1.

INTRODUCTION

The recent recessionary trends began during the first quarter of 2007- 08 and resulted in
negative growth in the manufacturing sector, during the October to December2008
period. The situation was further aggravated in the wake of the intensification of the
global financial crisis that hit most export-oriented industries in India. The engineering
industry represents one such case, though the impact in this sector has been relatively less
severe than in several other export-oriented industries (that produce consumer goods such
as automobiles, textiles, diamonds, garments, leather manufactures) and in the
construction industry.

The engineering industry is characterized by wide-ranging products and has a spatially

diversified nature. The sector consists of a large number of intermediate and capital
goods industries, and therefore, has significant backward linkages with many vital sectors
in the economy, including agriculture (Morris, 2006). The sector is also characterized by
a fairly long value chain, entailing a number of processes namely foundry, casting and
forging, machining, parts and component manufacturing, assembly and transport, etc.
The major end-user industries for heavy engineering goods are power, infrastructure
(including real estate development), steel, cement, petrochemicals, oil and gas, refineries,
fertilizers, mining, railways, automobiles, textiles, etc. Light engineering goods are
essentially used as inputs by the heavy engineering industry. The engineering sector in
India has been riding on the back of the growth in the user industries and the several new
projects being undertaken in various core industries such as railways, power,
infrastructure, etc. Capacity creation in sectors such as infrastructure, oil and gas, power,
mining, automobiles, auto components, steel, refinery, consumer durables, etc., has also
been driving the growth of the engineering industry. Fundamental for Traffic Conflict
Techniques

Nuts and bolts are classified by two ways:

i) Their uses, ii) Shape of head.In terms of use, nuts and bolts are of several types:Larger
dia bolts, machine bolts, stand bolts, joint bolts, foundation bolts and nuts etc. in terms of

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shape, bolt and nuts are classified by head shape like hexagonal head, square head, round
head, pan head, truss head etc.

An industrial fastener comprises a very wide range of items like nuts and bolts, washers,
studs, nails etc. Nuts and bolts consist a major link in the family of industrial fasteners
and are used by every industry. Bolt is a piece of metal rod, whose one end is unsettled
and other end is threaded. Nut is the item, which rolls on these threads. Nut and bolts are
available in various shapes, designs and sizes. Nuts and bolts are used for fastening
purpose in industries where the replacement of pieces and the parts is necessary. There
are many industries producing these nuts and bolts of various sizes, but the demand too is
increasing as well as the raw material for the product is easily and indigenously available.

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2. LITERATURE REVIEW
Amol Manwatkar, Prof. A. A. Kher & Sunil Chavan [1]: This paper focused on the
overview of failure analysis of high tensile fasteners. An industrial fastener comprises a
very wide range of items like nuts and bolts, washers, studs, nails etc. Nuts and bolts are
used for fastening purpose in industries where the replacement of pieces and the parts is
necessary. Although, fastener is a low cost class C item but fastener failure is undesirable
as is the first item that gets the blame when there is a failure, aftereffects of fastener
failure are cumbersome which cause financial loss to machine & process. Hence, the
cause of failure is understood & eliminated. Hydrogen embrittlement remained as the
only probable cause of the failure observed. Unlike stress corrosion cracking and
quenching cracks, cracks caused by hydrogen embrittlement usually do not branch
neither show oxidized surfaces. Typical features of hydrogen embrittlement were
observed on the fracture surfaces of both bolts. Bolts had been zinc electroplated, which
is one way to introduce hydrogen into metals, and baking treatment.
If any of these factors are not present, the chances of the failure being confirmed as
hydrogen embrittlement are unlikely. Unhardened fasteners or those of Grade 5 or
Property Class 8.8 or lower do not fail due to hydrogen embrittlement. Parts that are
cleaned by mechanical processes instead of acid are highly unlikely to fail due to
hydrogen embrittlement. Failures that occur while parts are being installed are not due to
hydrogen embrittlement.

Dennis Edwin Showalter, More Than Nuts And Bolts [2] The relationship between
technological innovation and military effectiveness in the modern Prussian/German army
continues to generate more heat than light. On one side of the debate is a school of
argument emphasizing material, from needle guns to Tiger tanks and from steel helmets
to potato-masher hand grenades, as proof of the military establishment’s commitment to
material modernization. Usually and unfortunately associated with buffs and hobbyists,
this approach has significant credibility as well in operationally oriented military
narratives.1

