The web guide system is mainly applied to the lateral deviation control of the coil materials, which can control various reel materials on a production line. The automatic web guide system is simple to operate, easy to install and has fast response speed, strong anti-interference, high-precision web guiding.
The coils are on a long and fast production line, as the speed, tensile, the nonuniform material thickness and all kinds of mechanical damage, resulting in moving and unidirectional deviation, causing the machining operation of the middle section not easy to cooperate, resulting in the loss of many materials and the difficulty of subsequent processing. The automatic web guiding system can solve these problems, which can always keep the edge postilion of the web always be neat and consistent. Web guide control can make steel, corrugated paper, textile, printing, labeling, non-woven fabric processing and other much more industries realize automated control.
A typical automatic web guide system which is a closed-loop system, includes a web guiding controller, a web guide sensor, a web guide framework, and a driver. The sensor detects the difference between the detection value of the edge or the line and the set value, and converts it into a proportional signal through the PLC controller. The driver realizes the web guide. It has three guiding methods, including edge position control, line control and center control.
Technical Parameters Of Automatic Web Guide System
1. Support photoelectric sensor, ultrasonic sensor, CCD sensor.
2. Intelligent detection sensor parameters, no need for calibration sensors in most situations.
3. Automatic stroke measurement, not any mechanical switch needed.
4. Adopts variable PI adjustment algorithm, high precision, fast responding, with smaller error.
5. Super high response speed of 500 microseconds.
6. Analog sensor signal adopts 16-bit AD sampling.
7. Adopts the FIR digital wave filter, with strong anti-interference ability and more stable signals.
v8. DC servo motor pushing the ball screw
9.Support Simplified Chinese, Traditional Chinese, English, three languages.
10. User-friendly operation, fast and easy.
11. Support MODBUS and PLC operation.
High-precision Automatic Web Guide System
The precision of the web guide system is defined as the position accuracy of the web just coming out of the probe. The accuracy of the web guiding system is determined by three factors, including the deviation of the invasive web, the accuracy of the web guiding system itself, the installation accuracy of the web guide machine.
The automatic web guide system is a controller of tracking edge or printed line of the working material to perform high-precision differential and swing, which is composed of large-scale industrial integrated circuits, with strong anti-interference ability, high reliability and long service life. The lateral web offset in the transmission is detected by the photoelectric sensor, and the electrical signal proportional to the offset will be sent to the controller. After power amplification, it is sent to the motor to make it rotate forward, stop or reverse and the motor shaft end is connected with a lead screw. The screw drives the roller to move the rolling roller in the rolling rail to move laterally in the offset direction, thereby reaching the purpose of the automatic web guide. The signal is being firmly measured and the high-precision of the web offset is the premise of automatic web guiding.
Wide Applications Of Automatic Web Guide System
An automatic web guide system can be widely used for various coils such as web films, non-woven fabric, woven fabrics, on a production line.
Applicable industries: printing, packaging, paper, non-woven fabric, lithium battery, rubber tire, metallurgy.
Applicable coils: wrapping materials, such as roll paper, film, metal foil, film, leather, non-woven fabric, woven fabric, etc.
Applicable equipment: print packaging, flexo printing machine, gravure printing machine, label printing machine, slitting machine, coating machine, composite machine, die cutter, blown film machine, etc.
The automatic web guide system is an integrated high-tech product with a wide range of applications, It has the characteristics of fast responding speed, high accuracy, long service life and high stability. It is essential in the coil material production line.
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Disc springs, aptly named for their bowl or dish-like shape, are integral components in various maritime, industrial, and mechanical applications. Comprising four key parameters—outer diameter (D), inner diameter (d), thickness (t), and height (H)—these washer-type springs exhibit a truncated conical section and are crafted from metal sheets or forging blanks.
Principle of Disc Spring:
The fundamental principle behind disc springs involves their function as conical annular discs bearing axial loads. Typically, the disc thickness remains constant, with the load evenly distributed on the inner edge of the upper surface and the outer edge of the lower surface. Constructed from spring steel, disc springs excel in withstanding static, impact, or dynamic alternating loads, meeting stringent requirements for fatigue life.
