Beveling tool for bolts
Features of the chamfering process
For cutting edges on metal products special units are used. chamfering machines, which are distinguished by the method of cutting into three types (air-flame, mechanical and gas-oxygen equipment).
- The chamfering tool is clamped to the sheet edge or the inside of the metal pipe.
- Next, the desired bevel angle is set.
- When the machine is switched on, the cutter head is moved onto the workpiece and the chamfering takes place.
- The cutter returns to its starting position when work is complete.
- After the chamfer is cut, the worktop is considered to be welded.
When chamfering, a welding reservoir (bath) is formed where the hot welding compound is collected. Chamfered edge has a defined bluntness of about 3-5 mm. When the reservoir is filled with welding compound, the blunted area is fused by itself. This ensures the necessary seam tightness and creates additional safety.
Removal heads for “flattened” bolts and nuts
When repairing cars, sometimes it is necessary to unscrew fasteners with “mitered” edges, which can not be unscrewed with a standard tool. This occurs most often when working with an exhaust system where the fasteners corrode particularly badly.
There are many “folk” ways to unscrew such fasteners, for example, weld a nut on top and unscrew for it, pound on a smaller head, finally, just cut with an angle grinder, etc.д. There are special nut breakers. But these ways are not always suitable, especially if you have to work in limited space.
Recently I had to unscrew “swollen” bolt of exhaust manifold heat shield fastening. The bolt is stuck and attempts to unscrew it even with good 6- and 12-point sockets only made things worse. There is not enough space for work, the engine shield is in the way (photo 1, 2). No head to hammer, no welding to get under. A special salute to designers who used bolts with a head of 10 mm for fixing the exhaust system. Even the 12mm heads burn out quickly here, let alone the 10mm.
In that case a good solution is a special extractor head. I use two kits and show them below and how I used one of these to remove the problem screw.
The first set of extractors GEDORE RED R68003010 (Photos 3, 4).
Extraction heads have a special screw profile that plunges into the slipped faces while unscrewing. Standard 1/2″ square sockets.
The bolt unscrewed with the extractor without any problems (photo 7-9):
I also use “unnamed” Chinese kit. Their advantage is that besides the square drive, they have an external edge for screwdriver heads to work in very limited places where you can’t reach with a driver (Photos 11-13).
Besides extractor head, there are also screw extractors for screws with flared slots (photo 14, 15). They are also suitable for removing broken bolts and studs.
Already many times convinced that the special tool helps faster and easier to solve complex tasks that can not be solved by standard improvised means.
Deburring tool NB1100
Good day to you all. In my last review where I dealt with the deburring tool I wrote: after receiving the set “file all parts”. And then I remembered from the analogy with the commercial: “where was? drinking beer ah. and men probably don’t know”, because “they don’t clean guns abroad with bricks”, and there is a special tool for this purpose, named “grate-cleaner” (“grate”. from German word “grat”. surplus metal, left on edges of products after any kind of machining). But abroad of course it has a different name, more often it is called “Deburring tool”. All of you who are interested in this, please go here. A bit of history. Many Soviet construction kits have a footnote in the manual that the parts should be “filed” before assembly, and later on this even gave birth to a popular meme and many anecdotes on this topic. But it could not last forever because it is not convenient and productive, this is the 21st century. Over time, for this purpose came up with a whole class of tools. “Deburring Tools”, and we just have to use them. A little about the product itself. Of course, it is not a Kraftool, Rothenberger or RUKO, for example. NB1100. this is a typical representative of Chinese-program, it does not have anything outstanding, but it works well, and the price is inexpensive in contrast to the branded. Except NB1100 two more models are commonly found on eBay: EO2000. as a fountain pen: But as for me “in the Chinese version” of similar form factor is too flimsy. I saw similar enclosures from Milwaukee, but I never held them in hands, and those I got at work had a body made of aluminum. In addition to these two aforementioned, very often found in ali and NG1000, but I did not buy it. for home episodically “scrape” dural enough and NB1100, and at work in the pantry give out brand-name. Purpose As many other “Deburring Tools” NB1100 is designed for deburring and chamfering of various profile surfaces, external and internal burr removal from copper, plastic, aluminum and steel pipes, and for chamfering of straight edges, keyways etc.