Manufacture Of Screws Research Articles

PROSES PEMBUATAN THUMB SCREW DENGAN MENGGUNAKAN MESIN CNC BUBUT SERTA PEMBUATAN ULIR SECARA KONVENSIONAL DI PT. AMANAH JAYA PERSADA

Thumb Screws are multi-purpose fasteners designed to be tightened and loosened by hand. They are primarily used to secure cable panel covers, safety covers, battery compartments, and other parts or components that may need to be removed and reinstalled frequently. The screw system is known and has been used by humans for several centuries. The aim of creating this screw system is basically to find an easy way to combine or connect two components so that this combination becomes a single unit that is useful in accordance with its function. The Thumb Screw manufacturing process uses a CNC lathe and conventional tapping. A CNC lathe is used to make the Thumb Screw using Alumunion copper alloy series 2000 material in the form of a long pipe with a length of 26.50 mm and a diameter of 15.20 mm and a tap is used to make the thread hole. Then measure the material dimensions again as the final finishing stage

An Intelligent Manufacturing Management System for Enhancing Production in Small-Scale Industries

Industry 4.0 integrates the intelligent networking of machines and processes through advanced information and communication technologies (ICTs). Despite advancements, small mechanical manufacturing enterprises face significant challenges transitioning to ICT-supported Industry 4.0 models due to a lack of technical expertise and infrastructure. These enterprises commonly encounter variable production volumes, differing priorities in customer orders, and diverse production capacities across low-, medium-, and high-level outputs. Frequent issues with machine health, glitches, and major breakdowns further complicate optimizing production scheduling. This paper presents a novel production management approach that harnesses bio-inspired methods alongside Internet of Things (IoT) technology to address these challenges. This comprehensive approach integrates the real-time monitoring and intelligent production order distribution, leveraging advanced LoRa wireless communication technology. The system ensures efficient and concurrent data acquisition from multiple sensors, facilitating accurate and prompt capture, transmission, and storage of machine status data. The experimental results demonstrate significant improvements in data collection time and system responsiveness, enabling the timely detection and resolution of machine failures. Additionally, an enhanced genetic algorithm dynamically allocates tasks based on machine status, effectively reducing production completion time and machine idle time. Case studies in a screw manufacturing facility validate the practical applicability and effectiveness of the proposed system. The seamless integration of the scheduling algorithm with the real-time monitoring subsystem ensures a coordinated and efficient production process, ultimately enhancing productivity and resource utilization. The proposed system’s robustness and efficiency highlight its potential to revolutionize production management in small-scale manufacturing settings.

Comparative structural analysis of samples of transpedicular screws from titanium alloys

The article presents studies of transpedicular screws made of titanium alloy BT6. A metallographic and microstructural analysis of screw blanks, prototypes of transpedicular screws made of BT6 alloy and commercially produced screws made of Ti-6Al-4V was performed. Specimens of transpedicular screws were manufactured using the vortex thread cutting method on a CITIZEN Cincom K16E-VII automatic lathe. The microgeometry of the screw surface was created by sandblasting using quartz sand as an abrasive material. Studies have shown that experimental and foreign samples of transpedicular screws have a similar microstructure, consisting of globular crystals of the β-phase located in a light matrix of the α-phase. The microhardness of the rod part of the screw made of Ti-6Al-4V alloy was 312...338 HV, the microhardness of the material of the prototypes was from 264 to 394 HV. Conclusions have been drawn that determine the feasibility of choosing rods made of titanium alloy BT6 as a blank for the manufacture of transpedicular screws.