Types of Disc Springs:
Anti-loose Disc Spring:
Application: Ideal for bolts subject to severe vibration but not under excessively large loads. Effectively prevents bolts from loosening and reversing, ensuring lasting and reliable sealing. Versatile for various bolt and equipment configurations.
High-Temperature Preloaded Disc Spring:
Application: Suited for bolt preloading in high-temperature environments, such as flanges, pipe flanges, valves, and heat exchangers. Especially valuable in applications with temperature differences exceeding 100°C.
High Torque Preloading Disc Spring:
Application: Applied in scenarios demanding substantial load and torque, such as pre-tightening valve and pipe flange bolts. Used in diverse engineering applications involving anchor bolts, fans, pumps, centrifuges, heat exchangers, reactors, agitators, generators, pipe supports, and hanger devices.
Buffer Tension Disc Spring:
Application: Widespread use in various industries, including brakes, safety overload devices, mechanical starters, industrial furnaces, clutches, molds, and more.
Advantages of Disc Springs Compared to Other Springs:
Space Efficiency:
Disc springs bear substantial loads in minimal space, making them efficient in applications with spatial constraints.
Variable Stiffness:
By altering the ratio of the inner cone's height to the disc thickness, disc springs exhibit variable stiffness characteristics, providing flexibility in spring curves.
Different Bearing Capacities:
Varying the number or combination of discs enables obtaining different bearing capacities, facilitating adaptability to a wide range of applications.
Long Service Life:
Correctly designed and manufactured disc springs boast a prolonged service life, contributing to their reliability in diverse settings.
How to Select Disc Springs:
When choosing disc springs for specific applications, several factors come into play:
Load Size and Characteristics:
Consider the magnitude and nature of the load, including static, impact, or dynamic loads.
Working Temperature:
Select disc springs suitable for the working temperature range, accounting for variations up to 600°C.
Equipment Working State:
Assess factors such as pre-tightening, stroke, vibration, pulse pressure frequency, and pre-tightening force.
Medium Corrosivity:
Evaluate the corrosivity of the working medium and the pH value, as these factors influence disc spring selection.
Pressure:
Different working pressures in pipes produce varying pulse pressures and thermal expansion and contraction, influencing disc spring selection.
Conclusion:
The versatility, efficiency, and durability of disc springs make them indispensable in a myriad of applications. Whether serving as strong cushioning devices or as components in safety valves and clutches, disc springs continue to play a vital role in diverse industries, offering small deformations, high loading capacities, and extended service lives. As their usage expands, understanding the selection criteria becomes crucial for optimizing their performance in various operational environments.
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Surface treatment is a crucial aspect of spring manufacturing, aimed at preserving and protecting these vital components. Springs are often exposed to challenging environmental conditions, making it essential to employ protective layers. These protective layers of springs can be categorized into metal protective layers, chemical protective layers, and non-metallic protective layers, each chosen based on the specific needs of the application.
Metal Protective Layers for Springs
One common method of providing protection to springs is by applying a metal protective layer. Among the various techniques available, electroplating is a widely used method for obtaining a metal protective layer. Two of the most prevalent options in this category are galvanization and cadmium plating.
Non-Metallic Protection for Springs
Non-metallic protective layers are applied by dipping or spraying substances such as asphalt or paint onto the spring's surface. These layers serve as a barrier against environmental factors, safeguarding the spring from corrosion and other forms of degradation.
Chemical Protection of Springs
Chemical protection involves creating a dense protective film on the spring's surface through processes like oxidation treatment or phosphating. This film acts as a shield against corrosion and extends the spring's lifespan. Both oxidation treatment and phosphating are cost-effective methods, with oxidation treatment being the preferred choice among Spring manufacturers.
Oxidation Treatment of Springs
Oxidation treatment, also known as bluing or blackening, results in the formation of a protective magnetic iron oxide layer on the spring's surface. The color of this oxide film can vary, ranging from blue and black to dark brown. The specific hue depends on factors like the oxidation process, the spring's surface condition, and its chemical composition.
Methods of Oxidation Treatment
Oxidation treatment encompasses various methods, including alkaline oxidation, alkali-free oxidation, and electrolytic oxidation. In most cases, alkaline oxidation is the method of choice. However, it's important to exercise caution during oxidation treatment, as it can erode surface grain boundaries, potentially reducing fatigue strength.
