In many cases, a screw cold heading machine can unexpectedly break a screw during operation, and removing the broken head can be quite challenging. If this happens, here’s a step-by-step guide that you can follow to safely extract the broken bolt:
First, clean the surface of the broken screw to remove any dirt or debris. Then, use a center drill to create a small indentation at the center of the broken section. Next, drill a hole in the center using a 6–8 mm drill bit, making sure it goes all the way through. After that, replace the small bit with a 16 mm drill bit and continue enlarging the hole until it is fully drilled through.
Next, take an electrode with a diameter of 3.2 mm or smaller and weld it into the broken bolt using medium or low current. Start the arc carefully so that it doesn’t burn through the outer wall of the bolt. Once the welding reaches the top of the broken bolt, continue by adding a cylindrical piece of 14–16 mm in diameter and 8–10 mm in height.
After the welding is complete, gently tap the end face of the bolt with a hammer. This vibration, combined with the heat from the welding and subsequent cooling, will help loosen the bolt from its threaded hole.
Once you notice a slight rust leak after tapping, place an M18 nut on the welded stud and weld them together. After welding, let it cool slightly and then use a pipe wrench to turn the nut back and forth. You can also use a small hand hammer to strike the nut, helping to free the broken bolt.
Finally, once the broken bolt is removed, use a suitable wire brush to clean the threads inside the frame, ensuring that any rust or debris is thoroughly removed.
This method is effective for retrieving broken bolts without damaging the surrounding material, and it can be applied in various industrial settings where precision and care are required. Always ensure proper safety measures are taken when working with tools and welding equipment.
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