1. step in the production of our self-tapping thread inserts: Production of the raw material
The basis for the production of self-tapping thread inserts is, of course, the raw material. It determines important properties of the later thread inserts, such as pull-out strength. We usually use free-cutting steels and stainless steels for the production of self-tapping thread inserts. Other materials such as brass are used only in special cases or at the special request of the customer.
In order to bring the raw material into the right shape for the further steps of the production of self-tapping thread inserts, it must first be melted. It is then pressed through an opening under pressure. This process is also known as extrusion. In this way, steel wire is produced, which is wound onto large spools for further processing.
After this first step in the production of self-tapping thread inserts, we are still a long way from the final result. With large rolls of steel wire, we move on to the next machine.
2. step in the production of our self-tapping thread inserts: Machining
The heart of the production of self-tapping thread inserts is the rotary transfer machine or multi-spindle machine, where the next phase of the manufacturing process takes place. These machines are capable of automatically performing several operations in quick succession.
First, the machine prepares the blanks. The steel wire is straightened and then cut to the appropriate length. The individual pieces are then given their cylindrical shape.
The production of the self-tapping thread inserts now continues with the more complex processes. Now the thread insert is given its final shape. First, the external thread is cut and the cutting slots are milled. These are used so that the thread insert can later cut its own holding thread in the material during use. Finally, when the self-tapping thread insert is produced, the internal work continues. The rotary transfer machine drills into the blank so that the internal thread can finally be cut. And finally, the edges are countersunk or chamfered.
What falls out of the machine at the end, you would directly recognize as one of our BaerFix® thread inserts. All the important features are already there. But the production of the self-tapping thread insert is far from complete.
3. step in the production of our self-tapping thread inserts cleaning.
The next step is cleaning. This is necessary because residues of cutting oil or other substances can stick during the production of the threaded inserts. So that these do not hinder the further course of production of the self-tapping thread inserts, they must now be removed. This is done in large industrial washing machines. The inserts are transported through a long drum in which they are gently cleaned. Once this process is complete, the BaerFix® thread inserts shine in new splendor.
4. step in the production of our self-tapping thread inserts Case hardening.
BaerFix® thread inserts must meet very special requirements in terms of hardness. After all, they should be able to cut a thread from a material themselves. To prepare them for this, special measures are used in the manufacture of self-tapping thread inserts.
One of these is case hardening. In this process, the threaded inserts are heated to a very high temperature in special furnaces and then cooled. In the process, the inserts are first exposed to a carbon-rich environment during carburizing. In this way, the surface layer of the steel is enriched with carbon. Subsequent quenching then ensures that the surface layer becomes very hard while the core remains relatively soft. In this way, the hardness required for the self-tapping property can be achieved in the manufacture of a thread insert. In addition, case hardening also increases wear resistance, thereby ensuring particularly durable and robust inserts.
The change takes place at the molecular level, and at first you can't see any of it with the naked eye. But our thread insert is significantly harder after this production step than before!
5. step of manufacturing our self-tapping thread inserts: Galvanizing
The production process for the self-tapping thread inserts continues with galvanizing - at least in most cases. During galvanizing, the thread inserts receive a thin zinc coating that increases their corrosion resistance. Galvanizing can be done in different ways. In the production of our threaded bushings, we use the so-called galvanic zinc coating, which works with electric current. The disadvantage of this method is that it can cause hydrogen embrittlement, which in turn leads to cracks and a particular type of corrosion - exactly the opposite of what galvanizing is supposed to achieve. For this reason, we subject our thread inserts to a special heat treatment during production called annealing. This allows us to effectively prevent hydrogen embrittlement. The galvanized thread insert is now not only particularly corrosion-resistant, but also stands out with a bright shine.
6. step of the production of self-tapping thread inserts: Quality control
The production of self-tapping thread inserts is not enough for us. Before a thread insert leaves production, it must undergo a precise quality control. In the process, we put the inserts through their paces once again. Are the dimensions right? Does the surface finish meet our requirements? Can the desired hardness be verified? Only if all the tests are to our complete satisfaction has the production of the threaded insert been a complete success and it can move on to logistics.
This completes the production of the self-tapping thread inserts and our product has reached its final state: a clean, precisely machined self-tapping threaded bush.
7. step in the production of our self-tapping thread inserts: Packing
So that the thread inserts can be stored and shipped safely and well protected, it is now time for packaging. As with the entire production of the self-tapping thread inserts, we also receive active support from machines here. The packaging machine knows how many inserts are to be combined into one packaging unit and packs quickly and accurately.
8. step of manufacturing our self-tapping thread inserts: Storage and shipping
At the end of the manufacturing process, the finished thread inserts first go to our warehouse. There they then wait to be ordered by you. A sophisticated logistics system helps us keep track of stock levels and incoming and outgoing orders. In this way, we can always offer fast delivery times.