The Process of Alkaline Oxidation
Alkaline oxidation involves immersing the spring in a sodium hydroxide solution at approximately 140°C for a specified duration. During this process, the oxidant and sodium hydroxide react with iron to produce Na2FeO2 and Na2Fe2O4, ultimately forming the protective magnetic iron oxide. The thickness of the oxide film typically ranges from 0.6 to 2 μm. Factors affecting corrosion resistance include oxide film compactness, thickness, oxidant concentration, sodium hydroxide concentration, and solution temperature.
Phosphating Treatment of Springs
Phosphating treatment entails immersing the spring in a phosphate solution containing manganese, iron, and zinc to create a water-insoluble phosphate film on the metal surface. The resulting film appears dark gray, gray, or dark gray, imparting a dull finish. Generally, the thickness of the phosphating film ranges from 5 to 20 μm.
Precautions for Phosphating Treatment
Several precautions should be taken during phosphating treatment:
Phosphating films possess microporous structures, making them ideal for paint and grease adhesion. Hence, phosphating is often combined with coating methods like painting.
Phosphating films can withstand high temperatures (400~500℃), making them suitable for springs operating in elevated temperature environments.
Springs should be sandblasted before phosphating. Immediate phosphating after sandblasting is recommended. If sandblasting equipment is unavailable, chemical degreasing and pickling can be used to remove oil.
Phosphating processes produce hydrogen, which can lead to hydrogen embrittlement in critical parts of the spring. Dehydrogenation treatment is essential after phosphating to mitigate this risk.
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In the realm of fasteners, the self-locking nut stands as a formidable solution against vibrations and loosening. Its role becomes paramount in specialized contexts. Operating primarily through friction, self-locking nuts encompass a range of functionalities, including nylon ring embedded nuts, necked nuts, and metal locking devices. This article delves into the world of self-locking nuts, spotlighting 5 distinct types, their working principles, and application landscapes.
Understanding Self-Locking Nuts
The self-locking nut represents a novel class of fasteners characterized by exceptional anti-vibration and anti-loosening properties. Engineered for mechanical and electrical applications spanning temperatures of -50°C to 100°C, the demand for nylon self-locking nuts has surged across various domains, including aerospace, automotive, mining, and machinery. This is due to their superior performance compared to other anti-loosening methods, offering prolonged vibrational endurance.
Working Principle of Self-Locking Nuts
Friction serves as the cornerstone of self-locking nuts. Typically, these nuts feature embossed teeth that engage with pre-set holes in the sheet metal. For square preset holes, the hole diameter is marginally smaller than that of the rivet nut. A locking mechanism connects the nut, ensuring that tightening locks the ruler body in place. Conversely, loosening disengages the locking mechanism, allowing the ruler frame to move along the ruler body.
Standards for Self-Locking Nuts
In accordance with GJB125.1~125.6-86 specifications, the double-eared traveling self-locking nut comprises four components: sealing cover, self-locking nut, pressure ring, and sealing ring. This compact and reliably sealed configuration is ideal for products with operating pressures up to 22 atm, handling mediums like gasoline, kerosene, water, or air, within a temperature range of -50°C to 100°C. Despite its manufacturing complexities and stringent airtight testing, this standard serves diverse applications.
Types of Self-Locking Nuts
High Strength Self-Locking Nut
Designed for robustness and reliability, high-strength self-locking nuts cater to demanding applications in road construction, mining, and vibration-heavy machinery. With European technology influences, these products are relatively scarce in China's market.
Nylon Self-Locking Nut
Nylon self-locking nuts emerge as champions of anti-vibration and anti-loosening performance across a broad spectrum of mechanical and electrical applications. With a temperature range of -50°C to 100°C, they have witnessed soaring demand in aerospace, automotive, machinery, and more. These Nylon nuts not only outperform other anti-loosening devices but also exhibit unmatched vibrational longevity.
