of the ring using dual gratings. Three types of cold-rolled blanks are prepared: bearing steel bars are cut, forged with a hole, and then processed to the required size; bearing steel pipes are cut and finely adjusted to the cold blank size; cold-drawn bearing steel pipes are cut, roughed at the ends, and cooled. Using pipe materials offers advantages, as large-diameter steel pipes can be expanded into large outer diameter rings, which greatly expands the application range of steel pipes and increases material utilization to over 70%.
According to preliminary statistics, about 1 billion sets of bearings suitable for cold heading technology are used in China, but only around 3 million sets (3%) currently use the cold heading process, indicating significant development potential in the bearing industry. Foreign countries, such as Japan, produce similar high-level products, with imported cold-rolling ring machines costing up to $25.3 million, while domestic versions cost only 400,000 yuan. The cold heading ring machine is not only suitable for cold heading of bearing inner and outer rings but also for cold expansion of ring parts in other industries, offering broad development prospects.