п. Thanks to replaceable blades, there is no need to resharpen or completely replace the tool when it wears out. Steel, aluminum, plastic, copper, brass, cast iron. For these purposes you can find and buy a lot of interchangeable blades of different types at aliexpress. Here are for example some of the simplest most common blades: When buying blades of course need to look at for treatment of what materials they are designed, so as not to try to remove burr with steel blade designed for plastic treatment. For this purpose sellers selling them as a rule have plates like this: Here are some of the stores where you can buy replacement blades: https://aliexpress.ru/item/item/1005001626270980.html https://aliexpress.ru/item/item/1000004810988.html https://aliexpress.ru/item/item/33023695930.html https://aliexpress.ru/item/item/32800040127.html Besides simple blades, there are often highly specialized ones, e.g. for working through holes. In appearance, some of them resemble countersinks: And also in the form of “funnel”. it is convenient to remove burr from the outside of pipes and rods: The class of tools “Deburring Tools” certainly does not end there, but today we have basically only a review graphite remover NB1100, so this information simply passed the context as a supplementary nozzle. Application of course further in the text would have to show a lot of photos from which would be little understandable, and even more so seen (any metal tends to shine and give a glare), so I think it is uninformative and will limit myself to one photo “was / is. In a more informative way, you can watch professionally filmed videos on “Deburring Tools”:
Note: of course the video is slow, in real life you do it quickly and without looking. often than not, one sits on a chair and chats with the person he is talking to (looking more at him than at the part), rather than “savoring” a similar process t.е. everything is done by feel and checked with a “finger gauge. Cautions: When you buy other (less common) models of gravity lifters at aliexpress be careful not to go like this: Of course “should”, but where were his eyes when he bought the product with a collet?
And the traditional: and what the hamster said? Homa flatly refused to participate in the photo shoot with the tools from the last century and ran away: He must have mistaken them for instruments of the Medieval Inquisition and thought they wanted to skin him alive. And here is a modern tool for deburring Homa examined closely: and “want to”)) by the way sets of jigsaws native to the USSR Homa is also not afraid of. So, the choice between these tools is up to you: And we’ve finished our business with Homa and wash our paws until the next review. Beaver all and good luck with your needlework.
The package came in a standard polyethylene bag, but the tool itself is in an unusually colorful (for a product under 3 bucks) cardboard box. What this tool is all about? It consists of a blue plastic pen-shaped body and a rotating blade, which is fixed by turning the black part around its axis. The quality of casting is average, the black part shows signs of wear and tear on the mold. The blue body has a 5mm diameter through hole inside. you can fit a scribing/marking awl. Complete blade and black retainer close-up:
Classification of machining tools
All tools designed for quality edge treatment can be classified into several categories.
For Purpose
- Devices that are used for edge trimming of sheets and pipe ends. They are called root-cutting machines and chamfering machines.
- Tools designed to adjust pipe sizes or holes to specific diameters. These are called calibrators.
- Some chamfering machines have a countersinking function that makes it possible to make holes for bolted connections.
In terms of application
- Hand tools that allow you to work with the force of one hand. These are the simplest and least expensive tools.
- Tools that have a shank or mounting head designed for use with cordless or corded power tools. They can be clamped in the jaws of screwdrivers, drills, or electric pliers. expensive, but at a much higher productivity than manual tools.
By material of products to be machined
- Universal bevelers, as a rule, are able to process products made of copper, aluminum, steel, brass, plastic.
- Some models are only used for plastic pipes.
- Shapers are designed for beveling reinforced polypropylene pipes.
For sheet metal
Sheet metal is widely used in a variety of fields and applications. Therefore, the beveler for sheet metal is in demand among performers at various levels. This type of equipment has design features: supporting rollers allow the edger to hold on the flat surface, pressed to the end face and perform processing; an ergonomic handle ensures convenience and easy movement of the unit without much effort.
MT-24
Chamfering MT-24 is designed for processing the edges of sheet metal materials, used in the manufacture and installation of steel structures.
- The maximum chamfer width is 22 mm.
- Maximum chamfering angle 60°.
- Power 1100 W.
- Rotation speed 3600 rpm.
- Weight 19.3 kg.
- Number of cutters 2 pcs; number of slats per cutter 12 pcs.
CHP-12
CHP-12 chamfering machine used for the machining of single- and double-sided edges of stainless and carbon steel sheet materials, aluminum and its alloys.
Manufacturer of this universal unit is CeVisa (Spain).
- Max chamfering angle 45°.
