Wire Diameter Product size wise and Gold Forming per day output in Metric Ton

, tl l.U \Jr.iVLl-

Size

No.of Coldforming Machines

1 1 1

Per day Cold Produet Types

:
rl

f6rming'
Output in
r.

,Before Wire I Drawing

(lnput Wire) Diameter in mm

5,5 5.5 5,5

After Wire Drawing (Final Wire) Diameter in mm

2.85 3.45 or 4.80 4.38 or 4.80 5.25 or 5.80 7.69 9.76
11.6 13 6 15.6

M3 M4 M5 M6 M8 M10

4
B

I
8 2

M12 M14
M16 M18 M20

b
1

3
1

M22 M24
M27 M30 M3 M4 M5 M6
MB

3
1 1

0.33333333 0.33333333 0.66666666 0.66666666

1 1

Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts Screws & Bolts NUTS
UTS N UTS NUTS N UTS NUTS NUTS N UTS NUTS N UTS NUTS NUTS NUTS NUTS NUTS NUTS
N

0.75 0.75 0.75 3.75 12.75 42.00 42.00 13.50 38.25 9.00 27.00 9.75 29.25 11.25 11.25 0.03 0.06 0.19 0.35 0.68
1.47

6.5 or 8.0
9
11

13 15
1B

M10

M12

3 2

Ml4
M16 M1B M20

4.5 0.5
1.5 0.8 1.4 0.6 1.3 0.4

M22 M24
M27 M30 M33
(
)

4.47 6.93 12.08 1.92 6.86 3.99 8.00

441
14.09 5.00

20 22 23 25 or 27 27 or28 32 5.50 7.00 8.00 10.00 13.00 17.00 19.00 22.00 24.00 27.00 30.00 32.00 34.00 38.00 42 or 44 48

176
19.6 21.6 23.6 24.90 or 26.70 29.6 4.5

645
7.3 9.3
12.1

16.3 18.3 21.1 22.9 25.5 28.9 31.2 33.2 37.3 41.2 or 43.2 47.2

Total Tonnaqe

gZZ.Sq

We need Wire drawing machines on each size 25o/o excess capacity on above mentioned tonnage
Tonnage Workout

for

MP.

Plant -

tli L\ 1 ,/ 16th June 2011. x1s

t I i't

J*..,",,i,

{^t1-;u,l&"
! r#

*.-

I of

RM Spec

Chemical Composition (%)

c
0.10 max 0.08-0.13 0.13-0.18 0.15-0.20

Si

Mn
0.30-0.50 0.30-0.60 0.30-0.60 0.60-0.90

S max

P max

Cr

Ni

Mo

Cu

AI

Others

L 2

Atst 1008 Atst 1010/swRcH10A

Arsr 1015 Atst 1018

< 0.10 < 0.10

0.025
0.025

0.025 0.025
0.025

<

0.15

0.025 0.025

0.05-0.10

0.025

5 6

scM435/ArSr ML40Cr/AlSl 5140 / aICra lSCr440lEN 18D

0.33-0.38

0.15-0.30

0.70-0.85

<0.025 <0.025

<0.025 <0.025

0.90-1.10

<0.25

0.15-0.25

< 0.3

02:15ppmm
N2 : 90 ppm mi H2 :2 ppm m; 0.01-0.10 0.01-0.10

0.38-0.43 0.35-0.39 0.40-0.44 0.38-0.43 0.38-0.43

0.15-0.30

0.70-0.85 0.6-0.9 0.6-0.9 0.7s-0.85 0.75-1.00 0.70-1.00 0.70-1.05 0.55-0.90 0.60-0.8s 0.45-0.70

0.90-1.10 0.2-0.4 0.2-0.4 0.9-1.10 0.80-1.10 0.40-0.60 0.40-0.70 0.35-0.75 1.55-2.00