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On the other side of the discourse is an advocacy group insisting that the modern German
army’s defining institutional characteristic is an emphasis on mass shaped by moral force:
beginning with the patriotism of the Wars of
Unification, extending through the chauvinism and nationalism of 1914–18, and
degenerating into National Socialism. Wilhelm Deist describes an Imperial army that
privileged willpower over technical innovation, devolving under
Allied pressure into a citizen militia that finally ended a hopeless war by going on a kind
of strike.2 Omer Bartov presents a systematic “demodernization” of the German army
between 1941 and 1945. In his model, heroic vitalism inspired by Nazi ideology was
increasingly substituted for the tanks and guns either destroyed by the Allies, or never
produced because of Nazi ineffectiveness on the homefront.3

Amol Manwatkar*, Prof. A. A. Kher**, Sunil Chavan. [3] Failure Analysis of High
Tensile Industrial Fasteners This paper focused on the overview of failure analysis of
high tensile fasteners. An industrial fastener comprises a very wide range of items like
nuts and bolts, washers, studs, nails etc. Nuts and bolts are used for fastening purpose in
industries where the replacement of pieces and the parts is necessary. Although, fastener
is a low cost class C item but fastener failure is undesirable as is the first item that gets
the blame when there is a failure, aftereffects of fastener failure are cumbersome which
cause financial loss to machine & process. Hence, the cause of failure is understood &
eliminated.

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2. BOLTS & NUTS:

An industrial fastener comprises a very wide range of items like nuts and bolts, washers,
studs, nails etc. Nuts and bolts consist a major link in the family of industrial fasteners
and are used by every industry. Bolt is a piece of metal rod, whose one end is unsettled
and other end is threaded. Nut is the item, which rolls on these threads. Nut and bolts are
available in various shapes, designs and sizes.

Nuts and bolts are used for fastening purpose in industries where the replacement of
pieces and the parts is necessary. There are many industries producing these nuts and
bolts of various sizes, but the demand too is increasing as well as the raw material for the
product is easily and indigenously available. The main raw material is mild steel wire
coil/rod of required diameter. The composition of materials controls the quality of the
bolts and nuts. The recommended composition for nuts and bolts raw material is given as
under:

Sr No Material Content Percentage

1 Carbon 0.22 to 0.23%

2 Phosphorus 0.40%

3 Manganese 0.39 to 0.60%

4 Sulphur 0.50%

Nuts and bolts are classified by two ways: i) Their uses, ii) Shape of head.

In terms of use, nuts and bolts are of several types:

Larger dia bolts, machine bolts, stand bolts, joint bolts, foundation bolts and nuts etc. in
terms of shape, bolt and nuts are classified by head shape like hexagonal head, square
head, round head, pan head, truss head etc.

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2.1Types of Nut:

 Hex or flat nut: general usage

 Lock nut (Nylock nut): used for safety reasons when a nut should not come loose
due to vibrations. Lock nuts are often found on front wheel drive axles or exercise
equipment.
 Taper nut: used to help centre objects, for example on the wheel of a car
 Slotted or castle nut: used in conjunction with a cotter pin on objects that turn or
twist, for example on a tie rod or ball joint
 Cap or acorn nut: used to give a finished appearance by covering the end of the
thread
 Wing nut: used when only hand tightening is needed
 Cap screw: often referred to as a bolt
 Thumb screw: used when only hand tightening is needed
 Set screw: used to secure objects without the head protruding, for example on a
pulley so the belt does not rip
 U bolt: used to secure objects to a shaft, for example springs to the differential

Fig. 1 Nut & Bolt

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2.2 Nut and bolt terminology:

2.2.1 Thread: A thread is a ridge of uniform section in the form of a helix on the internal
or external surface of a cylinder (IFI description) or it could be described as a sloping
plane curled around a cylinder. External threads are on bolts or screws.

2.2.2 Runout: The thread runout portion of a bolt is where the threaded section
transitions into the bolt shank. This area exists beyond where the usable thread
stops.

2.2.3 Shank: The smooth part of a fastener above the threads. Also called the body.

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 Fig2. Fasteners

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3. TYPES OF FAILURES IN FASTENERS

3.1 Failure As A Result Of an Overload

Many accidents can be characterized as an impact with a non-compliant object such as a

truck impacting a concrete bridge support. The fine, gray appearance of the fracture
surface is consistent with a sudden overload failure.

3.2 Failure From Lack Of Locking Mechanism

In order to prevent bolts from loosening over time, various locking mechanisms are
employed. They include lock washers, locking nuts, jam nuts, mechanical deformations,
wire wrap, cotter pins, metal locks, expansion anchors, helical coils and polymer locking
compounds. Machinery that is subject to vibratory environments usually is equipped with
some sort of locking mechanism. If the locking mechanism is not applied to the
machinery during manufacture, a catastrophic event may result.

3.3 Metal Fatigue

Metal fatigue is the phenomenon characterized by progressive crack growth during cyclic
loading. A crack is often initiated at a flaw or stress riser (sharp notch) in a part. Cyclic
forces such as vibrations or repeated impact cause the crack to increase in size until the
part can no longer sustain the load, and a final fracture occurs.

