Parts

Countersink vs. Counterbore Holes in Machining

March 7, 2023

Countersink vs. Counterbore Holes in Machining

Machined parts can have holes of all different shapes and sizes. Each type of hole has a name that describes the shape of it. Two popular types of machined holes are countersunk holes and counterbored holes.

Countersink vs. Counterbore Holes

The difference between countersink and counterbore holes is the shape of the top of the hole. Countersink holes have a cone-shape, while counterbore holes have a cylindrical shape.

Both types of holes are designed to hide the head of a fastener, making it flush with the part when it’s assembled. The different type of hole is designed to be used with different fasteners.

Fasteners that have an angled head require a countersunk hole to be flush. A fastener with a flat head needs a counterbored hole.

Countersunk holes

A countersunk hole is a cone-shaped hole that is drilled into a material. A cone-shaped cutting tool is used to machine the chamfer at the desired angle, and then the rest of the hole is drilled with a regular drill bit.

Countersink holes are often used in woodworking or when working with softer materials. The angle can be adjusted, but the 3 most common are 60°, 82°, and 90°. ISO standard screws often have a 90° angle. In the aerospace industry, countersunk fasteners usually have an angle of 100°

Advantages and disadvantages

Countersink holes are used to hide the screw head by making it flush with the metal. This protects the screws and increases their lifetime. This also improves the visual appearance, and can make the part or assembly more aerodynamic.

Drilling countersink holes does add to the machining cost compared to drilling a regular thru hole.

Counterbore holes

A counterbore hole is a type of machined hole created to seat a fastener flush with, or below, the surface of a part. Counterbore holes are typically shallower than a countersink hole and have straight sides rather than angled sides.

Washers and lock washers can also be used in counterbored holes to secure the fastener.

Advantages and disadvantages

A counterbore usually has more holding strength compared to a countersink hole because the force applied by the socket cap screw head is parallel to the axis. The force applied by the screw or bolt is distributed evenly over a larger surface area. This is not the case with a countersunk hole, which has tapered sides.

Countersink vs. Counterbore: Applications

Countersinks are typically used for wood and metal screws, while counterbore holes are used for larger fasteners such as lag bolts, and socket head fasteners.

Countersink and counterbore holes are often used in applications with moving parts, and for assemblies with limited space. Because they provide more space for lock washers, counterbores are used in heavy-duty applications including machinery, construction, and automotive applications.

Callout symbols

The callout symbol on a machining blueprint for a countersink hole is “⌵” and the callout symbol for a counterbore hole is “⌴”. The symbols are designed to match the top shape of each hole.

Countersink and counterbore sizes are expressed in terms of their diameter, depth, and angle of countersink. The diameter is the width of the countersink or counterbore, while the depth is the distance from the surface of the material being drilled down to the top of the pilot hole.

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Types of Precision Fasteners

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Everything You Should Know About Thread Galling

January 31, 2023

Everything You Should Know About Thread Galling

Thread galling is wear that happens when two threaded parts rub against each other. Over time, the build-up of friction causes the threads to stick together. Vibration, changes in temperature, and pressure causes the threads to rub against each other. This build-up of friction can cause excessive wear and tear on the threads, leading to seized bolts, and stripped threads. Galling makes it impossible to disassemble the threaded parts without breaking them.

Thread galling is commonly found in bolted joints, and it’s often caused by insufficient lubrication or incorrect assembly.

What causes thread galling?

One of the main reasons thread galling happens is because of how the threaded parts are manufactured. On a bolt, the threading is cold rolled. This means, the bolt blank was rolled between thread dies to form the threads. The threads on a nut are formed with a cutting tool.

If you looked at a matching nut and bolt under a microscope, you’d see that neither set of threads is perfect. This difference in manufacturing methods can cause some resistance when the nut and bolt are threaded together.

Thread galling is also caused by heavy pressure on the threaded assembly. If a threaded part is holding weight, or being pressed up against something, the threads are being pushed into each other which can cause galling over time.

Vibrations or movement in an assembly also causes galling. Because the threads aren’t perfectly matched together, if the parts are moving there will be friction and heat causing galling.

Temperature changes also cause thread galling. The metals expand and contract and the threads rub against each other.

What metals are most likely to be affected by galling?

When most people experience thread galling, it’s happening with stainless steel fasteners. Any type of metal can be affected by thread galling. However, harder metal alloys are less susceptible.

Metals that are more prone to thread galling are stainless steel, aluminum, brass, and titanium. Galling can happen to other materials depending on the design of the threaded assembly, and the surrounding environment.

Which environments does it happen in?