/s30A40
7 8

35ACr 40ACr

< 0.1

0.025 0.025 0.025

0.025 0.025

0.025
0.025 0.025 0.025 0.025

<

0.1

9 42CrMoA/SCM

0.15-0.30 0.15-0.30 0.15-0.35 0.1s-0.35 0.15-0.35 0.10-0.35

<0.25

0.15-0.25 0.15-0.25

< 0.20

10 Atst 4140M
1,1 1.2

Arsr 8740

/ AISI8640

sNcrvr 240

0.38-0.43 0.37-0.44 0.37-0.44 0.43-0.48 0.36-0.44 0.14-0.19 0.12-0.18

0.20l0.30
0.15-0.25 0.20-0.30 0.15-0.30 0.20-0.30

,J

0.02s 0.025 0.02s 0.025

0.025 0.025

0.025 0.025
0.025 0.025 0.025 0.025

0.3s-0.6s
0.65-0.9s 0.90-1.20 1.00-1.40
0.80-1-.10

13 AISI 4340H

t4 scM 445
15

<0.25
1.55-2.00

< 0.30

02 : 1-5 ppm m N2:90ppmm

N24

H2:2ppmm

16 16MnCr5 /AlSl 5120H

1-7

0.17-0.37 0.15-0.35 0.15-0.35 0.15-0.35

1.00-1.30 0.5s-0.90 0.55 0.90 0.70-0.90

<0.30 <0.25 <0.25

0.40-0.70

<0.10
0.15-0.35 0.1s-0.35 0.15-0.25
\.ik:,;+e4ti]W 5iiMN:Brri

SCM415H ;CM42OH

0.85-1.2s 0.85-1.25 0.40-0.60

1B

o.t7-o.23
0.18-0.23

0.025
0.025

0.025 0.025

19 AISI 8620H

20 DIN 36CrB4 21 Alst 51835Nl 22 Aist 15830

1a

0.34-0.38 0.34-0.40
0.27-O.33

< 0.30
0.15-0.30 0.20-0.30 0.15-0.30

isffi*]fitr
I

0.70-1.00 0.35-0.50 1.15-1.45 1.10-1.40

0.025 0.025 0.025 0.025

0.025
0.025

0.90-1.20 0.90-1.15 0.15-0.35 0.10-0.20

0.0008 - 0.005

S o.rs

< 0.10

0.0005 - 0.003 0.001 - 0.00s

0.0005 - 0.003

0.025
0.025

Atst 15840

0.36-0.44

4-6-

tw&:+z,|frnnt* U

Atst 15841

0.36-0.44

0.15-0.30 0.15-0.30 0.15-0.30 0.15-0.30

1.35-1.65

0.025

0.10-0.20

0.0005 - 0.003 0.0005 - 0.003 0.0005 - 0.003

02:15ppmm
N2 : 90 ppm mr

H2:2ppmmi

AlSl

1035H

f\f
0.34-0.43 0.37-0.44 0.15-0.35 0.15-0.35

02 : L5 ppm ml N2 : 90 ppm mi

/ ro4s/c4sE/CKA'
1042 S43C
I 1045H (<= 26mm)

H2:2 ppm mi

(Cr+Mo+Ni) <=6.5 0.42-0.47 0.46-0.s1 0.1s-0.35 0.15-0.3s

02 : 15 ppm max
: 90

1045H (>26mm)

ppm max,
ppm max

Alst 1541
0.47-0.55 (Cr+Mo+Ni) <=0.6

Alx

[uo

tia

MATER]AL GRADE

''

,,.' ""

MATERIAL SPECIFICATION
FORGTNG
SPEC|FICAT|ON NO

scM435 ALLOY STEEL FOR COLD

85314

3.3 Metallurqical Requirements

Geftifi cation required ; YES

3.3.1
3.3.1.

Hardness

Hot Rolled Rod - Hot rolled and finalanneal. Final annealed hardness of 85Rb maximum is a criterion for forge-ability and therefore shall be controlied below the maximum.

3.3.1

.2

Cold drawn Wire - Cold drawn hardness of 105Rb maximum is an indicator,

but final judgement of steel is to be made by a forging trial.

3"3.

2 3

The microstructure of the spheroidize annealed material shall consist of a minimum of 90 o/o spheroidal carbides reasonably diffused in the fenite matrix. Grain size shall be number 5 or finer as determined by ASTM E 112 companson or fracture method Harden-ability. The steel shall be capable of being hardened to 40-45Rc across the finished wire diameter cross section by quenching from 1600'F in an agitated conventional compounded quenching oil (150'F) and tempering for not less than 1 hour at 700'F minimum. Hardness shall be tested in accordance with the methods of Unbrako spec. 85107.

3.3.

3.3. 4

3.3.5

Material shall be free from carburisation and complete decarburisation. Partial

decarbonisation shall not exceed the tolerance limits specified below:

Wire Diameter, lnches

Max Partial Decarb. lnches

Wire Diameter Metric

Max. Partial Decarb. Metric mm

Uo to 0.093" 0.093" to 0.141" 0.141" lo O.273" 0.274" lo 0.387" 0.388" 1o 0.527" 0.528" 1o 0.648" 0.649" to 0.985" 3.3.

