deepak fastner grade .pdf

7/28/2019 Deepak fastner grade .pdf

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Wire Diameter Product size wise and Gold Formingper day output in Metric TonSize No.ofColdforming

MachinesProduet Types

, tl l.U \Jr.iVLl-Per day Cold: f6rming'Output inrl r.

,Before WireI Drawing(lnput Wire)Diameter in mm

After WireDrawing(Final Wire)Diameter in mm

M3 1 Screws & Bolts 0.75 5,5 2.85M4 1 Screws & Bolts 0.75 5.5 3.45 or 4.80M5 1 Screws & Bolts 0.75 5,5 4.38 or 4.80M6 4 Screws & Bolts 3.75 6.5 or 8.0 5.25 or 5.80M8 B Screws & Bolts 12.75 9 7.69M10 I Screws & Bolts 42.00 11 9.76M12 8 Screws & Bolts 42.00 13 11.6M14 2 Screws & Bolts 13.50 15 13 6M16 b Screws & Bolts _ 38.25 1B 15.6M18 1 Screws & Bolts 9.00 20 176M20 3 Screws & Bolts 27.00 22 19.6M22 1 Screws & Bolts 9.75 23 21.6M24 3 Screws & Bolts 29.25 25 or 27 23.6M27 1 Screws & Bolts 11.25 27 or28 24.90 or 26.70M30 1 Screws & Bolts 11.25 32 29.6M3 0.33333333 NUTS 0.03 5.50 4.5M4 0.33333333 N UTS 0.06 7.00 645M5 0.66666666 N UTS 0.19 8.00 7.3M6 0.66666666 NUTS 0.35 10.00 9.3MB 1 N UTS 0.68 13.00 12.1M10 1 NUTS 1.47 17.00 16.3M12 3 NUTS 4.47 19.00 18.3Ml4 2 N UTS 6.93 22.00 21.1

M16 4.5 NUTS 12.08 24.00 22.9M1B 0.5 N UTS 1.92 27.00 25.5M20 1.5 NUTS 6.86 30.00 28.9M22 0.8 NUTS 3.99 32.00 31.2M24 1.4 NUTS 8.00 34.00 33.2M27 0.6 NUTS 441 38.00 37.3M30 1.3 NUTS 14.09 42 or 44 41.2 or 43.2M33 0.4 NUTS 5.00 48 47.2

Total Tonnaqe I gZZ.Sq

tli L\ 1 ,/16th June 2011. x1sonnage Workout for MP. Plant -J*..,",,i, {^t1-;u,l&" )

We need Wire drawing machines on each size 25o/o excess capacityon above mentioned tonnage

*.-t I i't

I of I


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H RM Spec Chemical Composition (%)c Si Mn S max P max Cr Ni Mo Cu B AIL Atst 1008 0.10 max < 0.10 0.30-0.50 0.025 0.0252 Atst 1010/swRcH10A 0.08-0.13 < 0.10 0.30-0.60 0.025 0.0253 Arsr 1015 0.13-0.18 < 0.15 0.30-0.60 0.025 0.0254 Atst 1018 0.15-0.20 0.05-0.10 0.60-0.90 0.025 0.025

5 scM435/ArSr 0.33-0.38 0.15-0.30 0.70-0.85


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0.15-0.30 0.0005 - 0.0030.15-0.30 0.0005 - 0.0030.15-0.30

AlSl 1035H f\f 0.34-0.430.37-0.44 0.15-0.35

1042 / S43C 0.15-0.35ro4s/c4sE/CKA'I 1045H (26mm) 0.46-0.s1 0.15-0.3sAlst 1541

0.47-0.55

Atst 15841 0.36-0.44 0.15-0.30 1.35-1.65 0.025 0.0005 - 0.003 0N

0NH

(Cr+02: 90

(Cr+

0.10-0.20

Alx [uo tia


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, . '' ,,.' "" t MATERIAL SPECIFICATIONMATER]AL GRADE SPEC|FICAT|ON NOscM435 ALLOY STEEL FOR COLD FORGTNG 85314

3.3 Metallurqical Requirements Geftifi cation required ; YES3.3.1 Hardness

3.3.1. 1 Hot Rolled Rod - Hot rolled and finalanneal. Final annealed hardness of 85Rbmaximum is a criterion for forge-ability and therefore shall be controlied belowthe maximum.3.3.1 .2 Cold drawn Wire - Cold drawn hardness of 105Rb maximum is an indicator,but final judgement of steel is to be made by a forging trial.