Thread galling can happen right away when the threaded parts are being assembled. If you tighten a nut onto a bolt and experience friction, the threads will heat up and stick together. That galling can happen in any environment, but it can be avoided with proper assembly and anti-seize lubricant.

Galling can also happen over time. It’s more likely to happen when threaded parts are exposed to high temperatures, high pressures, and high levels of vibration. When there’s more movement or pressure, the threads are rubbing against each other more. And in high temperature applications, the metals are weaker and more likely to deform.

Can you prevent galling?

You can’t guarantee that thread galling will never happen, but there are steps you can take to reduce the chances of it happening.

Proper lubrication

Thread galling can be prevented by using proper lubrication before assembly. Adding a small amount of anti-seize lubricant onto your bolt creates a barrier between the metal threads, reducing the chances of galling. You’ll also want to clean off all the threads to avoid any debris between the threads.

Proper assembly techniques

A lot of thread galling happens during assembly. If you’re screwing a nut onto a bolt and it gets stuck, you might try to keep threading it on. This will cause thread galling and can snap the bolt, or ruin the threading on both parts.

Making sure the parts aren’t cross threaded, and assembling the parts slowly helps prevent galling.

Using two different metals

Using two different metal alloys (like a softer metal and harder metal) can also reduce thread galling. Two stainless steel parts can stick when they’re being assembled, but a stainless steel bolt and brass nut are less likely to have threading issues. Of course, there are many situations that require certain alloys to be used, like in the marine industry.

Thread galling can be repaired in some cases by adding new threading to the parts. However, it’s usually best to aim to avoid it or replace the damaged parts.

Does thread galling happen more with smaller threads?

Finer threads are sometimes easier to cross thread, but thread galling can occur in both large and small threads. The size of the thread doesn’t necessarily make it more or less prone to galling.

Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

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Different Types of Gears And Their Applications

January 18, 2023

Different Types of Gears And Their Applications

Gears are one of the most commonly used mechanisms in systems that have moving parts. Mechanical gears, or cogs, are used to transfer torque or power from one part to another.

If you look inside of a clock, you’ll find gears controlling the movement and speed of the hands. Cars also use gears to transfer power from the engine to the wheels.

The general purpose of every gear is the same, but there are many different types of gears, each with pros and cons.

This article covers the various types of mechanical gears and what they’re used for.

Internal vs External Gears

To start, there are external gears, and internal gears. As you probably guessed, external gears have the gear teeth on the outside of the part, while internal gears have teeth on the inside.

Internal gears can be more efficient than external gears, but they come with limitations. Internal gears can only work with an external gear, and only spur and helical gears can be internal gears. Internal gears have a size advantage, because the two centers of the meshed gears can be closer together. They’re commonly used in applications where space is limited.

Another difference between internal and external gears is the way they spin while working together. When two external gears are working, they spin in opposite directions. While an internal and external gear work together, they spin in the same direction.

Spur Gears

Spur gears are the simplest and most common type of gear. The teeth on spur gears line up parallel and transmit the power and torque to a parallel shaft. Spur gears are commonly used in vehicles, conveyor systems, speed reducers, and more.

The purpose of these gears is to change speed in a system. For example, a smaller spur gear is used with a larger gear to reduce speed. The smaller gear might spin 100 times, and spin the larger gear 1 time.

Spur gears are easy to manufacture, and they’re fairly efficient.

Rack and pinion

A rack and pinion is more of a system than gears. The pinion is the spur gear, and the rack is the toothed straight edge. This system uses a spur gear and a flat surface with matching gear teeth. Rather than transferring continual movement, a rack and pinion transfers rotational power into linear movement.

Rack and pinion systems are often used in a linear actuator, stairlifts, and steering systems.

Helical Gears

Helical gears are very similar to spur gears. The difference is, the teeth on helical gears are cut at an angle, and the gears line up in opposite directions so the teeth mesh together.

Just like spur gears, these gears transfer power to a parallel shaft.

The advantage of helical gears is that there are multiple gear teeth in contact, and when the gear teeth come into contact, it’s more gradual. This offers two benefits:

Because multiple teeth are in contact, helical gears can carry larger loads.
Because the teeth come into contact gradually, they are quieter and less friction.

There are also double helical gears that have two helical gears side by side to increase the contact area of the teeth.

Bevel Gears

Bevel gears are gears formed on a cone, rather than a cylinder. Instead of meshing parallel, bevel gears mesh together perpendicularly. This changes the direction of the movement, turning linear power into vertical power.

These gears are commonly used in a vehicle’s differential and rear axle assembly. Bevel gears are also common in the manufacturing industry, including lathes and drilling machines.