0.001 "

0.002' 0.003' 0.004' 0.005' 0.006' 0.007'

Uo to 2.4 2.4 to 3.5 3.6 to 7.0 7.1 to 9.85 9 86 to 13.4 13.5 to 16.5 16.6 to 25.0

0.025 0.050 0.076

0.1 01

0 127 0.152 0.178

Surface and sub-surface seams shall not exceed the tolerance limits specified
below:
Max. Deoth

Wire Diameter

Wire Diameter mm

Max. Deoth mm

Up to 0.256" 0.257" 1o 0.646" 0.648" 1o 0.985"

0.002'
0.003" 0.004"

Uoto65
6.6 to 16.4

0.050 0.076
0.101

165to250

3.3.7
3.4.

Reduction of area 60% Min

3.4 Source Approval.

Material shall be purchased only from vendors wlro have supplied material meeting

all the requirements of this specification. The vendors' facilities shall be surveyed
before making routine production purchases.
APPROVED BY RA
DATE

REVISION LEVEL DAIE

STATUS

PAGE

SPECIFICATION

11.12.08

Level -

Current

Page 3 of

8s314

.-,,,.

,l. ,r, .,;,,

i:.,..

.:illtil,,Sl.irli:li:l)ii'!;rr.

:)uf,:l,)lit(i,l:r'r'|],

|lll'-

, i, l;.

,:i: MATERIAL SPECIFICATION

SPECIFICAI rON NO

MATERIAL GRADE

SCM435 ALLOY STEEL FOR COLD FORGING

85314

1,

SCOPE

1.1 This specification covers the requirements for hot rolled rod and cold drawn spheroidized annealed alloy steel SCM435 for cold, headed fasteners.

2,

APPLICABLEDOCUMENTS 2.1 The latest issue of the following document shall be applicable Unbrako 85'1 07 Procedures for Hardness Testing Fasteners
ASTM E

112

Methods for Estimating the Average Grain Size of Metals

3.

REQUIREMENTS

3.1 Chemical Composition

Certifi cation required: YES

Ladle Analvsis %

Element Carbon (C) Manganese (Mn) Phosphorus (P) Sulphur (S) Silicon (Si) Chromium (Cr) Molybdenum Copper (Cu) Nickel (Ni)
3.1

Min 0.33 0.60

Max 0.38 0.85 0.030

0.030
0.15 0.90 0.15 0.35 1.20 0.30

.1 1

The Material shall be Mercury free.

Certifi cation required: YES

3.2 Condition

3'2.

The material shall be melted by the open hearth, electric or basic oxygen furnace
process.

The material shall be clean, sound, and free from such detrimental defects as laps, slivers, pipe or other defects detrimental to the fabrication or performance of the
parts.

HOT ROLLED ROD 3.2.2.

The rods shall be spheroidize annealed to meet the applicable metallurgical

requirements of 3.3. The rod to have a surface lubricating coating to assist in the drawing of the rod to required diameter. rod shall be coated with Phosphate Coating suitable for double extruslon processing. Phosphate Coating levels are as follows; Minimum: 6.00 glm2 Maximum: 12.92 glm2

3.2.2.2

3.2.2.3 The

APPROVED BY RA

DATE 11.12.08

REVISION LEVEL DATE

STATUS

PAGE

SPECIFICATION

Level -

Current

Page 1 of5

85314

MATERIAL SPECIFICATION
SPECIFICATION NO

SCM435 ALLOY STEEL FOR COLD FORGING

85314

. . . . .

Purchase Order Number Quantity of each Lot Tensile strength State that the Raw Material is Mercury Free Steel Date A lot constitutes all coils of one size of one heat shipped at one time.

5.4 Each item on a purchase order shall preferably be filled using one Heat Number. When the size of the item requirement is such that it cannot be filled using only one Heat Number, another Heat Number may be used. Every effort shall be exerted to supply each item
ordered in one Heat Number only.

5.5 Delivery docket to accompany each shipment for each individual size and grade of material
stating the following:

. . . . . . . . .

Despatch reference number Customer order number Customer part number Steel date Batch number Material size No. of coils

Totalweight
Despatch date

5.6 Bundles of material shall not contain more than one heat and size per bundle. 5.7 Excessively mixed shipments (partials of several lots) shall be avoided.
5.8 Vendor to take all necessary precautions destination in a condition fit for production.

to ensure that the material arrives at

final

6.

NOTES

6.'l Sampling plan and analytical procedures for check analysis testing agree with the requirements specified in the Steel Products Manual, Wire and Rods, Carbon Steel,
published by the American lron and Steel lnstitute.

