Optimization of the Cold Extrusion Process of SAE 1004 Steel for the Production of Hexagonal Flange Head Screws

Introduction: This study aims to optimize the manufacturing process of hexagonal flange head roofing screws. The fastener is produced in two cold forming stages using SAE 1004 low-carbon steel wires. The addition of a direct extrusion operation to the manufacturing route is proposed, resulting in a 7% reduction in raw material consumption. Analytical and numerical approaches are employed to select the parameters for the extrusion process. The mechanical and metallurgical characterization of the work material is conducted and used as input data for the process analysis approaches. Considering the forming force and the stresses on the tools, the extrusion angle and the matrix casing dimensions were defined. Analytical and numerical results are compared with experimental data. The accuracy of the analyses was validated by a 3% agreement between analytical calculations and numerical simulations. This approach demonstrates the effectiveness of combining methods for process optimization, aiming at sustainability and competitiveness in the fastener industry. Objective: The study aims to optimize the manufacturing process of hexagonal flange head roofing screws by proposing a new manufacturing route that includes a direct extrusion operation, resulting in a 7% reduction in raw material consumption. Theoretical Framework: The study is based on analytical and numerical approaches applied to selecting parameters for cold forming processes, considering the mechanical and metallurgical characterization of materials. This foundation enables the integration of analysis and experimentation methods, aiming for efficiency gains, sustainability, and cost reduction in the industrial sector. Method: The research used SAE 1004 low-carbon steel wires for manufacturing fasteners in two cold forming stages. The new route included the addition of a direct extrusion stage. The mechanical and metallurgical characterization of the material was performed to provide input data for the analyses. Parameters such as forming force, tool stresses, extrusion angle, and matrix casing dimensions were defined based on analytical and numerical analyses. Results and Discussion: The obtained results demonstrated the effectiveness of the proposal. The forming force and tool behavior were suitable for the new manufacturing route. Comparisons between analytical calculations, numerical simulations, and experiments showed a 3% agreement, proving the precision of the analyses and validating the proposed model. This approach highlights the feasibility of combining analytical and experimental methods to optimize industrial processes. Research Implications: The research contributes to the fastener industry by demonstrating that process optimization based on integrated methods can enhance sustainability and competitiveness. The reduction in raw material consumption and the application of analytical and numerical tools represent significant advances in efficiency and innovation in manufacturing processes. Originality/Value: The study presents an innovative approach by integrating analytical, numerical, and experimental methods to optimize industrial cold forming processes, specifically in screw manufacturing. The originality lies in the inclusion of a direct extrusion operation in the conventional manufacturing route, resulting in a 7% reduction in raw material consumption, a significant advancement for industrial sustainability and efficiency. Moreover, the demonstrated precision among different analysis methods adds value by providing a robust and applicable solution for the fastener industry, contributing to more sustainable and competitive practices.