The use of methods for generating control programs of the CNC in the manufacture of the Troost screw

Companies are facing a growing demand for small-scale production of ship components. This increases the relevance of production systems that optimize the production time of complex products. Automatic generation of individual blocks of CNC programs opens up great opportunities to accelerate and improve the preparation of production of complex and especially small-scale orders, such as the manufacture of Troost screws of various configurations. This study is devoted to the creation of blocks of CNC programs based on the parameters provided by product configuration systems. Various approaches to the pre-production process are described and characterized. It is shown that the direct transfer of parameters to the CNC program can be fully automated, but is limited by the geometry of the manufactured part, which can be obtained using parametric processing cycles. In order to determine the most appropriate procedure for generating a program for a specific case, a solution methodology was developed. An approximate implementation is presented, showing the possibilities of automated generation of CNC programs in the production of Troost screw parts. It is established that when choosing the optimal method of generating a program for a CNC machine in the manufacture of a Troost screw, the amount of ROM memory required can be reduced by 10.86 times. The processing time is reduced by 1.07 times, or 39 minutes

Sustainable additive manufacturing of interference screws made from eco-friendly filament for anterior cruciate ligament reconstruction

Additive manufacturing (AM) is a sustainable manufacturing approach because it can lower emissions and have a lower negative impact on the environment. 3D-printed interference screws from poly-lactic acid, eco-friendly filament, by fused deposition modelling (FDM), were fabricated with different process parameters. The most popular technique for reconstructing the anterior cruciate ligament is interference screw fixation. This study considered the role of the AM sustainability paradigm in terms of material input for FDM and product manufacturing. This study considered the role of the AM sustainability paradigm in terms of material input for FDM and process efficiency by investigating the effect of the AM process parameters, such as printing temperature (PT), printing speed (PS), and infill percentage (IP) on the density and stripping torque (ST). Later, the degradation profile of the screw was analyzed using the weight loss of screws. The experimental design of the fully factorial design was with two levels for each process parameter. The significant process parameters and their interactions were through statistical analysis of the resulting design. Results have shown that PT, PS, and IP significantly influenced the density and ST of 3D-printed interference screws. In five weeks, 3D-printed interference screws started to lose weight.

Investigation on thread rolling processes of screws for intelligent thread rolling system

The traditional screw production equipment is very large, and many procedures need manual operation, which has a certain influence on the production of screws. In order to improvement the production efficiency, a new type of “Intelligent Thread Rolling System” is to be designed for the requirement. In this system, it is necessary to provide and transmit the relevant data for screw manufacturing, especially in the process of thread rolling. The thread plate design changes the traditional flat shape to become the curved shape. This paper has used the numerical model of the finite element method to calculate and simulate thread rolling process of thread plate of curved shape to understand the applicability. The results of relevant parameters on the thread rolling are obtained to compare with experimental data of Intelligent Thread Rolling System. Under certain test condition, the screw embryonal material can produce threads and cut off tails, but the created thread shape and depth are non-standard. The results are consistent with experimental data. The main reason is that the thread surface of thread plates of curved shape has not been redesigned. Due to the comparison and verification, the numerical parameters can be provided for the actual thread rolling operation of the ITRS. This is very helpful for the completion of the ITRS development.

FEM simulation on forming vacuum hexagon socket screws using tube workpiece

This study proposes a new forming design concept to produce vacuum hexagon socket screws using tube workpiece, and uses the finite element simulation software DEFORM-3D to simulate the multi-pass forming process of vacuum hexagon socket screws. The simulated material is SUS-304 stainless steel, and the frictional conditions are assumed to be constant shear friction, the die is assumed to be a rigid body. In the past, the traditional vacuum hexagon socket screw manufacturing process used a multi-pass process to manufacture a standard screw using a solid workpiece (wire rod), and then drilling an air channel in the core of the screw. This process not only wastes time, but also needs to increase the processing cost. In this study, the time and cost of drilling the air channel can be reduced by forming the vacuum hexagon socket head screw through the hollow tube. The finite element simulation results confirm that this design is a feasible method. The pass schedule can be reduced from 6 stages to 3 stages, the maximum effective stress decreased by 28.13%, and the total forming force decreased by 57.66%. The research results can be provided to relevant industry as the reference.