7.

REVISION HISTORY
Section
ECR Chanoe

Revision

lnitial

Date

APPROVED BY RA
11

DATE

REVISION LEVEL DATE

STATUS

PAGF

SPECIFiCATION

.12.08

Level -

Current

Page 5 of 5

85314

Material

- AlSl.1035
S% P%

Chemical Composition
CYo

Mn%
0.60 0.80

si% 0
'10

Remarks

Specified

Min.
Max.

0.33 0.38

0,35

0 025
n,rP,

0.025

Dim:ehsiop l . Diarne.,te r- as s peoif idi Mechanical Properties Hardness

UTS (Max.)
Specified Specified

O,

73 HRB Max. (152 BHN Max 46.0 Kg/mmz

Metallurgical Properties
Grain Size
Decarb
A

6-8(ASTMNo.)
0.0'15 m.m. max. ('l5Micron Max.)
B D

Remarks

lnclusion Rating (Maximum)

Thin

2.0

2.0

20

2.0

ASTM E-45

Heavy

(lS:4163)
(ASTM E-381) Better than CzRzSz

Macro Etching

Microstructure

Uniform Ferrite

Surface Condition

No visible surface defect.

NDT

Ultrasonic Testing as per procedure SA-388, acceptance as per Para- 3.3.4 (200i)ASME SecVlll, DlV.2 (ED: 2007) Should be OK.

Cold Upsetting Test

Size Tolerance Size Ovality

( out of roundness )

+ 0.20

mm

+ 0.10 mm

Approved BY

Mr A, Ghosh (SGM, 0A &

l)

Material

- EN-8D/CR 0.35/0,45
Cttemioal, eompositlon

ffi
Grain Size Decarb

lnclusion Rating (Maximum)

Macro Etching

Microstructure

Surface Condition

Cold Upsetting Test

Size Tolerance

Size Ovality
(

out of roundness )

+ 0.10

mm

Approved BY
Mr. A, Ghosh (SGM, QA & l)

tr-,*

%,*
. :.

t:..::..:::::it,:.....:1.- ::.

ffitu

a::

Ma:terial

- 19MnB4(M)

Specified

lsff.e6ifdgi#*.ej$j

Hardness
UTS (Max.)

$ltdt*Hl$ffffiHf$fi6$fi i6s Grain Size Decarb

lnclusion Rating (Maximum)

Macro Etching

Microstructure

Uniform Ferrite

Surface Condition

No visible surface defect. Ultrasonic Testing as per procedure SA-388, acceptance as per Para - 3,3.4 (2007) ASME SecVlll, DIV 2 (ED:

NDT
i

2007)

Cold Upsetting Test

Should be OK

+ 0.20 mm
Size Ovality out of roundness

0.'10 mm

Approved BY

Mr A, Ghosh (SGM, 0A & t) _

l\ ,..-\ tt-'

I
i

Material

- SCM-435
S%
PYo

Chemical Composition
Co/o

Mn%
0,60

si%
0.15

Cr.
0.90

Mo
0.1 5

Remarks

Specified

Min. Max.

0.33

0.38

085

035
:

0 025

0 025

1.20

0.30

Dimension

- Diameter- as specified in P.O.

Mechanical Properties Hardness

UTS (Max.)
Specified Specified

83 HRB Max, (159 BHN Max.) 55.0 Kg/mmz

Metallu rgical Properties

Grain Size
Decarb
A

6-8(ASTMNo.)
0.015 m.m. max. ('lSMicron Max.)
B D

Remarks

lnclusion Rating (Maximum)

Thin

2.0

2.0

2.0

2.0

Heavy

ASTM E-45 (lS: 4163)

Macro Etching

(ASTM E-381) Better than CzRzSz

Microstructure

Uniform Ferrite

Surface Condition

No visible surface defect.

NDT

Ultrasonic Testing as per procedure SA-388, acceptance as per Para - 3.3.4 (2007) ASME SecVlll, DlV.2 (ED: 2007) Should be OK.

Cold Upsetting Test

Size Tolerance Size Ovality

( out

+ 0.20

mm

of roundness

+ 0.10 mm
)

Approved BY Mr. A, Ghosh (SGM, 0A & l)

.:: ,
MATERIAL

GRADE

SpeCtfrCettO1t

r.to

scM435 ALLOY STEEL FOR COLD

FORGTNG

95314

4.