Traveling Self-Locking Nut
Configured with double ears as per GJB125.1~125.6-86, the traveling self-locking nut boasts a compact, reliable, and sealed structure. It finds utility in environments with working pressures up to 2 atm, accommodating mediums like gasoline, kerosene, water, or air. Its operational temperature spans -50°C to 100°C, though its manufacturing intricacies and rigorous airtight testing pose challenges.
Spring Self-Locking Nut
Comprising an S-shaped spring clip and a self-locking nut, the spring self-locking nut offers convenient installation and reliable post-installation performance. The elastic force of the spring clip secures the nut to the connecting plate or support, making it a versatile assembly carrier and tool.
SPIRALOCK Nut
Distinguished by its 30-degree wedge bevel at the female thread base, the SPIRALOCK nut generates substantial locking force when bolt and nut are tightened. This force results from the interaction between the bolt's tooth tip and the wedge bevel. The unique tooth shape angle enhances friction and load distribution, offering prolonged service life and mitigating loosening under vibrational conditions.
Conclusion
The realm of self-locking nuts is both intricate and diverse, comprising an array of types catering to specific needs. Operating on the foundation of friction, these nuts have solidified their place in anti-vibration and anti-loosening strategies across industries. As their applications evolve and expand, self-locking nuts continue to play an indispensable role in ensuring secure and reliable fastening solutions.
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There are different types of springs that frequently play an important function. As a result, each spring has equivalent tight standards in the manufacturing process and must pass a series of strict testing to verify that it meets the standard performance.
1. Spring fatigue performance and relaxation rate detection
These two factors, it may be argued, directly influence the spring's reliability and life, and are the key to the spring's quality. These two indicators can be acquired following specified cycle numbers of load-strain testing utilizing a spring fatigue testing machine.
Spring fatigue testing machine is used for testing.
2. Spring hardness test
Springs, particularly exceptionally big springs, are usually quenched. HRC44 to 52 is the typical hardness range for ordinary springs. And such an aircraft carrier-level spring will outperform HRC52 and possibly even HRC54.
The purpose of evaluating hardness is to evaluate the spring's failure performance.
Testing equipment: hardness tester.
3. Nondestructive testing of springs
Non-destructive testing includes visual inspection. Because of the various production procedures, it is possible that some flaws like as cracks, creases, delaminations, pits, pits, scratches, wire drawings, and other surface defects will occur during the spring's processing. These surface quality flaws are usually detectable through visual inspection or ultrasonic frequency.
Testing equipment: magnifying glass, microscope, ultrasonic detector.
4. Geometric size detection of springs
Size testing components primarily include the spring's material diameter, free length, free angle, spring diameter, total number of turns, length of torsion arm, bending angle of torsion arm, and so on. These are the fundamental spring testing items. discrepancies in size, especially with super-large springs, are likely to contribute to discrepancies in overall device performance.
Testing equipment: calipers, two-dimensional, three-dimensional, projector, etc.
5. Spring elasticity test
If the spring force value is clearly marked on the drawing, the matching spring force test must be performed. Typically, the elastic force tester can be used to detect the necessary elastic force; simply pay attention to the distance of pushing or stretching according to the drawing requirements and then check the relevant elastic force. This type of test is commonly used for slightly bigger springs, such as mechanical springs and engineering springs, whereas battery box springs or ultra-precise micro springs do not normally require it.
Testing equipment: elastic tester, tensile tester, etc.
6. Salt spray test of spring
The Salt spray test is also a popular test for spring items. Use varied hours of salt spray oil to prevent rust on the spring according to customer specifications, then take pictures and record the test results in 2/4/8 hours, and finally generate a test report.
If it fails the salt spray test, the spring must be treated with salt spray oil to meet the test criteria, preventing rust and deterioration during its service life and causing safety issues.
Testing equipment: salt spray tester.
7. Impedance test
Impedance levels are commonly specified for battery box springs and springs with conductive applications. The requisite impedance test must then be performed in accordance with the specifications of the customer's designs. If the test fails, the impedance value
Testing equipment: resistance tester.
The things listed above are the most common spring detecting methods and associated equipment. You are welcome to submit supplements and ideas if there are any deficiencies!is normally adjustable by adjusting the material, inner and outer diameter, wire diameter, length, plating, and so on.