Most bevel gears are used at a 90°, but they can be used at various angles.

Worm Gears

A worm gear consists of two differently shaped gears. One gear is shaped like a screw, and the other gear is similar to a spur gear. The worm gear meshes on top of the other gear and rotates to move the other gear. Like bevel gears, worm gears also transfer the power perpendicularly rather than parallel.

Worm gears have less friction and are typically quieter, but they are less efficient in terms of power transfer. Worm gears can produce significant reductions in speed in compact spaces, making them useful in many industrial applications.

How are gears manufactured?

There are many different ways to manufacture gears. The right manufacturing method depends largely on the size, material, and precision requirements of the gears.

Casting

Die casting is a common method used to manufacture gears, and gear blanks. Casting is a process where molten metal is poured into a metal die mold. Secondary machining processes can be used to add the gear teeth or improve the surface finish.

Casting is typically used for larger gears, and gears that don’t require high precision.

CNC Milling

CNC milling is a common precision machining process. The raw material—usually a round metal bar stock—is held in place and a rotating cutting tool removes material to form the part.

CNC milling can be used to form any type of gear, use any material, and maintain tight tolerances.

Broaching

Broaching is a precision machining process that uses a cutting tool called a broach to remove material and form a part. A custom broach is expensive, so broaching is used to manufacture high quantities of identical gears.

Broaching is most commonly used to cut internal gearing, and less common to cut angled gearing.

Common materials

Gears are continuously in contact with other metals, and most gears are in high-fatigue work environments. The common materials used for gears are high-strength steels.

4000-grade Molybdenum steel alloys offer excellent strength, wear resistance, and heat resistance. This steel alloy is very common in the automotive industry.

86xx steel alloys are low-carbon alloy steels that offer good toughness and core strength. These alloys have better machinability compared to 4000-grade steels.

9310 is low-carbon steel similar to the other alloys. It has high core hardness and high fatigue strength. This alloy is commonly used for aircraft gears, but less suitable for high temperature applications.

Steel alloys are almost always heat treated after machining to increase the strength and durability of the parts.

Some softer alloys like brass and bronze are used for gears that require less strength and hardness. Because these alloys are softer, there’s less physical wear on the gears. Brass and bronze are also more resistant to corrosion compared to steel. The tradeoff is that the softer metals can’t handle high loads that steel can.

Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

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Types of Precision Fasteners

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Coarse Thread vs Fine Thread Comparison

January 12, 2023

Coarse Thread vs Fine Thread Comparison

Threading is one of the most important aspects of fasteners and part assemblies. You need to choose the proper type of thread to ensure your parts will function properly. Screws, nuts, and bolts are the most common threaded parts, but tons of other parts have internal or external threads to attach with other parts and form a secure assembly.

Threads can be made in any shape and size, but there are two main categories: coarse threads and fine threads.

Coarse threads vs Fine threads

Coarse threading is when the thread peaks are further apart and bigger. Fine threads are closer together and smaller.

Imperial measurements measure the number of thread peaks per inch. For example, a 2in bolt has 50 peaks, or 25 threads per inch (tpi). Fine threads have a higher TPI, although there isn’t an exact number of threads per inch that tells you if the threading is coarse or fine.

The metric system measures threads by how far, in millimeters, a fastener advances in one turn. If the bolt advances 1 millimeter with each rotation, the thread measurement is 1M. Coarse threaded parts have a higher measurement, because the part moves more with each turn.

Choosing the right type of threading depends on the part’s purpose and environment.

Pros and cons of coarse threads

Coarse threads are used for most screws and construction fasteners. The coarse threads create a stronger bond with softer and more brittle materials like wood, drywall, and sheet metal. Coarse threads are also less likely to be cross threaded.

Coarse threads are stronger when they’re not connecting with other threading, but weaker when they are. For example, a coarse threaded screw drilled into plywood is stronger than a fine threaded screw. But, a coarse threaded nut and bolt are weaker than a fine threaded nut and bolt.

Pros and cons of fine threads

Fine threads are used in smaller and more precision fasteners. Finer threading offers a stronger hold because more threads per inch add more surface area to the parts threaded together.

Fine threading also allows fasteners to be tightened with more precision. The downside to finer threading is the higher chance of cross threading and thread galling, when the threads are misaligned with each other. This can also cause damage to the threads.

Fine threads also limit the options to add plating, paint, or other protective coatings to the fastener.

How threads are measured

There are many different thread measurements in addition to threads per inch. When you look at different measurements, it can be confusing to figure out what each measurement means.