QUALITY ASSURANCE PROVISIONS

4.1 The test methods shall be as specified in the applicable ASTM, lSO, DlN, BS Standards.

4.2 Receiving inspection shall inspect and test the samples (submitted per paragraph 5.2) to establish if they conform to this specification. lf samples do not conform, the lot will be
rejected.

4.3 4.4

lf

submitted samples conform

to this

specification, the lot will be released for further

processing and production. accumulated, and the trouble is related back to the condition of the "as received" material, the entire lot may be rejected. Rejection of the coil shall be based on the following:

lf, during

production and processing, defective coils representing 10% of the lot are

No more than 1.5% split or upset fractures will be accepted on standard headed cap
screws.

4.5 Purchasing shall notify the vendor of rejected lots and arrange for negotiation with the
supplier for physical disposition of the material.

4.5.

Samples that represent rejected material shall be preserved for two weeks from the date of the test report. ln case of dissatisfaction with the results of the test, the manufacturer may make claim for a rehearing within that time.

4.6 Any deviations from the Specification must be covered by a Concession agreed with the Company. Concession to be recorded and approved by Engineering and Quality
departments,

PREPARATION FOR DELIVERY

5.'1 A durable tag, to be securely wired to each coil, bearing the following information; . Description . Material Grade

. . . .

Diameter Applicable specification number Coil weight Steel Date

5.2 Samples approximately 18 inches long shall be cut from 10o/o of the cold drawn coils in a lot, tagged with the purchase order number, grade of steel and heat number, and shipped with
the iot of material and steel date. 5.3 The vendor shall furnish, with each shipment, one copy of a certified report (i.e. Certificate

of Conformance), for each lot. At minimum, the report shall indicate the
information: . Description . Size

following

. . . . .

Applicable Specification Heat Number (Cast Number) Chemical Composition

Hardness

Reduction of Area
REVISION LFVEL DATE SPECIFICATION

Page 4 of 5

MATE RIAL S PEC I FICATION

MATERIAL GRADE SPECIFICATION NO

SCM435 ALLOY STEEL FOR COLD FORGING

85314

3.2.2

Unless otherwise specified on the purchase order, diameter tolerances shall be

as follows:

Rod Size lnches

Tolerances

Rod Size Metric

Tolerances

Up to 0.312 incl. Over 0.312 to 0.437 incl. Over 0 437 to 0.625 incl Over 0.625 to 0.875 incl. Over 0.875 to 1 000 incl

t
r

0.005

Up to 8.0 incl.

0.006

Over 8.0 to 11.0 incl Over 11,0 to 15,8 incl. Over 15.8to 22.0ind. Over 22.0 to 25,5 incl Over 25.5 to 28.5 incl.

t 0.007 t 0,008 I 0.009

r
0.010

!012 r 0.15 t 0.18 r 0.20

x 0.23

Over 1.000 to 1.125 incl.

t 0.25

3.2.2.5
Rod Coil Dia. inch

The rod coils shall be supplied to the weight limits below

Rod Coil

Dia. mm

Coil O.D. mm

27 .s',-31.s',

Up

to '13,5mm

COLD DRAWN WIRE

3.2.3.1

The material shall be cold drawn from pickled or abrasive cleaned spheroidize annealed rods that have been rolled from fully ground and inspected billets.
(Special cold heading quality).

3.2.3.2
Wire Diameter inch

The wire shall be supplied in coil form to the size and weight limits specified
below:

Coil l.D.

Coil O.D.

Wire Diameter mm

Coil l.D. mm

Coil O.D. mm
1 1 1 1 1

Weight Kgs

Up to 0 300 0.301 to 0.400

0.40'1 to 0.500

27"-30" 27"-30" 28"-32" 28"-32"

38',-40" 38',-40',

42" max 42" max 42" max

42"
ma><

Up to 7.5 7.6 to10.0

10.1

686-762 686-762
710-810
7'10-8'10 965-1 000 965-1 000

000 000 000 000 350

200-300 200-300 400-500 700-750

750-1 000

lo 12.7
17 .8

0.501 to 0.700 0.701 to 0.860 0.869 to 1.000

12.81o

53" max 53" max

17.9 to 22.0

22j1o25.5

I 350

750.1 000

3.2.3.

Unless otherwise specified on the purchase order, diameter tolerances shall be + .000 - .003 inches. (+ 0 0 -0.076mm) The wire shall be coated with Phosphate Coating suitable for double extrusion processing. Phosphate Coating levels are as follows,
Minimum: 6.00 g/m2 Maximum: 12.92 glm2

3.2.3.4

REVISION TEVEL DATE

SPECIFICATION

Page 2 of 5