In many situations, a screw cold heading machine can unexpectedly break a screw during the process, and removing the broken head can be quite challenging. If you find yourself in this situation, here’s a step-by-step guide to help you extract the broken bolt effectively:
First, clean the area around the broken screw to remove any dirt or debris. Use a center punch to create a small indentation at the center of the broken surface. Then, drill a hole using a 6–8 mm drill bit through the center of the bolt. After that, replace the small drill with a larger one—around 16 mm in diameter—and continue enlarging the hole until it goes all the way through.
Next, take an electrode with a diameter of 3.2 mm or smaller and use medium to low current to start welding from the inside out. Be careful not to let the arc be too long, as this could damage the outer wall of the bolt. Once you’ve welded halfway along the length, continue by adding a cylindrical extension on top of the broken bolt. This cylinder should be about 14–16 mm in diameter and 8–10 mm in height.
After the surfacing is complete, gently tap the top of the bolt with a hammer. The vibration caused by this action, combined with the heat from the welding and subsequent cooling, will help loosen the bolt from its threaded hole.
As you work, keep an eye out for any signs of rust escaping from the break. When you notice this, place an M18 nut over the welded stud and weld them together securely.
Once the welding is done, allow the nut to cool slightly. Then, use a pipe wrench to twist the nut back and forth. You can also gently tap the end of the nut with a small hand hammer to help dislodge the broken bolt.
Finally, after removing the broken bolt, use a suitable wire brush to clean the threads in the hole, ensuring all rust and debris are removed for future use.
This method combines mechanical force, welding, and vibration to safely and effectively extract a broken bolt without damaging the surrounding material. It’s a practical solution that can save time and prevent further complications in your work.
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