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Hexagon nuts, also known as hex nuts, are one type of commonly used nuts found in a wide range of industries, including the automobile industry (cars, trucks, buses, etc.), construction machinery, wind power equipment, and more. These nuts are crucial for connecting and securing machine parts alongside screws, bolts, and other fasteners. Let's explore the characteristics and uses of different types of hex nuts.
Ordinary Hexagon Nut:
The ordinary hex nut is the most widely used type and is commonly employed in machinery, equipment, and structures with rough surfaces that don't require high precision. It serves as a general-purpose fastener found in various applications. This nut offers a relatively large tightening force but requires ample installation space. Live wrenches, open wrenches, or glass wrenches are commonly used during installation.
Cylindrical Inner Head Hexagon Nut:
The cylindrical inner head hexagon nut is extensively used for machines, equipment, or structures with relatively smooth surfaces and precision requirements. It provides a relatively large tightening force and can be conveniently operated using an Allen wrench. This type of nut is versatile and finds application in diverse structures. It boasts a neat and aesthetically pleasing appearance. However, its tightening force is slightly lower than that of the outer hexagon, and repeated use may damage the inner hexagon, rendering it non-disassemblable.
Pan Head Inner Hexagon Nut:
Pan head inner hexagon nuts are less commonly used in machinery but are frequently found in furniture. They possess similar mechanical properties to the aforementioned nuts and serve to increase the contact surface with wooden materials while enhancing the overall aesthetic appeal.
Headless Hexagon Nut:
Headless hexagon nuts are essential for specific structures, such as those requiring significant jacking force or where the cylindrical head needs to be concealed.
Countersunk Head Hexagon Nut:
Countersunk head hexagon nuts are predominantly utilized in power machinery and serve a similar purpose to regular hexagon nuts.
Nylon Lock Hexagon Nut:
Nylon lock nuts feature a nylon apron embedded in the hexagonal surface, which prevents the thread from loosening. These nuts are commonly employed in high-power machinery applications.
Flange Nut
Flange nuts, also known as pad nuts, tooth nuts, hexagon flange nuts, etc., are extensively utilized in power, communication, transportation, and other industries. These nuts offer several advantages, including integration of the gasket and the nut, anti-slip tooth patterns on the bottom, and increased contact surface area between the nut and the workpiece. This enhances the firmness and pulling force of the connection.
However, flange nuts have certain limitations. They are restricted by the workpiece, resulting in smaller specifications compared to regular hex nuts. Additionally, their irregular shape may require threaded fit. Flange nuts are commonly subjected to cold galvanizing surface treatment, as the hot-dip galvanizing process may introduce defects such as difficulty in screwing the threads after plating and reduced mechanical strength in high-strength flange nuts.
Flange nuts primarily serve the purpose of increasing the contact surface area with the workpiece and are frequently employed in pipeline connections or applications where enhancing the nut's contact surface is necessary.
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Self-tapping screws are commonly used to connect thin metal plates such as steel plates and saw blades. When connecting, first drill a threaded bottom hole in the linked piece, then screw the self-tapping screw into the threaded bottom hole.
The self-tapping screw on the consolidated material can drill one of the matched female threads in the pre-drilling of metal or non-metallic materials by its own thread. Its primary application is to join thin metal plates such as thin iron sheet, copper sheet, aluminium alloy, and other metals. The main distinction between self-tapping screws and conventional screws is that self-tapping screws have a pointed head and can pass through walls or other metal materials without drilling. It not only reduces the workload of fixed projects, but it also has user-friendly properties, thus it is extensively utilised in household appliances.
Structure of Self-tapping Screw
A self-tapping screw is made up of three parts: the head, the rod, and the rod end. Each tapping screw has four primary components: the head form, the screwing method, the thread type, and the end type.
Shapes of screw heads
Screw heads come in a variety of forms. There is a round head, a half round head, a flat round head, a round head flange, a flat round head flange, a pan head, a pan head flange, a countersunk head, a half countersunk head, a cylinder head, a spherical cylinder head, a horn head, a hexagon head, a hexagon flange head, and so on.
Screwing methods
The screwing method relates to how the screw head is twisted during installing and tightening the screw. External screwing and internal screwing are the two most common procedures. In general, the allowed torque of an exterior wrench is greater than that of any internal wrench.