P37. Automated pedicle screw manufacturer identification in plain radiograph with deep learning method

P37. Automated pedicle screw manufacturer identification in plain radiograph with deep learning method

Automated pedicle screw manufacturer identification in plain radiograph with deep learning method

Automated pedicle screw manufacturer identification in plain radiograph with deep learning method

Determination of Two-Stage Heat Treatment Parameters in Industrial Conditions in Order to Obtain a TRIP Structure in Low-Alloy Carbon Steel Wires.

The research presented in this article aimed to obtain a semi-finished product in the form of TRIP wires, which in further research will be used to produce fasteners in the form of KPS-6 screws used in the construction industry. At present, the process of manufacturing this type of fastener (from wire rod to the finished product) involves two technological lines: one for carrying out the drawing process and obtaining a semi-finished product in the form of a wire with appropriate properties, and the other for the production of fasteners. Semi-finished product wires with a ferritic-perlitic structure obtained after the drawing process are the starting product for the production of fasteners, the tensile strength of which is approximately 450 MPa. In order to be able to obtain fasteners characterized by an increased level of properties in 8.8 grade, after the screw manufacturing process, heat treatment should be carried out by hardening and tempering. The new technology proposed in the article includes: a drawing wire rod with a semi-finished product diameter, two-stage heat treatment on the line for pass-through heating and cooling, ensuring the obtaining of a TRIP-type structure in drawn wires, and calibration drawing. The product of this process was a wire whose tensile strength was in the range of 700-800 MPa with a TRIP structure. Thanks to obtaining a TRIP-type structure with the assumed amount of retained austenite, we obtained wires with higher strength properties and very high plasticity in relation to wires with the same chemical composition and ferritic and perlitic structure. The research carried out in the article also allowed us to obtain, in the semi-finished product wires, a favourable relationship between the strength properties and plasticity of the material, expressed by the value of the Re/Rm coefficient (yield strength/tensile strength) and the so-called yield ratio, which determines the material's susceptibility to cold deformation; the smaller these coefficients, the greater the yield strength. The subsequent stages of the research will include the development of forming fasteners in the form of KPS-6 screws used in the steel construction industry with TRIP structures, with increased properties of products in the 8.8 property class, without conducting heat treatment by hardening and tempering. It is assumed that the resulting product will have an additional usable feature: preserving a certain amount of retained austenite in the structure of the finished fasteners, which will be transformed into martensite during operation, and thus affect the longevity of the fasteners.

Study of Pedicles in Dried Human Lumbar Vertebra : A Morphometric Analysis

Background: In the dynamic part of the spinal column the lumbar vertebra are the largest vertebra that support the maximum body weight and exhibit the greatest degree of degenerative changes. Pedicles of the vertebra act as a port to perform procedures inside the bodies of the vertebra such as biopsies, vertebroplasties or kyphoplasties. Pedicle screw fixation is a technically demanding procedure. Accurate anatomical knowledge of the morphometry of vertebral pedicle are also important for preoperative procedure, planning and in the design and manufacture of pedicle screws. The objective of this study to observe the morphometry of lumbar pedicles to determine the size of the screw in transpedicular screw fixation on the perspective of Bangladesh.
 Materials and methods: A descriptive observational study was conducted at Southern Medical College and Hospital in the Department of Anatomy on 65 dry adult human lumbar vertebra from December 2020 to May 2021. Width height of pedicle along with antero-posterior diameter of lateral recess (Depth) were observed by using digital Vernier Calipers and after recording data were analysed.
 Results: The study shows that there is gradual increase in the mean width of the pedicles on both right and left side from L1 to L5. Mean height of the pedicle and antero-posterior diameter of lateral recess both showed decrease at the level of L3 both on the right and left side. Conclusions: The measured data will give a gross measurement of pedicle of lumbar vertebra on Bangladeshi people, hope to provide the clinicians a better support during working with pedicles.
 IAHS Medical Journal Vol 4(2), December 2021; 51-54

Haematological and Biochemical Parameters of Blood in Patients after BIOS of the Tibia using Bioinert and Biodegradable Implants based on Magnesium Alloy MA-10