Thread pitch: the distance between the thread peaks.
Thread length: the distance from the start and end of threading.
Nominal length: the total length of the fastener.
Minor diameter: the smallest diameter of the threaded area.
Major diameter: the largest diameter of the threaded area.

How threads are made

There are a few different common methods to forming part threads.

The first method is called thread rolling. A blank (part without threads) is rolled between two thread dies to form the threading.

The second method used to make threads is CNC milling, or Swiss screw machining. Both of these methods use a cutting tool to remove material and form threads. These machining methods are more precise than thread rolling, but also slower and more expensive.

Spex offers a large selection of custom precision machined parts for whatever your project needs. We are an ISO 9001:2015 certified company, and our team specializes in precision machining and supply chain efficiency. Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

Reach out to our team to get a quote for custom precision fasteners.

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What is a Square Head Screw?

January 4, 2023

What is a Square Head Screw?

Precision screws come in virtually any shape and size. One of the popular choices for durable screws are square head and square drive screws. These screws offer better durability and longevity compared to typical phillips head screws.

A square head screw is a type of fastener that has a square recess at the top, rather than the philips plus or flat head screw slot. You’ll need a square bit to install and remove the square head screw.

You’ve probably experienced the frustration of a screw head getting stripped. The square recess holds its shape significantly better than the phillips head screw. One of the reasons for this is because phillips head screws are designed to “cam out” to prevent the screw from breaking. The screwdriver or drill bit moves out of the screw head to prevent shearing the screw in half.

Square head vs Square drive

Technically, square head screws are screws with a square shaped head, not a square recess. Actual square head screws aren’t very common. Square head bolts, which don’t have a pointed end and use nuts to secure an assembly, are more common.

Screws with a square recess are technically called square drive screws. When most people say square head screws or square drive screws, they’re talking about the same part—a screw with a square recess.

What are square head screws used for?

Square head screws are commonly used for applications that require high torque. This includes most deck screws, drywall, furniture manufacturing, and other high-demanding applications.

Square drive screws are also better suited for removal and reinstalling. If something needs to be assembled and disassembled often, this type of screw is one of the best options.

How square head screws are manufactured

There are a few different methods used to manufacture screws.

One of the common screw manufacturing methods is a process called cold heading and thread rolling.

A piece of wire is cut to the desired length.
The wire is stamped to create the head of the screw.
The screw blank is rolled between two dies to create threading.

Swiss screw machining is another manufacturing method. Swiss screw machines are used to make precision parts that typically have a long and skinny shape. These machines were originally developed to make Swiss watch parts, and they’re still used to make precision screws. Swiss screw machining isn’t used for regular screws you buy at the hardware store, because those don’t require a high level of precision. Screws used in the aerospace, medical, and electronics industries require tight tolerances which Swiss screw machining provides.

The third screw manufacturing method is a screw lathe. This is much less common today. The lathe rotates the part and uses a single-point cutting tool to remove material and form the screw threads. CNC lathes are used to make precision parts, but not commonly used for screws.

Common screw materials

Because one of the advantages of square head screws is increased durability, these screws are typically made with harder metals.

At Spex, we use a wide variety of materials:

Heat treated steels
Stainless steels
Nickel alloys
Titanium
Monel
Brass

The ideal material depends on what the screw will be used for. Different metal alloys perform much differently in different work environments. Heat treated steel alloys are strong and less expensive, but aren’t ideal in a wet environment.

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A Quick Guide to Linear Shafts

October 15, 2022

A Quick Guide to Linear Shafts

A linear shaft is a metal rod that moves large objects or assemblies on a linear plane. These precision parts are used in a variety of industries, and they provide smooth and precise movement. You’ll find linear shafts in things like MRI machines, vehicle seats that move back and forth, and printing and packaging machines. The linear shaft is the part that provides support and keeps everything in the proper place as they move.

There are a few different types of linear shafts. Most of these are made with hard metals and have the strength required to support 100s or 1,000s of pounds.

This guide to linear shafts will give you some info about how the shafts are manufactured, the various types, and their use cases.

What is a linear shaft?

A linear shaft is a metal rod that supports linear motion (moving in a straight line). Usually this is a sliding or gliding motion. The shaft is mounted onto the application and doesn’t move, but rather supports the parts and components that are moving. In the case of powered mechanisms, the shaft works with an actuator, support rails, or bushings and ball bearings for manual movements.

The shaft is the piece that’s usually bearing most of the weight, so they’re manufactured with durable metals that can withstand the weight and resistant to wear over time from the other parts sliding back and forth.

Types of linear shafts

The general shape of the linear shaft is the same—a smooth metal rod. There are slight variations, depending on the specific use of the rod.