External wrench
hexagon flange face, hexagon flange, hexagon torx, and so on
Internal wrench
Internal spline, internal hexagonal spline, internal triangle, internal hexagon, internal 12 corner, clutch slot, six-blade slot, high torque cross slot, and so on.
Types of screw threads
Screw threads come in a variety of shapes and sizes, including self-tapping thread, machine thread, plasterboard screw thread, fiberboard screw thread and other specialised threads. Screw threads are further classified as single lead, double lead, multiple lead, and high and low teeth double head threads.
Screw end forms
Ends are classified into two types: cone ends and flat ends. However, depending on the application, the screw-in end can process grooves, notches, or sections comparable to the shape of the drill bit.
Features of Self-tapping Screw
1. A self-tapping screw is a screw that has a drill bit attached to it. A unique electric tool is used to make the hexagonal socket bolt. Drilling, tapping, fastening, and locking are all done at the same time. The self-tapping screw is mostly used for connecting and fixing some relatively thin parts, such as the connection of colour steel plate to colour steel plate, the connection of colour steel plate to purlin, the connection of wall beam, and so on. Its penetrating capacity is often no more than 6mm, with a maximum of 12mm.
2. Self-tapping screws are frequently exposed to the elements and have a high corrosion resistance. Its rubber sealing ring prevents water from entering the screw.
3. The self-tapping screw, also known as wood screws, is appropriate for usage with wood products. They are typically operated by hand. Due to labour constraints, these screws are often quite small, with a limited range of applications.
4. The self-tapping screw integrates the tap and the bolt. The tap is on the front, and the thread is on the back. Drill a hole in normally soft materials and then screw it in immediately. Tap out the thread before tightening the bolt thread. If the screw diameter is tiny enough and the material is soft enough, it can even be screwed into wood without prior drilling.
5. Self-tapping screws are typically defined by three parameters: screw diameter series, threads per inch length, and screw length. There are 10 and 12 screw diameter levels, with screw sizes of 4.87mm and 5.43mm, respectively. Threads per inch length is available in 14, 16, and 24 levels.
How Can Self-tapping Screws Be Easily Installed?
The main advantage of self-tapping screws is that they do not require nuts and can be locked and attached by their own thread. It is a pretty commonly used screw in everyday life. When self-tapping screws are inserted into holes in plastic metal materials, extrusion can generate internal threads in the holes, which is the primary function of self-tapping and self-drilling.
Self-tapping screws can be installed with an air screwdriver, a screwdriver, a pistol drill, or an electric hammer. In most cases, an electric hammer is required to drive concrete. Ordinary nails cannot be used to nail concrete walls with a mark over C10, however cement steel nails can be used directly if the bearing gravity requirements are not severe. If there is a high load bearing need, it must be secured using expansion screws, common plastic expansion pipes, and self-tapping screws.
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More than 200 billion fasteners are used in the U.S. each year. from technological to construction-based industries, that’s a lot of demand. Screws are responsible for holding your product or project together.
The electronics industry has always been driven by innovation. Whether a company is involved in creating consumer electronics, medical devices, small toys, miniaturized robots, circuits board assemblies, or electrical components, they all invest heavily in the research and development of new products. With constant pressure on company engineering teams to create new, and improve existing products, more quickly and more cheaply, many electronics companies are using analytics to gain insights into improving their manufacturing processes. In addition, a growing number of companies in the electronics industry are outsourcing the manufacturing of their parts or even their products, so they can concentrate instead on developing strategies to remain competitive in the global marketplace.
Another factor of cost-control, often overlooked in manufacturing cost-analysis, is the importance of specifying the correct fasteners in the conceptual and research phases of product design. Not using the best type or size of fastener can have a major impact on production costs and the ultimate success of the product in the marketplace.
The cost of making small electronic screw changes during the production cycle can be significant. However, making the right fastener decisions, such as specifying custom-designed small screws for electronics, early in the product’s design phase, can lower production and assembly costs by reducing the component’s per-piece price or eliminating manual operations.