Nowadays, the search for new artificial materials to replace damaged tissues and organs is becoming increasingly important. Biodegradable materials occupy an honorable place among medical materials. Depending on the purpose, biodegradable implants should be gradually replaced by living tissue and function over a given period of time, as well as not have a negative impact on surrounding tissues and the body as a whole. Magnesium-based alloys are considered promising. Clinical studies of the dynamics of a number of key biochemical parameters that characterize the reactive response and regenerative processes in the body are of scientific and practical importance. The aim of the research was to study the laboratory - biochemical parameters of blood in patients after BIOS of the tibia using bioinert and biodegradable implants based on magnesium alloy MA-10 Materials and methods. 36 patients with tibial fractures were operated in the traumatology department of MNCE “CH of Emergency and Urgent Medical Aid” in Zaporizhzhia. After closed repositioning, the tibial BIOS was performed using biodegradable alloy screws. Blood sampling for biochemical and cytological studies was performed before and in 2, 4 weeks, 2 and 4 months after surgery. Biodegradable magnesium alloy MA-10 (TU U 24.4-14307794-270: 2018) certified for use in medicine. Results. The study of the total bilirubin dynamics in blood plasma showed that the maximum values of the indicator accompany the acute period of the pathological process. From the second week, slight fluctuations in α-amylase activity were detected, which is most likely due to the energetic support of the inflammatory process and the regeneration of damaged tissues. The use of magnesium alloy for the manufacture of screws showed stable enzyme activity for 4 weeks. In the group of patients who used magnesium alloy implants immediately after surgery, there was a significant (p≤0.05) increase in AST / ALT by 44%, compared with the initial value of the de Ritis coefficient, not by increasing the activity of AST, but by reducing activity ALT. The undulating dynamics of ESR, fibrinogen B and total bilirubin in the blood of patients of both groups reflects the stages of the reparative process. Conclusions. The bioinertness and expediency of using implants made of biodegradable magnesium alloy MA-10 in the dynamic BIOS for diaphyseal fractures of the tibia are substantiated.

The die holder interaction variable analysis of 1D2B screw heading machine and its adjustment algorithm design

Die forming is a key process in a production line of metal screw manufacturing, the most commonly used industrial process equipment type is one-die two-blow (1D2B) heading machine. Current solutions for die holder adjustment among manufacturers rely mostly on inheritance of experience. The lack of systemized solutions for fundamental machine tuning causes a gap in technological and intelligent upgrade. This study analyzed the most difficult eccentric tuning of the 1D2B heading machine. The adjustment behaviour of die holder from first blow and second blow were systemized, and the relevant interaction was divided into the following procedures: first die eccentric component adjustment, second die eccentric component adjustment, decoupling of interactions, and precompensation process design. The dimensional differences corresponding to die holder adjustment mechanisms were used to allow operators to implement the adjustments sequentially to complete die holder tuning. This study developed a systemized tuning procedure based on designed algorithm. In the developed procedure, precompensation coupling design was conducted for effectively reducing tuning errors. Tuning based on the proposed procedure enabled the precise adjustment of the die holder positions relative to the eccentric errors of corresponding manufacturing dimensions. The developed procedure can solve the problems of manual trial-and-error operations and excessive abrasion of the die holder resulting from unstable tuning qualities. Key parameters proposed by one type of heading machine, such as equipment die holder’s adjusted pitch, die center distance, and position of the axis of rotation, were examined regarding the proposed adjustments to verify the feasibility of the systemized tuning method.

