Introduction Terminology Processes Benefits Coatings and Lubricants Applications Steps to Manufacture Coatings and Lubricants Material Characteristics

Cold Forming Terminology

Cold Forming terms:

Cold Heading:
cold

forming process in which the force of the punch must exceed the materials elastic limit to cause plastic flow limit = yield strength operation without the heat

elastic

forging

Cold Forming Terminology

Cold Forming terms:

Cold Extrusion
decreasing reduces

the diameter of the blank by pushing it through a smaller hole size without yield loss

Cold Forming:
generic

term describing the combination of cold heading with cold extrusion

Applications:

Cold forming machines - by the number of dies and blows

for

example:

1 Die/2 blow

2 Die/3 blow
2 Die/4 blow

Open Extrusion

Trap Extrusion

30% area reduction

75% area reduction

Examples using trap extrusion and open extrusion.

7 Station Cold Forming Process

Fig : 1 Cut off to specified length

7 Station Cold Forming Process

Fig 2 : Squring

7 Station Cold Forming Process

Fig 3 : Impact Extruction

7 Station Cold Forming Process

Fig 4 : 2nd Blow Extrusion

7 Station Cold Forming Process

Fig 5 : Backward Extruction

7 Station Cold Forming Process

Fig : 6 Forward Extrusion

7 Station Cold Forming Process

Fig 7 : Finishing Blow

Benefits of Cold Forming

Advantages of Cold Forming Design Versatility
High strength parts from non-heat-treatable alloys Most cost effective way vs. milling, machining, hobbing and chemical etching High production rates

Metallurgical Effects
Grain flow Improves strength, hardness, toughness & fatigue resistance

Material Savings

Applications for Cold Formed Parts

Automotive
brake

parts ball joints & steering parts starter pinions oxygen sensors constant velocity joints manifold bolts engine valves

Appliance Industry
gears fasteners

for assembly

Applications for Cold Formed Parts

Construction, Off-road equipment
bolts,

nuts screws tapping, window, roofing, deck transmission gears similar parts for automotive

Aerospace
rivets,

fuselage engine bolts fasteners - landing gear, interior

Process Chain of Cold Forming

Raw Material

Heat Treatment

Surface Treatment

Cold Forming

Formed Part

Metal Removal

Heat Treatment

Metal Removal

Finished part

Coatings and Lubricants

Coatings Uses
prevent metal to metal contact with tooling, galling act as a carrier for machine lubricants

Types
precoat lime copper plating zinc phosphate molybdenum disulfide oxalate

Coatings and Lubricants

Lubricants Types
soaps
calcium stearate sodium stearate

drawing oils Metal-removing coolants

oil emulsion synthetics

Since cold working is done at room temperature or low temperature , no oxidation and scaling of the work material occurs This results in reduced material loss. Thin gauge sheet can be made by cold working(forming) Since higher force are required, High capacity and costly machines are needed for cold working. Severe stresses are set up in material during the cold working.

Coatings and Lubricants

Process
Hot Rolling Drawing

Lubricant
Water Pre-coat: phosphate, lime, oxalate Lubricants: Soaps, Oils

Cold Forming Thread rolling

Cutting/slotting

Oils
Metal removal coolant: Emulsion, Solution, Oil Metal removal coolant: Emulsion, Solution