Many linear rods are solid metal to provide the necessary tensile strength. They can be hollow or have a key slot that allows wiring or liquid to move through them.

Other features are added to the ends of the rods. Inner and outer threading, stepped and chamfered ends, or holes can be added to the ends for mounting purposes.

Common applications

Linear shafts are used in just about anything that moves or slides back and forth with precision. You won’t find these shafts in your sliding kitchen drawers, because precise movement isn’t required.

Here are a few of the real-world applications:

Aerospace industry: Linear shafts are used to move seats and to slide out stairs and ramps.

Automotive industry: Linear shafts are used for electric seat adjustment.

Medical industry: Linear shafts are used for many different machines like MRI machines, scan machines, operating tables, and more.

Manufacturing industry: Linear shafts are used for printers and packaging machines, and sliding tables.

Linear shafts can only be mounted and supported from each end, because the other parts are moving up and down the shaft. In cases where longer distances are required, and more weight is being moved, a rail system is preferred. The rail system can be supported at multiple points without interrupting the movement because the moving parts only use the top part of the rail.

How are shafts machined?

To provide smooth back and forth movements, the shafts need to be machined with precision, and have a smooth surface finish. The most common machining method is CNC turning or lathe machine.

These machines hold the raw bar stock in a spindle and rotate it at high speeds. A cutting tool works to remove the material to the specified part design. CNC turning machines are the most efficient type of machine for making cylindrical parts with precise measurements like linear shafts.

In most cases, the milling machine can form all of the part features at the same time, so no secondary machining is required. Depending on the surface roughness requirements, the shafts might be polished after machining to improve the smoothness.

Materials and coatings

The primary function of linear shafts is to support weight and provide smooth movements.

The most common materials used are stainless steel alloys. Stainless steel provides great strength and resistance to wear and corrosion. 304, 316, and 316L stainless steel alloys are the most commonly used because they provide excellent corrosion resistance. 316 and 316L are preferred for applications in food processing, semiconductor, and medical industries. 440 stainless steel is also great for high pressure applications.

In cases where lower tensile strength is needed, aluminum alloys are used. Aluminum is much lighter, less expensive, and still has good corrosion resistance. Most aluminum shafts are anodized to increase durability.

When rust and corrosion is less of a concern, carbon steel is used. This is much less expensive and offers similar tensile strength as stainless steel. Carbon steel can also be plated or heat treated to improve corrosion resistance.

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Different Types of Precision Pins

September 1, 2022

Different Types of Precision Pins

Pins are used in millions of consumer and industrial products. Pins are one type of precision fastener. They come in an unlimited variety of materials, shapes, and sizes and are commonly used to align and hold parts and assemblies together.

Precision pins are machined to hold two components together when a threaded screw or bolt shouldn’t or can’t be used. Most pins are semi-permanent, which means they can be removed and replaced fairly easily.

Types of precision pins

Pins are a simple part that’s usually cylindrical and without threading. Different types of pins are used in different capacities.

Dowel Pins: Precision dowel pins are short cylinders that keep multiple components in proper alignment. Dowel pins are usually solid metal and can be machined using stainless steel, brass, carbon steel, and nearly every other metal. You’ll find dowel pins used in furniture assemblies, but wooden dowel pins usually aren’t as precise as metal pins. Dowel pins are available in high-precision tapered, slotted, spiraled, stepped, and grooved designs.

Spring Pins: A spring pin, or rolled pin, is a hollow or coiled cylinder of metal—usually rolled steel. Spring pins are slightly larger than the hole they’re used for to provide a snug fit, and a chamfered edge on one or both ends to help facilitate starting the pin into the hole.

Grooved Pins: Grooved pins are solid dowel pins that have grooves running down lengthwise. Grooved pins don’t have less material. Instead, the grooves are swaged, which displaces material and increases the diameter of the pin. The grooves close when the pin is forced into a hole, which gives grooved pins more elasticity than standard dowel pins. Similar to spring pins, there is a pilot or taper on the end to help get the pin started.

Locating Pins: There are dozens of different styles of locating pins that can be used in different situations. Locating pins can be used to locate and align a workpiece on a fixture, or to align two pieces of a fixture.

Where are precision pins used?

You can find pins nearly everywhere. Since we’re focusing on pins with more precision dimensions, they’re most commonly used in the automotive, electronic, aerospace, and defense industries. When the right materials are used, precision pins provide a secure bond between two metal parts, and they can withstand a decent amount of pressure.

Precision pins need to be manufactured precisely and with care to fulfill their purposes.

These can be found in industries where high standards and tight tolerances are necessary. Precise machining is required for pins being used in the aerospace and automotive industries.

