SCREW HEAD FORMATION
A screw having in its head a recess that includes two or three non-circular superimposed recess-tiers. The depth of each recess-tier is less than 1.35 mm and there is less than 1° draw in each recess. The screw head recess is formed using a punch ( 10 ) in a cold heading process. The punch is formed in a profilating CNC machine, cutting the profiles of the punch to a tolerance of better than ±0.0025 mm.
1 . A screw having in its head a recess comprising at least two non-circular super-imposed recess-tiers, a smaller one thereof in the base of a larger one thereof, wherein, the depth of each recess-tier is less than 1.35 mm; there is a less than 1° of draw in each recess recess-tier; and where the tolerance in the cross-sectional dimensions of at least one recess is better than ±0.0025 mm.
2 . A screw as claimed in claim 1 , in which each recess-tier has substantially no draw.
3 . A screw as claimed in claim 1 , in which each recess-tier is less than 1.2 mm deep.
4 . A screw as claimed in claim 1 , in which the tolerance in each recess-tier is better than ±0.0025 mm.
5 . A screw as claimed in claim 1 having three recess-tiers, each with a depth of 1.0 mm or less.
6 - 20 . (canceled)
21 . A screw having in its head at least two non-circular, super-imposed recess-tiers, a smaller one thereof in the base of a larger one thereof, wherein there is less than 1° of draw in each recess-tier and wherein the edge between the recess-tiers is chamfered.
22 . A screw as claimed in claim 21 , in which the chamfer has a radius of not less than 0.05 mm, preferably about 0.1 mm.
23 . (canceled)
24 . A screw whose head recess is formed by a punch in a cold-heading process, whereby the head recess is in the form of at least two superimposed recess-tiers, each tier being a straight-sided polygon whose sides are substantially parallel the axis of the recess, wherein the punch is made by a method comprising the step of adapting a computer numerical controlled machine center having a bar fed to a rotary chuck by providing a profilating head as one of the tools on a turret mounted adjacent the chuck and capable of both axial and radial movement with respect to the axis of the chuck, as well as rotation about its own axis, the profilating head comprising at least two cutting elements arranged on the head, the cutting elements being adjustable with respect to one another: axially, with respect to the head axis; radially, with respect to the axis; and angularly with respect to said axis, whereby the cutting elements can be arranged to rotate around the same circle and with the requisite angular separation that at least some of the sides of a polygon are formed on the end of the bar when the cutter is rotated in the same direction, with respect to the bar, as the bar is rotated in the chuck, and the turret is moved axially and/or radially with respect to the chuck to bring the cutter into contact with an end face of the bar.