3"3. 2 The microstructure of the spheroidize annealed material shall consist of a minimumof 90 o/o spheroidal carbides reasonably diffused in the fenite matrix.3.3. 3 Grain size shall be number 5 or finer as determined by ASTM E 112 companson or

fracture method3.3. 4 Harden-ability. The steel shall be capable of being hardened to 40-45Rc across thefinished wire diameter cross section by quenching from 1600'F in an agitatedconventional compounded quenching oil (150'F) and tempering for not less than 1hour at 700'F minimum.

Hardness shall be tested in accordance with the methods of Unbrako spec. 85107.Material shall be free from carburisation and complete decarburisation. Partialdecarbonisation shall not exceed the tolerance limits specified below:3.3.5

Wire Diameter, lnches Max PartialDecarb. lnchesUo to 0.093" 0.001 "0.093" to 0.141" 0.002'0.141" lo O.273" 0.003'0.274" lo 0.387" 0.004'0.388" 1o 0.527" 0.005'0.528" 1o 0.648" 0.006'0.649" to 0.985" 0.007'

Wire Diameter Max. DeothUp to 0.256" 0.002'0.257" 1o 0.646" 0.003"0.648" 1o 0.985" 0.004"

Wire Diameter Metric Max. PartialDecarb. Metric mmUo to 2.4 0.0252.4 to 3.5 0.0503.6 to 7.0 0.0767.1 to 9.85 0.1 019 86 to 13.4 0 127

13.5 to 16.5 0.15216.6 to 25.0 0.178

Wire Diameter mm Max. Deoth mmUoto65 0.0506.6 to 16.4 0.076165to250 0.101

3.3. 6 Surface and sub-surface seams shall not exceed the tolerance limits specifiedbelow:

3.3.7 Reduction of area 60% Min3.4 Source Approval.

3.4. 1 Material shall be purchased only from vendors wlro have supplied material meetingall the requirements of this specification. The vendors' facilities shall be surveyedbefore making routine production purchases.STATUSPPROVED BY DATE REVISION LEVEL DAIE PAGE SPECIFICATION

RA 11.12.08 Level - Current Page 3 of 5 8s314


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.-,,,. i:.,.. .:illtil,,Sl.irli:li:l)ii'!;rr. :)uf,:l,)lit(i,l:r'r'|], |lll'-,l. ,r, .,;,, , i, l;. ,:i: MATERIALMATERIAL GRADE

SCM435 ALLOY STEEL FOR COLD FORGINGSPECIFICATION

SPECIFICAI rON NO85314

1, SCOPE1.1 This specification covers the requirements for hot rolled rod and cold drawn spheroidizedannealed alloy steel SCM435 for cold, headed fasteners.

2, APPLICABLEDOCUMENTS2.1 The latest issue of the following document shall be applicableUnbrako 85'1 07 Procedures for Hardness Testing FastenersASTM E 112 Methods for Estimating the Average Grain Size of Metals

3. REQUIREMENTS3.1 Chemical Composition Certifi cation required: YES

Ladle Analvsis %Element Min MaxCarbon (C) 0.33 0.38Manganese (Mn) 0.60 0.85Phosphorus (P) 0.030Sulphur (S) 0.030Silicon (Si) 0.15 0.35Chromium (Cr) 0.90 1.20Molybdenum 0.15 0.30Copper (Cu)Nickel (Ni)

3.1 .1 The Material shall be Mercury free. Certifi cation required: YES3.2 Condition

3'2. 1 The material shall be melted by the open hearth, electric or basic oxygen furnaceprocess.The material shall be clean, sound, and free from such detrimental defects as laps,slivers, pipe or other defects detrimental to the fabrication or performance of theparts.HOT ROLLED ROD

3.2.2. 1 The rods shall be spheroidize annealed to meet the applicable metallurgicalrequirements of 3.3.3.2.2.2 The rod to have a surface lubricating coating to assist in the drawing of the rodto required diameter.3.2.2.3 The rod shall be coated with Phosphate Coating suitable for double extruslonprocessing. Phosphate Coating levels are as follows;

Minimum: 6.00 glm2 Maximum: 12.92 glm2

APPROVED BY DATE REVISION LEVEL DATE STATUS PAGE SPECIFICATIONRA 11.12.08 Level - Current Page 1 of5 85314


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MATERIAL SPECIFICATIONSPECIFICATION NO

85314CM435 ALLOY STEEL FOR COLD FORGING. Purchase Order Number. Quantity of each Lot. Tensile strength. State that the Raw Material is Mercury Free. Steel DateA lot constitutes all coils of one size of one heat shipped at one time.