Other applications where you can find precision pins include electronics, mining tools, plumbing, and power distribution. The power distribution industries are some of the most common users of precision pins. This type of pin is used for shafts, male connector pins, mechanical applications, and more.

Common materials used

Because the pin is in constant contact with other metal parts, the material used for pins needs to be complementary to the surrounding materials. It’s also essential to consider the environmental circumstances of the assembly– if there’s going to be moisture or chemicals present, or constant temperature changes.

Most pins are constructed with harder metals like steel, stainless steel, carbides, or superalloys like Monel or Hastelloy. Some applications may require softer materials. These materials are usually brass, aluminum, or mild steel.

Secondary processes are also used to improve the durability of the pins. It’s very common for pins to be galvanized, plated, heat treated, or anodized to increase the hardness and corrosion resistance of the metal.

How are precision pins manufactured?

There are many different ways to manufacture pins. Since most pins are ordered in large quantities, high volume machining methods like cold heading, spring pin machines, and Swiss screw machines are used.

The most common production process is called cold heading. Cold heading is the best way to manufacture high quantities of precision pins from a variety of metals.

The cold heading process starts with a long wire of metal, and then cuts the wire into smaller pieces called slugs. Then, the cold heading machine presses the slug into the desired shape. Depending on the specifications of the pin, there are one or multiple unique presses.

The cold heading machine uses a series of powerful hammer-like movements and dies to form the desired shape and dimensions. Since pins are a more simple shape than most parts, this process is more efficient than CNC machining. Cold heading allows rapid production of high quantities while maintaining tolerances within 50 microns (0.0002 inches).

For spring pins and rolled pins, a different type of machine is used. A spring pin machine takes a flat strip of metal and rolls the material into the desired pin shape, length, and thickness. This process is also ideal for high quantities and is relatively cheap compared to other machining processes.

Swiss screw machines are used to machine more complex precision pins. These machines specialize in making small, cylindrical shaped parts. The Swiss screw machine has exceptional precision, maintaining tolerances of ±0.005mm (0.0002in). This machining method is also efficient for high-volume orders because it can run automatically for hours without human involvement.

Order custom precision pins

Spex offers a large selection of custom precision pins and rollers for whatever your project needs. We are an ISO 9001:2015 certified company, and our team specializes in precision machining and supply chain efficiency. Our machined components are available in an array of different materials and finishes and are manufactured to meet all the highest quantity needs.

Reach out to our team to get a quote for your next project.

The Different Types of Manufacturing Processes & Approaches

Precision Machining in the Automotive Industry

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Types of Rivets: Learn About Different Rivets and Their Common Uses

May 30, 2022

Types of Rivets: Learn About Different Rivets and Their Common Uses

Rivets are a common type of fastener used to hold two or more parts together. Rivets are designed to be a more permanent faster, and out of all the different fasteners, rivets are most similar to nails.

Rivets are used in many different mechanical operations, and have been for a long time. The concept is very simple, and in fact, the first rivets were used around 3,000 BC. Rivets were used to hold ancient tools together, like the head and handle of a hammer, and to attach a carrying handle to a jar.

The rivets used today are more precise and durable, but they have the same general design and purpose. Rivets can be used for lightweight purposes, and heavy duty machines like tanks or aircraft.

How does a rivet work?

A rivet is similar to a nail, but they’re not exactly the same. Rivets usually don’t have threading, and they have a flat or rounded head. Unlike nails, rivets usually don’t have a sharp pointed end. Rivets also have a larger body, similar to a bolt.

When rivets are being used, a hole is drilled into the materials that the rivet is holding together. The hole drilled is slightly larger than the rivet. Then, the rivet is inserted, and the back end of the rivet is smashed or deformed so it’s larger than the hole drilled. This creates a tight connection between the two materials. And the rivet would need to break before the materials separate.

Smaller rivets are installed with a handheld tool called a riveter or rivet gun. Larger industrial rivets, like the ones used for bridge construction work the same way. But, those need to be heated up before the end is smashed so it can be deformed.

What are the different types of rivets?

Rivets are a basic type of fastener, but there are some different types designed for specific uses.

Solid rivets

Solid rivets are just what they sound like. They have a solid round body and either a flat or rounded head.

The rivet is inserted into the hole and the end is smashed with a hammer, or other squeezing tool. Depending on the size of the rivet, a lot of force can be required to deform the end so it stays in place.

Solid rivets are the most secure and can bear the most weight and are the most reliable. They’re used for load bearing applications like building frames and bridges, Solid rivets are also used in aircraft, cranes, and other vehicles.