3.4 Failure from Improper Torque

When threaded fasteners are utilized, the amount of tightening or bolt torque is often
important. Motor vehicle wheel studs require torques ranging from about 100 ft-lbs for
smaller vehicles to over 400 ft-lbs for large trucks. The appropriate torque is required in
order to prevent relative flexing of the two parts being fastened and to assure an
acceptable mechanical connection. Bolt failures as a result of improper torque have
occurred in automobile applications.

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3.5 Corrosion Failure

Corrosion of metals can be disastrous to threaded fasteners. Surface and pitting corrosion
attacks threaded fasteners as a result of contact with moisture or other corroding media.
Since bolts often carry high loads, stress corrosion cracking is another corrosion related
failure mode. Corrosion, coupled with forces in a bolt, tends to accelerate cracking.

3.6 Hydrogen Embrittlement (He)

A permanent loss of ductility in a metal or alloy caused by hydrogen in combination with

stress, either externally applied or internal residual stress.

3.7 Galling

If you've ever had the pleasure of installing or removing stainless steel fasteners, you've
more than likely experienced galling. Galling is a cold-welding process that results when
the threads are in contact under heavy pressure and friction. Or in other words, when
fasteners are assembled or disassembled. Read the article to learn more.

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 Fig. 3. Fastener Failure by observed

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2. MARKET POTENTIAL:

The demand of nuts and bolts is influenced by the following factors:

a) Transportation industries, Railways, aircraft, wagon, bicycles, automobile,

body builders, etc.
b) Electrical industries like manufacturing of transformer, electric motors, fans
etc.
c) Building activities such as construction of bridges, fabrication of various steel
structures etc.
d) Other heavy and light industries, steel and wooden furniture, machine tools,
Agricultural machines and agricultural implements etc.
As various types of MS and HT nuts and bolts are used in above sectors, the
market demand is directly proportionate to the development of these industrial
segments.

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6. BASIS AND PRESUMPTIONS:

1. Capacity Utilization : 75% on single shift basis

2. Time period of 1 year : 300 days
3. Labour wages : Estimated on the minimum wages
4. Rate of interest : 16%
5. Margin Money : 25% varying from state to state
6. Operation period of project : 10 years
7. Rental charges for land and building: 20,000 per month

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7. IMPLEMENTATION SCHEDULE:

Sr. Activity Period in

No. Weeks

Selection of site 2
1.

2. Preparation of project report 4

3. Provisional Registration 1

4. Financial arrangement 8

5. Procurement of machinery 8

6. Installation, electrification and commissioning of 6

machinery

7. Selection and placement of staff 2

8. Procurement of raw materials, tools etc. 2

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8. TECHNICAL ASPECTS:

8.1 Process of Manufacture:

The raw material used for manufacture of bolt is M.S. Rounds. As some of the rounds
available are rusty and not perfectly round and straight, it is necessary to make them
round. The rounds are pickled in the acid tanks, washed and drawn in a drawing machine.
The cleaned rod is fed into the cold heading machine. In the machine, one end of the rod
is cut into the desired length with cutting stroke and simultaneously the head formation
takes at another end. For the HT bolts, forging is done on hot forging press. The pins are
then trimmed in the trimming machine. In quality bolts, the lower side of the head is also
faced. Threading is done in the thread rolling machines.

While manufacturing nuts, the hexagonal rod of desired size is procured and the nuts are
cut on the automatic nut-cutting machine. Cutted nuts blanks are drilled and tapped on
the nut-tapping machine. Finally, these are deburred in the polishing barrel.

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8.2 Process of M S Bolt

Sr Processes Sr Processes

1 Mild steel rod 10 Wire drawing

2 Bolt cutting 11 Bolt cutting

3 Head making 12 Forging

4 Head trimming 13 Trimming

5 Thread rolling 14 Threading

6 Polishing 15 Heat treatment (800oC –

900oC)

7 Store/dispatch 16 Tempering (400oC –

500oC)

8 Process Flow Chart (H.T. 17 Plating/Coating

Bolts)

9 Mild steel rod 18 Store/dispatch

8.3 Manufacturing: Now demonstrate drilling out the damaged threads and installing a
HeliCoil insert. It may be cost-prohibitive for all students to install a thread insert, but it
would be best if they were able to do so.

8.3.1. General Instructions for Installing a HeliCoil Insert

Heli Coils are precision-formed screw thread coils of 18–8 stainless steel wire. They are
designed to replace damaged threads and to reinforce tapped threads in light materials,

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metals and plastics. Each coil possesses a tang that is used to drive the insert into a tapped
hole. After insertion, the tang is snapped off.

