Chapter II

Facilities Description
2.1 Introduction
Manufacturing is

the

production

of merchandise for

use

or

sale

using

labor

and machines, tools, chemical and biological processing, or formulation. The term may refer to a
range of human activity, from handicraft to high tech, but is most commonly applied
to industrial production, in which raw materials are transformed into finished goods on a large
scale. Such finished goods may be used for manufacturing other, more complex products, such
as aircraft, household appliances or automobiles.
Manufacturing takes turns under all types of economic systems. In a free market
economy, manufacturing is usually directed toward the mass production of products for sale
to consumers at a profit. In a collectivist economy, manufacturing is more frequently directed by
the state to supply a centrally planned economy. In mixed market economies, manufacturing
occurs under some degree of government regulation.
Modern manufacturing includes all intermediate processes required for the production
and

integration

of

product's

components.

Some

industries,

such

as semiconductor and steel manufacturers use the term fabrication instead. The manufacturing
sector is closely connected with engineering and industrial design.

2.2 Brief on Manufacturing Processes

Manufacturing processes are the steps through which raw materials are transformed into a
final product. The manufacturing process begins with the creation of the materials from which
the design is made. These materials are then modified through manufacturing processes to
become the required part. Manufacturing processes can include treating (such as heat treating or
coating), machining, or reshaping the material. The manufacturing process also includes tests and
checks for quality assurance during or after the manufacturing, and planning the production

process prior to manufacturing. Let us take a look at the overall manufacturing process take place
in the mass production of bolt.
Step 1: Continuous wire/bar drawing and cutting. The first step in the manufacturing of
any bolt is to cut the round bar to length. The Peddinghaus shears function much like a guillotine
and chop the steel, rather than using a saw blade to cut through it. Bolts that are larger in
diameter or longer in length are cut using a band saw.
Next, Step 2: A hexagon head is hot-forged onto one end of the steel rod. An induction
heating coil heats the end of the rod to approximately 2000 degrees Fahrenhein. A National
Upsetter is used to forge the heated end of the rod into a hexagon shaped head. Gripper blocks
clamp the round bar securely in place while a plunger or die compresses the heated end of the
rod reshaping it into the hexagon head configuration. A second position in gripper block is used
to stamp the head with manufactures logo and grade symbol as required. The hexagon head of
this anchor bolt will be embedded in concrete and is intended to provide pull-out resistance.
Step 3: Threading. Landis threaders are used to cut 8 inch of thread onto the end of these
anchor bolts. Rotating heads contain chasers which cut steel from the round bar to produce the
threads. A constant stream of cutting oil is applied to reduce friction and prevent overheating.
Threads are gauged by the threading operators to ensure conformance to dimensional tolerances.
Step 4: Heat Treatment. To improve the mechanical properties of the bolts. To improve
the ductility. To make an improvement in toughness. Hardening is done such that bolt is heated
to a temperature of 850 to 900celcius and then quenched in the cooling media.
Step 5: Hot-Dip Galvanizing. The bolts must be picked prior to galvanizing. This process
cleans the bolts and prepares the surface of the steel to accept the zinc. Parts are first submerged
in caustic soda which removes cutting oil and other organic materials that accumulate during the
manufacturing process. The bolts are then rinsed and submerged in sulfuric acid, which removes
any scale from the bolts and etches the surface of the steel. The bolts are rinsed again and then
submerged in flux which is a chemical that assists in the bonding of the zinc to the steel. After
pickling, bolts are placed in racks and lowered into tank of 840 degree molten zinc. The bolts
remain in the zinc for between 2 to 4 minutes. When the bolts are removed from the zinc, they
are spun in a high speed centrifuge to remove excess zinc from the threads.

Step 6: Surface Finishing. Lastly, is surface finishing process. Usually grinding process is
carried out to make the surface smoother according to the surface finish specification.
2.3 Brief on Equipment

Figure 1: Peddinghaus Anglemaster APS-2063

Automated Loading of material

One diameter per leg

Punch, shear, position, and unlaod angle/flat stock in one operation

Roller feed measuring processes material in unlimited stock lengths

To cut the steel.

Figure 2: Induction Furnace for Bolts

Heat treatment,
Thermal deformation quenching and tempering for standard parts
Gear shafts
Stell bars etc,the special equipment for nut manufacturing

Figure 3: National upsetter.

A National Upsetter is used to forge the heated end of the rod into a hexagon

shaped head
Gripper blocks clamp the round bar securely in place while a plunger or die
compresses the heated end of the rod reshaping it into the hexagon head

configuration.
A second position in gripper block is used to stamp the head with
manufactures logo and grade symbol as required.

Figure 4: Landis Threaders

Landis Threading Machine to hollow mill, cut or roll, thread pipe, bolt, rod, do straight or

tapered threads, etc.

Rotating heads contain chasers which cut steel from the round bar to produce the threads.

2.4 Brief on Materials

Screws and bolts are made from a wide range of materials, with steel being perhaps the
most common, in many varieties. Where great resistance to weather or corrosion is required,
stainless steel, titanium, brass (steel screws can discolor oak and other woods), bronze, monel or
silicon bronze may be used, or a coating such as brass, zinc or chromium applied.
Electrolytic action from dissimilar metals can be prevented with aluminium screws for
double-glazing

tracks,

for

example.

Some

types

of

plastic,

such

as

nylon

or

polytetrafluoroethylene (PTFE), can be threaded and used for fastening requiring moderate
strength and great resistance to corrosion or for the purpose of electrical insulation. Besides that,
vanadium is never used, except as part of a steel alloy. Cadmium is used only for plating for
corrosion resistance in some cases
Bolts and nuts are tightened so that some axial force is present that will prevent
movement of the connected members in the axial direction of the bolt. Proper tightening also
prevents loosening of the nut. Because of the small axial forces, little frictional resistance is
developed, and in most situations the bolt will slip into bearing. This results in shear stresses in
the bolts and contact stresses at the points of bearing.

Figure 5: Hexagonal bolt.