ATLAS 302HQ

Abstract Atlas 302HQ is a chromium-nickel-copper austenitic stainless steel. It is a specialized wire grade with very wide usage for the manufacture of stainless steel fasteners. The inclusion of 3% copper in the composition reduces the cold work hardening rate substantially compared to type 304 austenitic stainless steel. Atlas 302HQ is the standard for the manufacture of self-tapping screws and light machine screws. It is also used for some bolts, set screws, rivets, and specialized fasteners. It has now totally replaced type 384 and type 305 austenitic stainless steels for cold heading applications, because Atlas 302HQ has relatively higher copper content which is used a lower-cost alternative to the high nickel contents in those alloys. This datasheet provides information on composition, physical properties, elasticity, and tensile properties. It also includes information on corrosion resistance as well as forming, heat treating, machining, and joining. Filing Code: SS-1350. Producer or source: Atlas Steels.

Developing an Anomaly Detection System for Automatic Defective Products’ Inspection

Since unqualified products cause enterprise revenue losses, product inspection is essential for maintaining manufacturing quality. An automated optical inspection (AOI) system is an efficient tool for product inspection, providing a convenient interface for users to view their products of interest. Specifically, in the screw manufacturing industry, the conventional methods are the human visual inspection of the product and for the inspector to view the product image displayed on the dashboard of the AOI system. However, despite the inspector and the approach used, inspection results strongly depend on the inspector’s experience. Moreover, machine learning algorithms could improve the efficiency of human visual inspection, thus addressing the above problem. Based on these facts, we improved anomaly detection efficiency during product inspection, using product image data from the AOI system to obtain valuable information. This study notably used the visual geometry group network, Inception V3, and Xception algorithms to detect qualified and unqualified products during product image analytics. Therefore, we considered that the analyzed results could be integrated into a proposed cloud system for human–machine interaction. Thus, administrators can receive reminders concerning the anomaly-inspected notification through the proposed cloud system, comprising a message queuing telemetry transport protocol, an application programming interface, and a cloud dashboard. From the experimental results, the above-mentioned algorithms had more than 93% accuracy, especially Xception, which had a better performance during the defective type classification. From our study, the proposed system can successfully apply the obtained data in data communication, anomaly dashboards, and anomaly notifications.

Strength and fracture mechanism during torsion of ultrafine-grained austenitic steel for medical applications

The article considers evaluation of torsional strength and fracture of austenitic corrosion-resistant steel 08Kh18N9 with an ultrafine-grained (UFG) and coarse-grained (CG) structure, widely used in medicine for the production of plates, screws, rods for bone osteosynthesis and other medical products. The structure of the CG steel was studied using an Axiovert 40 MAT metallographic microscope, and the fine structure of the UFG steel was investigated with a JEM-2100 transmission electron microscope. Torsion tests of the cylindrical samples with a diameter of 10 mm were carried out at a temperature of 20 °C on MK-50 installation. JEOL JCM-6000 scanning electron microscope was used for the microfractographic studies of fracture surfaces. The analysis of the “Torque - torsion angle” diagrams showed that the torsional ultimate strength (τt) and yield strength (τ0.3) of UFG steel increase by 1.3 - 3.8 times, and the relative shear (g) decreases by 2.4 times in comparison with CG steel. High values of torsional strength properties of UFG steel make it possible to provide high torque without destroying the product. Consequently UFG steel 08Kh18N9 in comparison with CG steel is a more promising material for the manufacture of medical screws and other medical products that experience significant loads during the torsion process. Three areas were identified on the surface of all fractures: fibrous central part, transitional (middle) part, and a relatively smooth peripheral part. Fracture begins with the formation of shear pits in the middle and peripheral parts, which, with further rotation of the sample, are completely rubbed out (in case CG steel), or remain (in case of UFG steel). Final failure occurs under the action of normal stresses in the central part of the sample.

Analysis of Torque Maintenance and Fracture Resistance after Fatigue in Retention Screws Made of Different Metals for Screw-Retained Implant-Borne Prosthesis Joints.

