4-Die High-Speed Long Stroke Boltmaker (Cutoff Diameter: 3/8 inch) – Technical Explanation

A 4-die high-speed long stroke boltmaker is a specialized machine designed for the mass production of bolts, screws, and similar fasteners. It uses a multi-die forming process to shape metal rods into bolts with high precision and efficiency. Below is a detailed breakdown of its technical aspects:

Key Features of the Machine

1. 4-Die Configuration:
   • The machine has 4 forming dies arranged in a sequence.
   • Each die progressively deforms the metal blank into the desired shape, such as a bolt.
   • Multi-die systems allow for complex shapes and greater dimensional accuracy compared to single or two-die setups.
2. High-Speed Operation:
   • This machine is capable of producing bolts at high speeds (often up to hundreds of parts per minute).
   • High-speed mechanisms, like servo-driven feeders and precision tooling, minimize downtime and improve productivity.
3. Long Stroke Capability:
   • The long stroke refers to the extended motion range of the press, which allows the machine to accommodate longer bolts or parts.
   • This capability makes the machine suitable for producing bolts with extended lengths, commonly required in industrial, construction, and automotive applications.
4. Cutoff Diameter: 3/8 Inch:
   • The machine is designed to handle input wire or rod stock with a cutoff diameter of up to 3/8 inch (9.525 mm).
   • The cutoff mechanism cuts the raw material to the required length before forming begins.
5. Material Compatibility:
   • Typically processes materials such as carbon steel, stainless steel, aluminum, and brass.
   • Material selection depends on the intended application of the bolts.
6. Cold Forming Technology:
   • The machine uses cold forming, a process where metal is deformed at room temperature.
   • Cold forming results in:
     • Increased material strength due to work hardening.
     • Minimal material waste compared to machining processes.
     • High production efficiency with excellent repeatability.
7. Tooling System:
   • Features precision dies and punches made from high-grade tool steel or carbide.
   • Tooling must be carefully aligned and maintained to ensure consistent part quality.

Working Principle

1. Raw Material Feeding:
   • A coil of metal wire or rod is fed into the machine.
   • The cutoff mechanism cuts the wire into predetermined lengths for each bolt.
2. Progressive Forming:
   • The cutoff blank is transferred to the first die.
   • Each die in the sequence performs a specific forming operation:
     • 1st Die: Basic shaping (head formation or preliminary upset).
     • 2nd Die: Intermediate shaping.
     • 3rd Die: Further refinement and detailed features.
     • 4th Die: Final shaping and dimensional adjustments.
3. Ejection:
   • The finished bolt is ejected from the last die.
   • Excess material (flash) may be trimmed off if necessary.

Advantages of the Machine

1. High Productivity:
   • Capable of producing large quantities of bolts in short time periods.
   • Minimizes setup times due to automation.
2. Dimensional Precision:
   • The 4-die system ensures tight tolerances and consistent quality.
   • Ideal for bolts used in critical applications (e.g., aerospace or automotive).
3. Versatility:
   • Suitable for producing a variety of bolt designs and sizes, including long bolts.
4. Material Efficiency:
   • Cold forming reduces waste and enhances the strength of the final product.
5. Cost-Effectiveness:
   • Once tooling is set up, the process is highly economical for large production runs.

Applications

1. Automotive Industry:
   • Bolts for engines, transmissions, and structural components.
2. Construction Industry:
   • Long bolts used in steel structures, bridges, and buildings.
3. Aerospace:
   • Lightweight, high-strength bolts for aircraft components.
4. General Engineering:
   • Fasteners for machinery and equipment.

Technical Considerations

1. Machine Speed:
   • Depends on the material and complexity of the bolt. Typical speeds range from 100–400 parts per minute.
2. Tooling Wear:
   • High-speed operation and hard materials can wear down tooling, requiring regular maintenance or replacement.
3. Setup Time:
   • Proper die alignment and tool adjustment are critical for consistent production.
4. Cutoff Accuracy:
   • Precise cutoff length ensures consistent bolt dimensions.
5. Material Feed System:
   • Must accommodate wire or rod stock without tangling or misfeeding.

Summary

A 4-die high-speed long stroke boltmaker with a cutoff diameter of 3/8 inch is a highly efficient and versatile machine for manufacturing long bolts with precise dimensions. It combines the benefits of cold forming, high-speed operation, and progressive die systems to produce strong, high-quality bolts for demanding applications.

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