To assure that you can offer new products of maximum quality at the lowest cost, take advantage of the input of top design engineers, like the experts at Screw, to customize fasteners to your specific needs during design and development. The right fasteners can prevent costly failures and delays in production, and increase your ability to offer high-quality products at the lowest cost.
When considering a redesign, such as switching to a more durable material for a frequently impacted small component, you’ll want to consult a micro screw specialist to customize fastener compatible with the new material. If this element of the redesign is overlooked, the consequences could be very costly – with products being returned for repairs, lower customer satisfaction, higher warranty costs, or even a recall of the product.
We have the knowledge and expertise to offer materials and finish options for your specific product needs. The team at Screw works diligently to provide unparalleled solutions to meet the electronics industry need for micro fasteners by creating custom machine screws with the highest level of integrity for their product or assembly.
Finding a screw manufacturer that can produce high quality items is absolutely key — don’t take a risk on a cheap price and a cheap product. If you rely on custom fasteners, you’ve got a lot of options in terms of handpicking your own manufacturer. Selecting the right one can mean the difference between a product that withstands the test of time, or one that crumples at the first sign of stress; here are the most important characteristics you should look for in a custom screw manufacturer.
Screw operates a global network of world-class technical professionals to provide cost-effective solutions for any small diameter application. As a leading supplier of custom manufactured small screws for electronics, our goal continues to be saving our customers substantial costs with design and manufacturing efficiency. We accomplish this by working closely with company teams at the initial product design phase, or whenever a product change is deemed necessary. We also supply custom micro screws for small projects, encouraging innovation world-wide.
Did you know that it wasn’t until 1928 that the National Screw Thread Commission established a standard for screw threads? Before that, all screws needed to be handmade, so no two were ever alike. While those methods are obviously long gone, sometimes — especially in the case of extremely low-cost fasteners — inconsistencies exist. As a business owner, you can’t afford to have some products that stay together and some that fall apart. Look into your screw manufacturer’s previous clients’ experiences to see if they’ve had any similar issues.
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Many reasons can cause spring failure, but in general, it can be from two aspects, one is the spring quality, and the other is improper use. The quality problems of the spring itself include unqualified spring material, unqualified heat treatment, damage in the manufacturing process, and so on. Improper use includes use beyond the limit of use, use in an environment where the temperature is too high, use in a corrosive environment, etc. The main failure modes are as follows:
The Main Forms of Spring Failure
Plastic deformation
The stress produced by the external load is greater than the yield strength of the material. After plastic deformation, the spring cannot return to its original size and shape.
Rapid brittle fracture
Some springs have material defects, processing defects (such as folding, and scratches), heat treatment defects (such as excessive quenching temperature leading to coarse grains, insufficient tempering temperature leading to insufficient material toughness), and so on. These springs may experience sudden brittle fractures when subjected to excessive shock loads.
Fatigue fracture
Under the action of alternating stress, the surface of the spring is defective, resulting in a crack fatigue source. Fracture failure occurs after crack propagation.
Springs used in corrosive media are prone to stress corrosion cracking failure.
Spring fittings used at high temperatures are prone to creep and stress relaxation, resulting in permanent deformation.
The main factors causing spring failure can be divided into 3 categories: spring material, spring design, and spring manufacturing process.
Spring Material
The chemical composition and mechanical properties of different steel grades in spring steel have their own characteristics. Generally speaking, the manufacturing material of spring should have a high elastic limit, fatigue limit, impact toughness, and good heat treatment performance. Commonly used are carbon spring steel, alloy spring steel, stainless spring steel and copper alloy, nickel alloy, and rubber. The spring material should be selected reasonably and correctly according to the stress requirements, service life requirements, and working environment requirements of the spring. Generally, we divide the tensile strength Rm into three levels, that is, the standards are given according to high, medium, and low.
If we use low-strength spring materials to produce springs bearing high stress in production, it is easy to produce permanent deformation and fail. If high-strength spring materials are used to produce spring products that require high fatigue life, the possibility of brittle failure of the spring under high-stress conditions increases.
The higher the strength of the spring material, the greater the tendency of the material to brittle fracture. Therefore, the correct and reasonable selection of spring materials with moderate mechanical properties can not only make the spring workload excellent, but more importantly, it can have excellent working performance under high fatigue life. Therefore, spring failure is closely related to the spring material.