Tubular rivets

Again, tubular or hollow rivets are exactly what they sound like. They look the same as solid rivets, but the body is a partially or fully hollow tube. With these rivets, the tail end isn’t solid, which makes it much easier to deform. These rivets require about 25% of the force to secure compared to solid rivets.

Countersunk rivets

Countersunk rivets or flat rivets are designed to not stick out once they’re installed. There’s a small hole for the rivet, and a slightly larger hole made for the head of the rivet. These are used to improve dynamics on vehicles, and on sliding tracks where something needs to slide over the rivet without hitting it.

Split rivets

Split rivets have a split end. Usually there are two small legs on the end of the rivet that are spread apart to secure the rivet. These are commonly used with softer materials like drywall, leather, wood, or plastic.

Blind rivets

Blind rivets are unique because they can be installed without accessing the other side of the rivet. These rivets are technically two different parts. The rivet has a pin that pulls out when it’s installed. The pin is pulled out and squishes the end of the rivet to secure it. Blind rivets are used in aircrafts, watercraft, and electronics.

How are rivets manufactured?

There are two primary ways that rivets are manufactured.

Thinner rivers are made by cold forming. A round wire is fed into a machine and cut to the desired length. Then the piece of wire is punched into a dyes, or cutouts, to form the shape of the rivet. It takes a few different dyes to fully form the rivet body and head. But, this process all happens very quickly. Hundreds of rivets are made every minute, and they’re fairly accurate.

Rivets can also be made using Swiss screw machines. This process is used for solid rivets, when stronger materials are needed, and when more precision is needed. Since rivets have a simple design, Swiss screw machines are still efficient and keep manufacturing costs low.

What materials are rivets made with?

Rivets are made with a wide variety of metals. The harder metals offer greater strength, but they also require more force to install the rivet. Softer metals like copper or brass can’t handle as much stress, but they’re easier to install.

Rivets are commonly made with

Stainless steel
Steel
Aluminum
Copper
Brass

Spex is a precision machine shop located in Rochester, New York. We manufacture a wide range of precision parts and fasteners including rivets. If you need rivets, or other precision parts, fill out the form to connect with our team.

Types of Precision Fasteners

Using Custom High-Strength Bolts

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Different Types of Lock Nuts

May 15, 2022

Different Types of Lock Nuts

Lock nuts are a special part that’s designed to hold parts and assemblies together. These parts are built to be used for long periods of time.

Spex machines different types of precision lock nuts for various industries and uses. Today we’ll share some info about how lock nuts are manufactured and used.

What are Lock Nuts?

A lock nut is a type of nut that’s designed to not loosen over time. There are different methods to keep the nut secure, including adhesive, pins, and features that increase friction. Some lock nuts are designed for single use, making them less effective or unusable after they’re removed.

In general, nuts are used for assemblies that need to be disassembled. That’s helpful when different parts need to be cleaned or to perform regular maintenance. Lock nuts are more difficult to assemble and disassemble, but they provide greater security and reduce the risk of parts coming loose.

Lock nuts are commonly used for assemblies where there are moving parts or vibration, which causes other nuts to loosen over time.

How do lock nuts work?

There are a few different ways that a lock nut stays secure. The three common ways are adhesive, friction, and pins.

Adhesive

The most common type of lock nut has some type of adhesive. This could be a type of glue, or a nylon ring that creates a tight seal on the bolt.

Friction

Some lock nuts have specific features that increase the friction. Some have grooves on the bottom of the nut, which increases friction with the surface that the lock nut is touching. Other lock nuts have specific threading that increases the friction between the nut and bolt. Both of these designs make it more difficult for the nut to come loose.

Pins

Lock nuts that use pins have a hole or groove cut into them. Once the nut is tightened onto the bolt, a pin is inserted through a hole in the nut and bolt to prevent it from spinning off. A cotter pin can also be added on top of a lock nut with grooves cut in the top.

5 Different Types of Lock Nuts

1. Nylon insert lock nuts

These lock nuts have a nylon ring or patch on the inside threading of the nut. When they’re threaded onto the bolt, the nylon creates a seal. These nuts are subject to high temperatures which could melt the nylon, and they require more torque to assemble.

2. Hex jam nuts

Jam nuts are actually two nuts that are used on top of each other. The second nut is jammed on top of the first one, preventing it from spinning off the bolt.

3. Center lock nut

A center lock nut has a hold drilled into the center of it. Once the nut is tightened, a punch is used to distort the threading on the bolt, which prevents the nut from loosening.

4. Serrated Flange lock nut

The serrated lock nut has grooves on the back side of the nut. These nuts are usually used against sheet metal. The grooves on the back of the nut rub against the surface and prevent it from backing out.