5.4 Each item on a purchase order shall preferably be filled using one Heat Number. When thesize of the item requirement is such that it cannot be filled using only one Heat Number,another Heat Number may be used. Every effort shall be exerted to supply each itemordered in one Heat Number only.5.5 Delivery docket to accompany each shipment for each individual size and grade of materialstating the following:. Despatch reference number

. Customer order number. Customer part number. Steel date. Batch number. Material size. No. of coils. Totalweight. Despatch date5.6 Bundles of material shall not contain more than one heat and size per bundle.5.7 Excessively mixed shipments (partials of several lots) shall be avoided.5.8 Vendor to take all necessary precautions to ensure that the material arrives at final

destination in a condition fit for production.6. NOTES6.'l Sampling plan and analytical procedures for check analysis testing agree with therequirements specified in the Steel Products Manual, Wire and Rods, Carbon Steel,published by the American lron and Steel lnstitute.

7. REVISION HISTORYRevision Section ECR Chanoe lnitial Date

APPROVED BY DATE REVISION LEVEL DATE STATUS PAGF SPECIFiCATIONRA 11 .12.08 Level - Current Page 5 of 5 85314


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Material - AlSl.1035Chemical Composition

CYo Mn% si% S% P% RemarksSpecified Min. 0.33 0.60 0 '10Max. 0.38 0.80 0,35 0 025 0.025

Dim:ehsiop l . Diarne.,te r- as s peoif idi n,rP, O,Mechanical Properties

Hardness Specified 73 HRB Max.(152 BHN Max )UTS (Max.) Specified 46.0 Kg/mmz

Metallurgical PropertiesGrain Size 6-8(ASTMNo.)

Decarb 0.0'15 m.m. max. ('l5Micron Max.)

lnclusion Rating(Maximum)A B D Remarks

Thin 2.0 2.0 20 2.0 ASTM E-45(lS:4163)eavyMacro Etching (ASTM E-381) Better than CzRzSz

Microstructure Uniform Ferrite

Surface Condition No visible surface defect.

NDTUltrasonic Testing as per procedure SA-388,

acceptance as per Para- 3.3.4 (200i)ASME Sec-Vlll, DlV.2 (ED: 2007)Cold Upsetting Test Should be OK.

Size Tolerance + 0.20 mmSize Ovality

( out of roundness ) + 0.10 mmApproved BYMr A, Ghosh (SGM, 0A & l)


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Material - EN-8D/CR 0.35/0,45

Grain SizeDecarb

lnclusion Rating(Maximum)

Cttemioal, eompositlon

ffi

Macro Etching

MicrostructureSurface Condition

Cold Upsetting Test

Size Tolerance

Size Ovality( out of roundness )

Approved BYMr. A, Ghosh (SGM, QA & l)tr-,*

+ 0.10 mm


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%,* ffitu a::. :. t:..::..:::::it,:.....:1.- ::.

Ma:terial - 19MnB4(M)

Specified

i

HardnessUTS (Max.)

lsff.e6ifdgi#*.ej$j

$ltdt*Hl$ffffiHf$fi6$fi i6s

Uniform Ferrite

No visible surface defect.Ultrasonic Testing as per procedure SA-388,acceptance as per Para - 3,3.4 (2007) ASME Sec-

Grain SizeDecarb

lnclusion Rating(Maximum)

Macro Etching

Microstructure

Surface Condition

NDT

Cold Upsetting Test

Size Ovality( out of roundness )

Vlll, DIV 2 (ED: 2007) lShould be OK

+ 0.20 mm

Approved BYMr A, Ghosh (SGM, 0A & t) _l\ ,..-\tt-'t 0.'10 mm


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Material - SCM-435Ii Chemical Composition

Co/o Mn% si% S% PYo Cr. Mo RemarksSpecified Min. 0.33 0,60 0.15 0.90 0.1 5Max. 0.38 085 035 0 025 0 025 1.20 0.30

Dimension : - Diameter- as specified in P.O.Mechanical Properties

Hardness Specified 83 HRB Max,(159 BHN Max.)UTS (Max.) Specified 55.0 Kg/mmz

Metallu rgical PropertiesGrain Size 6-8(ASTMNo.)

Decarb 0.015 m.m. max. ('lSMicron Max.)

lnclusion Rating(Maximum)A B D Remarks

Thin 2.0 2.0 2.0 2.0 ASTM E-45(lS: 4163)Heavy

Macro Etching (ASTM E-381) Better than CzRzSz

Microstructure Uniform Ferrite

Surface Condition No visible surface defect.

NDTUltrasonic Testing as per procedure SA-388,

acceptance as per Para - 3.3.4 (2007) ASME Sec-Vlll, DlV.2 (ED: 2007)Cold Upsetting Test Should be OK.