Spring Design
A spring with good fatigue life needs to be designed by many people and through the knowledge of many disciplines.
When designing a spring, you need to understand what is necessary for a good spring fatigue life. Many spring products will fail due to unreasonable design parameters, resulting in permanent deformation in the early stage of use.
Spring Manufacturing Process
The forming, stamping, and bending of the spring during the manufacturing process may cause certain damage to the spring material. Some of these damages are obvious and some are invisible, especially for tension springs, torsion springs, and other special-shaped springs.
The maximum stress of the spring is on the surface of the spring material, and the fatigue fracture of the spring often starts from a small surface defect on the surface of the spring material. Then, under the action of alternating load, it gradually transitions and expands, and after a certain stress cycle, it will lead to spring fatigue failure.
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With the development of the aerospace industry, the demand for aerospace fasteners has increased rapidly. As aerospace fasteners are applied under an environment of high temperature, high pressure, and high intensity, their quality requirements are also particularly high. Here, we introduce some useful knowledge about aerospace fasteners.
What are aerospace fasteners?
The fastener is one kind of mechanical part that connect two or more parts that connect two or more parts together. The application is extremely wide. Aerospace fastener refers to the fastener which is specially used for the aerospace industry. It adopts specific materials with special properties or applications.
Aerospace fasteners are generally used in airplanes, satellites, and rockets. It is a typical high-end fastener. It is also a kind of important necessary basic part of aerospace aircraft. The performance requirements are much higher than the fasteners in other fields. There’re various kinds of aerospace fasteners and each category contains different specifications and types to meet the diverse needs of different materials and structures.
What are the categories of aerospace fasteners?
1. According to whether the fastener can be removable, it can be classified into removable fasteners and permanent fasteners. The removable fasteners include bolts, screws, and nuts. Permanent fasteners include high-locking nuts, rivets, etc.
2. According to product types, can be classified into bolts, screws, nuts, single-sided fasteners, special fasteners, etc.
3. According to the materials used in fasteners, it can be divided into carbon structure steel fasteners, alloy steel fasteners, stainless steel fasteners, high-temperature alloy fasteners, aluminum alloy fasteners, titanium alloy fasteners, non-metal fasteners, etc.
4. According to the differences in the requirements of the assembly operation, it can be divided into single-sided fasteners and double-sided fasteners.
Commonly used important aerospace fastener
Rivet fasteners
The rivet fastener which is applied in aerospace, quality guarantee and lightness are the most important choice factors. It is one of the most widely used fasteners on aircraft. The materials are aluminum alloy, stainless steel, heat-resistant alloy, titanium alloy, etc. Most rivets adopt composite materials, such as aluminum alloy, and titanium alloy. With the continuous improvement of the rivet material intensity, the support rivets used in corresponding important parts have also been developed, such as dual metal rivets and high shear rivets and their strength can reach the intensity of titanium alloy high lock bolts.
Bolt fasteners
The mostly applied fastener used to bear the larger parts of the aircraft is the bolt fastener which mainly includes ordinary bolts, high lock bolts, and tapered bolts. A high lock bolt is a single-sided thread fastener which is a type of bolt that is widely used in the aerospace industry. For airplane design, weight loss is an important indicator. The use of high-ratio intensity materials can achieve the replacement of large-sized fasteners with lower intensity. In addition, the anti-fatigue, corrosion resistance, rigidity, brittleness, compatibility, heat resistance, and other properties, also are needed to be considered.
Nut fasteners
Nut fasteners are used together with bolts. They have a variety of structural forms to meet the applications of different occasions, including hex nuts, bihexagon nuts, bracket nuts, barrel nuts, and high lock nuts, most of which adopt a self-lock structure. The hexagonal nut has been applied to the airplane in a large amount. The bihexagon nuts are widely used on the engine and high-strength bolts.
Single-sided fastener
There are two main forms of fastening parts used in the open parts of the airplane. One is the bracket nut/bolt and fast unloading fastener used in the removable parts such as the aircraft hatch. The other one is a single-sided nail used in the permanent connection part. The screw thread nail is specially designed for the composite material structure, which can improve the performance of sealing and anti-fatigue.
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