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Cold Forming

Cold Forming : Introduction

Cold forming is a manufacturing process that plastically deforms metal using dies. It allows for high speed production, little to no material waste compared to conventional machining, and creates a stronger end product due to work hardening of the material.

Basics of Cold Forming

*Header Machine (2-die, 3-blow)

  1. STEP.01
    Material Cut-off

    Material Cut-off

  2. STEP.02
    Forward Extrusion

    Forward Extrusion

  3. STEP.03
    Upset1

    Upset1

  4. STEP.04
    Upset2

    Upset2

  5. STEP.05
    Backward Extrusion

    Backward Extrusion

  6. STEP.06
    Processing Complete

    Processing Complete

1. Material Cut-off


1. Material Cut-off

Coil wire is cut into billets of a predetermined length.

2. Forward Extrusion


2. Forward Extrusion

A processing method to reduce the diameter of a material by pushing it into a mold that is thinner than the material.

3. & 4. Upset


3. & 4. Upset

A processing method that utilizes perforated dies to facilitate material displacement. It is used to form shapes wider than the original material diameter.

5. Backward Extrusion


5. Backward Extrusion

A processing method in which material is moved in the opposite direction of the force applied by the punch.

6. Processing Complete


5. Backward Extrusion

The completed part is ejected from the last die

4 Advantages of Cold Forming

High efficiency material utilization (high yield)
01

High efficiency material utilization (high yield)

The high material utilization of cold forging allows for significant reductions in material waste (scrap) compared to machining for the same geometry.
Figure: Material Yield Rate (multi-step rivet example)

Higher speed, more efficient production
02

Higher speed, more efficient production

Cold forming allows for high speed manufacturing (around 100 parts/minute) while still maintaining high precision and complex product geometries. No heating of the material is required.
Figure: Production Speed (multi-step rivet example)

Improved product strength by work hardening
03

Improved product strength by work hardening

Cold forming process design takes fiber flow lines (the crystal structure of metals) into account allowing for stronger more durable parts.
Figure: Fiber Flow Lines (multi-step rivet example)

Cost reductions through customized manufacturing processes
04

Cost reductions through customized manufacturing processes

If a customer design(tolerances, geometry, number of components required, etc) is practical using cold forming, significant improvements in part unit cost and reduced process complexity are possible.
Figure: Example of our Value Added / Value Engineering through cold forming

Materials Possible with Cold Forming

Materials Possible with Cold Forming

We have experience in processing the following materials with the cold forming process. If your preferred material is not listed below, please consult with us.

Steel, Stainless steel, Aluminum, Copper, Brass, Other special materials

Processing Equipments

Cold Header Machine
Cold Header Machine
Parts Former Machine
Parts Former Machine
Product info

Range of Forming Machines

1D2B~8D8B

Wire Diameter

Φ 0.0039 in ~ Φ 0.9842 in
(Φ 0.1 mm ~ Φ 25mm)

Length

0.0394 in  ~ 47.24 in
(1 mm  ~  1200 mm)

Control Precision

µin (㎛)
* Depending on client requirements, partial high precision control at the microinch level is possible.

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