5. Castellated nut

A castellated nut has grooves on the top, which look similar to the top of a castle. These lock nuts are used with a bolt that has a hole drilled in it. Then, a pin is inserted through the top of the nut and bolt to secure it in place.

What are lock nuts made of?

Because most lock nuts are used for heavy-duty and industrial applications where strength is a priority, most are made with stainless steel or mild steel. Stainless steel alloys are the most common material because it’s strong and resistant to corrosion. Zinc and brass locking nuts are also fairly common.

In cases that require less strength, nylon or plastic lock nuts are popular because they’re less expensive to manufacture and lightweight.

Spex is an ISO 9001:2015 certified precision machine shop in Rochester, NY. We machine thousands of unique metal and polycarbonate parts every month for different industries around the world. Reach out to our team to see if we can help with your next project.

Types of Precision Fasteners

Using Custom High-Strength Bolts

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Custom Dowel Pin Manufacturing

February 2, 2022

Custom Dowel Pin Manufacturing

Dowel pins are short cylindrical parts that are used to align or join two or more parts. Wooden dowel pins are commonly used to hold furniture together. Metal and plastic dowel pins with custom diameters and lengths are found in machinery, vehicles, and consumer goods.

Pins are a type of precision fastener and they’re made with any type of material and available in every diameter and length. Spex uses different machining processes to manufacture a wide variety of custom dowel pins. In this post, we’ll explain more about precision dowel pins and their uses.

Different types of pins

Pins usually serve a similar function as screws or bolts, but pins are unthreaded. Instead of threading, pins use different methods of staying in place and hold parts together. Usually a custom pin has a specific diameter size that matches the parts it will hold together. The lengths are also machined to the part specifications.

The names of pins usually refers to the different features of the pin. A grooved pin for example, has grooves running along the length of the part which gives them more elasticity. A spring pin is a hollow pin that’s able to be compressed and expanded. A spring pin or roll pin is another hollow pin that’s made with rolled metal.

Dowel pins are solid pins, and usually the most precise type of pin. These are also the most basic type of pins and don’t have the secondary features that other precision pins have. Because dowel pins are more precise, they can also be more difficult to insert and remove.

One or both ends of the pin is chamfered to help align and inset the pin into the hole. Once it’s in place, a precision dowel pin provides a very tight seal and hold components together for a long time and withstand a good amount of pressure. Because dowel pins are headless, they can be more difficult to remove than a screw or bolt.

Stepped dowel pins are used when components with two different sized holes need to be connected. One half of the dowel pin will be smaller than the other end. The last common type of dowel pin is a pull dowel. These pins have a threaded hole so a screw can be inserted to remove the pin more easily.

Common uses and materials used for dowel pins

Dowel pins are one of the simplest types of fasteners available and can be the perfect solution for many different machines. Pins in general have been used for thousands of years. Of course, modern machining technology has improved and expanded the use of precision metal pins. Our machines can mass produce dowel pins with extreme precision.

Because they’re incredibly versatile, simple, and cost efficient, pins are used in thousands of different applications.

Dowel pins are commonly used in machinery to keep components properly aligned. Solid pins usually do a much better job at maintaining alignment compared to screws. Metal dowel pins retain their physical dimensions, meaning they won’t easily wear down or lose their shape. This makes metal dowel pins ideal for machines where precision is required.

Dowel pins are also used in the automotive, medical, aerospace, and military industries.

You’ll find wooden dowel pins in your furniture, but using metals offers much greater precision and strength. At Spex, our Swiss lathes and other machines can produce custom dowel pins within a 0.0001″ tolerance.

Custom dowel pins can be made of various materials. Each material has different advantages and the best choice is dependent on how the is being used. Some industries require specific alloys to be used to meet strength requirements. The most common materials include:

Aluminum
Carbon steel
Stainless steel
Titanium
Nickel alloys
Brass

In some instances, plastics or polycarbonates will be used for pins in electronics or in components that require less strength.

If you’re not sure which material to use for your custom dowel pins, our team can help you decide which one is best for your unique application.

Get a quote for custom dowel pins

Are you looking for a dowel pin manufacturer?

Spex is an industry leader in manufacturing precision fasteners and pins. We are an ISO 9001:2015 certified organization, which means we use the highest industry standards for manufacturing parts. Our vast machining capabilities allow us to produce large quantities of parts that meet the tight tolerances that are often needed.

We have decades of precision manufacturing, customer satisfaction, and serve many industries around the world

Reach out to get a quote for your next project.

Different Types of Precision Pins

Types of Precision Fasteners

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