- Maximum chamfer width 12 mm.
- Maximum fillet depth 8,7 mm.
- Processing speed 2,6 m/min.
- Thickness of processed workpiece should not exceed 40 mm.
- Drive power 2200-3000 W.
- Power supply voltage 380 V.
- Rotation speed 1400 rpm.
- Weight 65 kg.
It should also be noted that this unit can be used to work with pipes from 100 mm.
UZ-12
UZ-12 automatic chamfering machine produced by NKO Machines (Czech Republic). This unit is designed for work on top and bottom edges, suitable for working on cast iron, stainless steel, copper, aluminum and brass, and has a high level of performance. The unit can be mounted on the sheet in vertical and horizontal position.
- Maximum chamfering angle achievable with 50° tooling.
- The maximum chamfer width of 12 mm.
- Maximum sheet thickness of 35 mm.
- The minimum size of the workpiece is 60 x 60 mm.
- Processing speed 1.8 m/min.
- Engine power 400 W.
- Important! A small weight of 30 kg. Allows to use the unit as a mobile as well as stationary machine.
Overview of beveling techniques for sheet metal and pipes
When welding sheets or tubes with wall thickness more than 6 mm, GOST 16037-80 requires beveling.
Edges can be straight or broken, as well as curved, one-sided or double-sided.
An example of a one sided straight cut is as follows:
Two-sided beveling looks like this:
Accordingly, a curvilinear cut would look something like this:
And one of the shapes of the broken chamfer corresponds to this sketch:
As prescribed by GOST, double-sided and broken bevels are used on workpieces with thickness over 15 mm.
There are several ways of shaping an edge for welding. Each has its own advantages, disadvantages and limitations. Let’s look at the most common ones in order. To begin with we classify all methods into two types: fire and non-fire.
Fire types. are gas, plasma and laser cutting. At the current level of technology, laser cutting at an angle to the metal surface. is exotic. But, of course, it is a productive method, although it requires significant investment. In addition, there are limitations. formation of a broken chamfer is difficult, that is theoretically possible, but in practice it is hardly achievable, and the curved one is not possible in principle. As a disadvantage, in addition to initial equipment costs, will require a powerful organization of ventilation. All these laser systems are quite bulky and are only installed indoors. Lack of field installations. is another disadvantage. At the time of writing, the industry offers three-axis laser systems capable of cutting metal up to 25 mm thick at right angles, and at. up to 15 mm. At the same time the maximum angle of inclination of the torch to the surface reaches 45 degrees.
- productive
- accurate and fairly straight
- only straight bevels
- only stationary version
- considerable quantity of harmful gases is emitted during operation
- high capital investment
Plasma cutting is inferior to laser cutting in terms of accuracy and roughness. it is not possible to make broken chamfers, and curved ones are sometimes made by themselves, due to wrong settings, equipment defect or errors. The capital investment required for plasma cutting is much less than for laser. Most of the harmful factors accompanying laser cutting are also inherent to plasma cutting: harmful ultraviolet radiation, toxic gases and fine dust from dross. at the current moment, industry has mastered the production of current sources for plasma cutting, which can provide lateral cutting in steel sheet of 100 mm thickness, while it is possible to cut material up to 50 mm thickness at an angle of up to 45 degrees by its weight the equipment is lighter and can theoretically be used for mobile units, although the current source and compressor are still very heavy and bulky components.
Advantages, limitations and disadvantages of plasma cutting:
- Performance
- only straight chamfers
- predominantly stationary design
- considerable amount of harmful gases is emitted during operation
- poor cutting accuracy, irregularities and overlaps
- Thermal change of the metal in the cutting zone
Finally, gas cutting, which among fire cutting methods, is the most inexpensive. Typically, gas cutting is used to cut thick metal, from 30-40 mm. Cutting at an angle to the surface, to form a chamfer, makes sense on even thicker materials, because the irregularities that arise at the edge of the metal cut with gas reach a height of 4-5 mm. A large amount of stationary and mobile equipment is designed for gas cutting, so this technology can be easily applied in the field. the maximum capabilities achievable at the current level of technology reach up to eighty millimeters for systems capable of cutting metal up to 150 mm thick, with a maximum bevel angle of 60 degrees. It is not difficult to cut X-shaped bevels in one pass with two consecutive cutters. But it’s on a flat sheet. For the pipe this technology will require two independent rotary joints with digital control. As for field settings, they tend to have manual settings.