Size Tolerance + 0.20 mmSize Ovality

( out of roundness ) + 0.10 mmApproved BY

Mr. A, Ghosh (SGM, 0A & l)


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.:: , .MATERIAL GRADE : SpeCtfrCettO1t r.toscM435 ALLOY STEEL FOR COLD FORGTNG i 95314

4. QUALITY ASSURANCE PROVISIONS4.1 The test methods shall be as specified in the applicable ASTM, lSO, DlN, BS Standards.4.2 Receiving inspection shall inspect and test the samples (submitted per paragraph 5.2) toestablish if they conform to this specification. lf samples do not conform, the lot will berejected.4.3 lf submitted samples conform to this specification, the lot will be released for furtherprocessing and production.4.4 lf, during production and processing, defective coils representing 10% of the lot areaccumulated, and the trouble is related back to the condition of the "as received" material,the entire lot may be rejected.

Rejection of the coil shall be based on the following:No more than 1.5% split or upset fractures will be accepted on standard headed capscrews.

4.5 Purchasing shall notify the vendor of rejected lots and arrange for negotiation with thesupplier for physical disposition of the material.4.5. 1 Samples that represent rejected material shall be preserved for two weeks from thedate of the test report. ln case of dissatisfaction with the results of the test, themanufacturer may make claim for a rehearing within that time.

4.6 Any deviations from the Specification must be covered by a Concession agreed with theCompany. Concession to be recorded and approved by Engineering and Qualitydepartments,PREPARATION FOR DELIVERY5.'1 A durable tag, to be securely wired to each coil, bearing the following information;. Description. Material Grade. Diameter. Applicable specification number. Coil weight. Steel Date5.2 Samples approximately 18 inches long shall be cut from 10o/o of the cold drawn coils in a lot,

tagged with the purchase order number, grade of steel and heat number, and shipped withthe iot of material and steel date.5.3 The vendor shall furnish, with each shipment, one copy of a certified report (i.e. Certificateof Conformance), for each lot. At minimum, the report shall indicate the followinginformation:. Description. Size. Applicable Specification. Heat Number (Cast Number). Chemical Composition. Hardness. Reduction of Area

REVISION LFVEL DATE SPECIFICATIONPage 4 of 5


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MATE RIAL S PEC I FICATIONMATERIAL GRADE

SCM435 ALLOY STEEL FOR COLD FORGINGSPECIFICATION NO

85314

3.2.2 4 Unless otherwise specified on the purchase order, diameter tolerances shall beas follows:Rod Size lnches TolerancesUp to 0.312 incl. t 0.005

Over 0.312 to 0.437 incl. r 0.006Over 0 437 to 0.625 incl t 0.007Over 0.625 to 0.875 incl. t 0,008Over 0.875 to 1 000 incl I 0.009Over 1.000 to 1.125 incl. r 0.010

Rod Size Metric TolerancesUp to 8.0 incl. !012

Over 8.0 to 11.0 incl r 0.15Over 11,0 to 15,8 incl. t 0.18Over 15.8to 22.0ind. r 0.20Over 22.0 to 25,5 incl x 0.23Over 25.5 to 28.5 incl. t 0.25

3.2.2.5 The rod coils shall be supplied to the weight limits below

COLD DRAWN WIRE3.2.3.1 The material shall be cold drawn from pickled or abrasive cleaned spheroidizeannealed rods that have been rolled from fully ground and inspected billets.(Special cold heading quality).3.2.3.2 The wire shall be supplied in coil form to the size and weight limits specifiedbelow:

Wire Diameter mm Coil l.D. mm Coil O.D. mmUp to 7.5 686-762 1 0007.6 to10.0 686-762 1 00010.1 lo 12.7 710-810 1 00012.81o 17 .8 7'10-8'10 1 00017.9 to 22.0 965-1 000 1 35022j1o25.5 965-1 000 I 350

3.2.3. 3 Unless otherwise specified on the purchase order, diameter tolerances shall be+ .000 - .003 inches. (+ 0 0 -0.076mm)3.2.3.4 The wire shall be coated with Phosphate Coating suitable for double extrusionprocessing. Phosphate Coating levels are as follows,

Minimum: 6.00 g/m2 Maximum: 12.92 glm2

Rod Coil Dia. inch Rod Coil Dia. mm Coil O.D. mm27 .s',-31.s', Up to '13,5mm

Wire Diameter inch Coil l.D. Coil O.D.Up to 0 300 27"-30" 42" max0.301 to 0.400 27"-30" 42" max0.40'1 to 0.500 28"-32" 42" max0.501 to 0.700 28"-32" 42" ma>

deepak fastner grade .pdf

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