These instructions should be considered guidelines only. Always follow manufacturer’s

instructions when installing a HeliCoil insert.

1. Drill

Identify the damaged threads by pitch and size. Drill them out using the specified drill
size.

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2. Tap

Using the screw thread insert tap, tap the hole to the minimum depth specified to fully
install the HeliCoil insert—and the bolt or screw that will be screwed in afterwards.

3. Install

Install the HeliCoil assembly using the appropriate installation tool. The coil should be
installed to between one-quarter and half a turn below the top surface of the tapped hole.

4. Remove Tang

Remove the tang to allow the bolt or screw to pass all the way through the insert. Break
off the tang with a flat-bottomed punch or the tang breakoff tool provided. Place the tool
squarely over the tang and then strike it sharply with a hammer. Tangs on spark plug
inserts and HeliCoil inserts with a diameter greater than ½" (12 mm), can be removed
using needle-nose pliers.

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5.Quality Control and Standards:

The Bureau of Indian Standards has laid down the following quality standards for M.S.
and High tensile fasteners such as Bolts and Nuts:

IS 1363 : 1992

IS 1367 : 1994

IS 4206 : 1987

Production Capacity:

Quantity Value (In Rs.)

Nuts and Bolts of various sizes - 360 MT 2,52,00,000/-

Motive Power: 85 HP

Pollution Control:

This industry involves pollution to some extent for which State Pollution Control Board
has to be approached.

Energy Conservation:

The unit is equipped with electric powered machinery. The energy conservation efforts
need in unit is the creation of awareness among the workers.

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9.METHODOLOGY

Idea

Data collection

Market survey

Working model

Funding agencies

Project planning

Implementation

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10.ADVANTAGES

 Use of unskilled labour and simple tools

 Noiseless and quick fabrication
 No special equipment/process needed for installation
 Fast progress of work
 Accommodates minor discrepancies in dimensions
 The connection supports loads as soon as the bolts are tightened
 HSFG bolts do not allow any slip between the elements connected, especially in close
tolerance holes, thus providing rigid connections.
 Due to the clamping action, load is transmitted by friction only and the bolts are not
subjected to shear and bearing.
 Due to the smaller number of bolts, the gusset plate sizes are reduced.
 Deformation is minimized.

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11. CONCLUSION:

Hydrogen embrittlement remained as the only probable cause of the failure observed.
Unlike stress corrosion cracking and quenching cracks, cracks caused by hydrogen
embrittlement usually do not branch neither show oxidized surfaces. Typical features of
hydrogen embrittlement were observed on the fracture surfaces of both bolts. Bolts had
been zinc electroplated, which is one way to introduce hydrogen into metals, and baking
treatment.

If any of these factors are not present, the chances of the failure being confirmed as
hydrogen embrittlement are unlikely. Unhardened fasteners or those of Grade 5 or
Property Class 8.8 or lower do not fail due to hydrogen embrittlement. Parts that are
cleaned by mechanical processes instead of acid are highly unlikely to fail due to
hydrogen embrittlement. Failures that occur while parts are being installed are not due to
hydrogen embrittlement.

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12. Referances:

Morris, S (2006), Infrastructure Development and Strategies for Gujarat,

(unpublished),paper prepared for the Gujarat Development Report, Gujarat Institute of
Development Studies, Ahmedabad.

Awasthi, D (1997), ‘The Diesel Engine Industry cluster – Rajkot’, in D. Awasthi (ed.)
Dynamics of Industrial Cluster in India, Entrepreneurship Development Institute ofIndia,
Ahmedabad.

Basant, R (1997), in D. Awasthi (ed.), Op.cit. Kashyap, S. P. and A. Shah (1995),

‘Induced Industrial Clustering and Efficiency: An

Exploratory Study of Gujarat’s Industrial Estates’, The Journal of Entrepreneurship, 4

(1).

Shah, A (1994), ‘Inter-firm Scalar Linkage in India: A Class Within the Small Scale
Industry’,

Small Business Economics, (6), Springer, Netherlands.

T.S. Subramanian, Against all odds: Challenged by the global financial crisis and a
crippling power cut, entrepreneurs are keen to develop their capability. Frontline, Volume
26 -

Issue 06 :: Mar. 14-27, 2009, Available at: http://www.hinduonnet.com/fline/fl2606/

stories/20090327260610700.htm.

GoI, 2009, Economic Survey: 2008-09, Government of India, Oxford University Press,
New Delhi.

GoI, 2004, Final results: Third All India Census of Small Scale Industries (2001-2002),
Development Commissioner (SSI), Ministry of Small Scale Industries, Government of
India, New Delhi.

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CMIE, 2009, Monthly Review of the Indian Economy, Centre for Monitoring the Indian
Economy, Mumbai.

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