To summarize the characteristics of gas cutting:
- performance
- cheap
- Can work in the shop environment or in the field
- straight chamfers only
- mostly suitable for thick metal
- considerable exhaust emissions during operation
- Low cutting precision, irregularities and overlaps
- Thermal change of metal in the zone of cutting
Now let’s take a look at the available bevelless pipe cutting options. This includes technologies of turning, grinding, milling and shearing.
One of the most popular types of equipment for chamfering pipes among oil and gas workers is the orbital split pipe cutter. This is a fairly accurate device that has a relatively large mass, and thus a high price. Regarding its performance, it can be said that it is inferior to fire methods and even manual grinding with bolt cutters, but that is not the main thing. The main one is that the orbital pipe cutter allows you to get almost a perfect edge, almost any shape. Turning with cutters, according to the turning principle, gives the edge, which fully meets the requirements of GOST and coincides with the level of roughness of the factory finish. However, this equipment has its own disadvantages. The perfectly round shape of the guide rails is not always identical to the slightly oval cross-section of real pipes, and the serrated edge left over from gas cutting in the field quickly puts cutters out of action. Besides, split tube cutters, despite their modest price, have a very limited range of diameters that can be cut. For example, the product line of split tube cutters includes the standard sizes, which are able to cut the tubes with the diameter difference not more than 200-250 mm. Pretty limited versatility, you agree.
So, you can gather the following information on the split tube cutter:
- high accuracy and low roughness
- ability to work in the shop or in the field
- no harmful emissions, low noise level
- chamfers of any profile, undercuts, etc. are available.п.
- high consumption of cutters on gas-cut pipes
- high equipment cost
- medium performance
- it is not possible to plan flat sheets by turning
Promotech. New Generation Beveling Machine (BM-21)
Chamfering on sheet metal is an option that allows you to use planers on longitudinal planing machines as well. These machines are not only very massive, but also very expensive. Therefore, we add these two unpleasant factors to the list relating to the detachable pipe grinder.
As for the above method of chamfering with an angle grinder, it is one of the most popular methods. This is primarily due to the fact that the angle grinder. it is extremely inexpensive and widely available tool. angle grinder allows you to chamfer thin and thick workpieces, but its performance can be considered satisfactory only on thicknesses up to 20 mm. with enough skill, you can form and broken chamfer, but its profile will not be smooth.
- exceptional cheapness and availability of the equipment
- lightweight and mobile
- the ability to effectively chamfer medium size (sheet thickness up to 10-12 mm)
- High consumption of abrasive wheels
- considerable emission of harmful dust
- because of this frequent failure of the angle grinder itself
- Low productivity on chamfers wider than 10 mm
- low dimensional and shape accuracy
- Rapid operator fatigue means risk of injury
Another, more productive, cleaner and virtually silent method. shearing of edges by a special machine. Work is carried out by the instrument of high-speed steel, which looks like a mill and a knife for opening cans. By shearing the metal between the stationary cutting edge and the rotating cutting edge, a triangular cross-section edge is cut. Because of the rolling of the knife. metal milling cutters, these chips are sometimes wound into a spiral and occasionally break off when they reach a large size; sometimes the chips fall into the tray separately. The whole process is almost silent thanks to the low speed.
The disadvantage of this technology is the high cost of knives. because they are entirely made of expensive high-speed steel, besides, only a flat bevel can be cut, and, although powerful self-propelled units are capable of shearing quite a thick sheet, this only applies to mild steel. when beveling stainless steel with four to five times the toughness and tensile strength, the capabilities of these machines drop sharply.
So, edge cutting machines, their advantages and disadvantages:
- high productivity for ferrous metal
- mobility and ability to work in the shop environment
- No noise and dust at work
- there is no thermal change in the area of the cut
- high cost of replaceable tools
- Metal thickness and chamfer width limited to 20 mm hypotenuse
- higher cost in comparison with edge cutters
- small chamfering capabilities on stainless steel. not wider than 10 mm
- no possibility to bevel or chamfer curves
As an alternative to this method is the technology of chamfering by manual or self-propelled electric edge mills. These machines use a prefabricated carbide cutter, less often a monolithic cutter. Depending on their design, edge routers can be lightweight. manual, or quite heavy and productive. automatic, mobile or stationary. Manual and stationary edgers can mill both sheet metal and pipes. The cutter in these units may have a rotational axis parallel to the plane of the bevel or plate. machining the formative as well as perpendicular to the chamfer plane. End machining. Besides small manual machines with single-piece cutters, all other machines of this type use different variants of cutters with replaceable carbide inserts. The vast majority of samples are of the cylindrical or face milling type to form flat chamfers, but there are also face milling cutters equipped with round shaped plates that can remove both flat and curved chamfers, the so-called ruched chamfer. An absolutely unique cutter is the prefabricated cutter for broken chamfering.