Purpose The aim was to evaluate the effect of different metallic alloys used in the manufacture of retention screws for universal cast to long abutment (UCLA) abutments for external hexagon (HE) and Morse taper (MT) connection implants, as well as of mechanical cycling on torque maintenance and fracture resistance through electromechanical fatigue testing by mastication followed by compression testing. Methods Sixty implants were used, 30 MT and 30 HE, with their respective titanium UCLA abutments and retention screws of 5 different materials (n = 6): Ti cp grade 2, Ti cp grade 4, Ti cp grade 4 hard, Ti grade 5—Ti6Al4V and surgical steel (DSP® Biomedical). The assemblies were positioned in an electromechanical masticatory fatigue testing machine. The fracture strength test was performed by compression testing in a universal testing machine EMICDL-200. Results The cycled screws and new screws of each alloy group for each connection type were evaluated, obtaining the maximum force (FM), in order to verify the effect of mechanical cycling. The data were tabulated and submitted to appropriate statistical analysis (α = 0.05). Conclusion It was concluded that for the MT, the alloy with the best performance was steel, both in the maintenance of torque and in the compression test, and cycling negatively influenced the maintenance of preload for this connection. The alloy material did not influence torque maintenance for HE. The new screws that were subjected to EMIC showed higher strength. The alloy with the lowest strength was Ti grade 2.

Performance Modeling and Availability Analysis of Screw Manufacturing Plant

In this research, we focus at the deviation of availability, which is used as a performance measure of screw plant with respect to time. This plantconsistsofnumerous units, viz., header, slotting, thread roller and burnishing unit. These units are operating in sequence. Working, partial failure and absolute fault are the system's three states. We originated the mathematical model of the plant Using Markov birth - death Process and we solve the differential equation by implementing the matlab tool to determine the availability of the system. Appropriate maintenance planning must be devised, which can be controlled after assessing availability variances over time. The theory of availability analysis will help to increase output and increase screw plant uniformity. We use data and graphical representation to depict the availability of the screw plant as it evolves over time the numerical data are provided for different configurations which are successful in enhancing the availability of the system..

Strength and Fracture Mechanism during Torsion of Ultrafine-Grained Austenitic Steel for Medical Applications

The article considers evaluation of torsional strength and fracture of austenitic corrosion-resistant steel 08Kh18N9 with an ultrafine-grained (UFG) and coarse-grained (CG) structure, widely used in medicine for the production of plates, screws, rods for bone osteosynthesis and other medical products. The structure of the CG steel was studied using an Axiovert 40 MAT metallographic microscope, and the fine structure of the UFG steel was investigated with a JEM-2100 transmission electron microscope. Torsion tests of the cylindrical samples with a diameter of 10 mm were carried out at a temperature of 20°C on MK-50 installation. JEOL JCM-6000 scanning electron microscope was used for the microfractographic studies of fracture surfaces. The analysis of the torque–torsion angle diagrams showed that the torsional ultimate strength (τt) and yield strength (τ0.3) of UFG steel increase by the factor of 1.3–3.8, and the relative shear (g) decreases by the factor of 2.4 in comparison with CG steel. High values of torsional strength properties of UFG steel make it possible to provide high torque without destroying the product. Consequently, UFG steel 08Kh18N9 in comparison with CG steel is a more promising material for the manufacturing of medical screws and other medical products that experience significant loads during the torsion process. Three areas were identified on the surface of all fractures: fibrous central part, transitional (middle) part, and a relatively smooth peripheral part. Fracture begins with the formation of shear pits in the middle and peripheral parts, which, with further rotation of the sample, are completely rubbed out (in case CG steel), or remain (in case of UFG steel). Final failure occurs under the action of normal stresses in the central part of the sample.

Darlaston: Growth of A Staffordshire Industrial Town During the Nineteenth Century

Darlaston, in the part of the English midlands known as the Black Country, grew from a small village prior to the Industrial Revolution to a town of over 15,000 inhabitants by the beginning of the twentieth century. It played an important role in the area’s coal and iron extraction, and manufacture of gun parts, screws and bolts. Hitherto little has been written about the social history of this significant industrial urban location but by using a range of sources including the national censuses, maps and newspaper reports, the nature of Darlaston’s changing built environment and the experiences of its residents is investigated in a close focus, microhistorical study.