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Secondary Processing

What is Secondary Process ?

Secondary processing allows for more complex shapes when combined with cold forming as the primary process.

Product Examples (Machining)
Product Examples (Bending, Flattening, Trimming)

Types of Secondary Processes

1.Rolling

In the rolling process, a blank is placed between two dies and rolled until the pattern on the dies is imprinted onto the blank. Typically used as a secondary process, rolling is used to create many different geometries including screw threads, grooves, diamond knurling and more. Rolling differs from cold forming with other types of machines, but because dies are used to plastically deform the workpiece, it is still considered a kind of cold forming.

Some Geometries Possible with Rolling

Screw Threads
Screw Threads
Grooves
Grooves
Pointed tips
Pointed tips
Rounded tips
Rounded tips
Straight Knurling
Straight Knurling
Diamond Knurling
Diamond Knurling
Spiral Knurling
Spiral Knurling
Leadscrews
Leadscrews

Machined vs Rolled Threads

Rolled threads enable high-speed thread forming with no material lost as scrap and a stronger product overall because, unlike machined threads, the fiber flow lines of the material are left intact. Rolling also allows for lower costs and better turnaround time than machining.

Machined vs Rolled Threads
2. Machining, Grinding

2. Machining, Grinding

Combined with cold forming, machining enables us to achieve a high-precision finish. Compared to a full cutting process, it results in less material scrap, greater cost savings and shorter delivery times.

3. Flattening

3. Flattening

This is a process which forms dents or protrusions by applying pressure to a metal material with a die.The flattening process can form various shapes such as cross-shapes and flat shapes as needed to suit part application and requirements.

4. Bending

4. Bending

This process bends metal materials to desired angles using a punch and die. One single machine can handle complex 3D bending.

5. Trimming

5. Trimming

This process cut off unnecessary sections after processing with processes such as cold forming.

6. Assembling

6. Assembling

This refers to composite processing technology that combines components made of different materials. These include fastening, press-fitting and resin molding.

7. Tapping

7. Tapping

This is the process of making a female thread using cold forming. Tapping can be conducted with either machining or rolling, however, we use roll taps which do not generate metal scrap.