To summarize for edging machines and machines:
- performance is 9 times higher than that of the angle grinder
- Costs are lower than for beveling machines
- ability to work in the shop or in the field
- no dust or harmful gases
- consumables are inexpensive and available
- There is no thermal change in the cutting zone
- high quality and edge accuracy
- chamfering and fillet chamfering possible
- The chips that are formed can be quite sharp
- beveling productivity is lower than with gas cutting
- chamfering is accompanied by noise
Having gathered the information available to us, we believe that now it will be easier for you to make a choice of equipment and decide which technology is best suited to your needs.
in the text of the article straight edge or straight chamfer refers to the cross-sectional profile of the edge. it does not refer to a chamfer along the edge.
EQUIPMENT FOR THE PRODUCTION OF STUDS
One of the most popular types of fasteners is the stud. The most popular type is high strength stud bolt B7. These studs are considered to be heat resistant up to a maximum operating temperature of 500°C. 510C. Structurally, a stud is a rod with a full or partial thread. Can be made with or without chamfering. The material for the production of stud bolts B7 is largely carbon-medium alloy steels, and sometimes stainless steels after heat treatment. Heat treatment is obligatory in order to achieve higher strength values. Stud bolt is produced by passing round steel rod through thread-cutting machines. It also features a chamfer on the ends of the stud, which facilitates connection to the nut and reduces the risk of thread damage on entry.
The RGS-33/42-B7 chamfering and punching machine line is designed for the production of high-strength B7 studs. Each chamfering machine model is designed for a wide range of wire diameters and lengths. These CE approved machines are safety, easy to set-up and low maintenance. They are designed specifically for the production of small and medium sized studs.
Powerful chamfering heads provide a clean, smooth chamfer and a long service life. Chamfers are cut at high speed and without lubrication, after which the dry chips are ejected from the machine so the working area remains dry and clean. Stamping can be single-sided or double-sided.
The machines accept pre-cut blanks which can be fed automatically by an external feeder or by a manual feed magazine. For long rods a fast exchangeable feeding table and scissors are used to cut the rods to a defined length. Coil feeding up to M24 (1″) is also possible. Optionally, a conveyor can be added to feed chamfered and stamped workpieces to the roller conveyor, if required.
Chamfering equipment specification
| RGS-33-B7 | RGS-42-B7 |
| M12 to M33 | M12 to M42 |
| 10.7 mm to 31 mm | from 10.7 mm up to 39 mm |
| 60 mm (for M12) to 100 mm (for M33) | 60 mm (for M12) to 120 mm (for M42) |
| 300 mm | 300 mm (optional 400 mm) |
| M12: 38pcs/min M16: 36pcs/min M20: 32pcs/min M24: 30pcs/min M27: 26pcs/min M30: 23pcs/min M33: 20pcs/min M36: 16pcs/min | M12: 38 w/min M16: 36 w/min M20: 32 w/min M24: 30 w/min M27: 26 w/min M30: 23 w/min M33: 20 w/min M36: 16 w/min M39: 14 w/min M42: 12 w/min |
| 8 kW | 10 kW |
| 2.0 м × 1.1 м | 2.3 м × 1.2 м |
| 2 tons | 2.2 tons |
Manufacturing methods
The methods used for edging depend on the following conditions:
According to the method used, the following types of edge preparation are distinguished:
To cut the bevel on metal products, various metalworking equipment is used, equipped with special tools. It can be used to achieve the required thread chamfer size. The use of special cutters, milling tools allows to perform chamfering in the holes.
Particular attention is paid to preparing the edges of the transition from one diameter of the shaft to another. This transition is called a fillet. It is quite common in mechanical engineering. Shaft beveling is performed in different ways in compliance with the established standards.
As already noted, special chamfering machines are used for more accurate edge removal. They allow you to get a given angle and length of the cathetus.