PROJECT REPORT

COLD FORMING
 Cold forming is the process of forging metals at near room temperatures.
In cold forming metal is formed at high speed and high pressure into tool steel or carbide dies. The
cold working of the metal increases the hardness, yield, and tensile strengths.
The cold heading process refers to the upsetting of a volume of metal into a head like on a nail or
screw.
Cold Forming and Cold Heading processes are flexible. Parts can be hit multiple times while staying in
one die ("one die, multiple blow"), or transferred from die to die to progressively form various
geometries ("multi-die forming").
Cold Forming consistency is excellent because each part is made in the same die. Material is used at
almost 100% efficiency. There is no scrap as found in machining. Because of the high productivity, the
efficiency of material use, and the use of precise dies, cold headed and cold formed parts have
significant cost and quality advantages.
The range of possible shapes is rather broad, including heads, threads, steps, knurls, chamfers,
grooves, undercuts, and tapers.
Some features that cannot be directly made with Cold Forming or Cold Heading can be added in
secondary operations, such as threading, pointing, or rolling.
Typical parts made using cold forming technology include screws, nuts, and bolts, electrical contacts,
and rivets. In addition to these "high volume standard" parts, there are many thousands of different
custom parts for a diverse set of applications.
MANUFACTURING OF SCREWS
Raw Material (Spheroidal Anneal Wire )

Heading Process

Slotting

Threading

Hardening and
Tempering

Zinc Plating
1.HEADING
Cold heading machines use a coil of wire and form the wire into desired parts at
very high rates of speed allowing the cold-headed parts to be made very quickly
and economically. The process begins by loading a large coil of wire in front of the
cold heading machine. The wire is purchased in a condition called spherodized
anneal. This special condition allows the material to be formed without cracking.
The wire is then pulled through a wire draw box to change the stock diameter to
the specific diameter required to manufacture the fastener. Running the wire
through a draw box makes the wire shape very round with a tolerance of .001. This
is very important to holding size on the final parts after it is cold headed. A wire
straightener can also be added which will align the wire prior to going into the cold
heading machine. Straightening the wire is especially important on long parts.
After the wire has been successfully drawn to size, the wire enters the inside of the
cold heading machine. The wire goes through a cut-off die and continues until it
reaches a wire-stop. Once it reaches the wire stop, a cut-off knife moves across
the wire, cutting it off to a specific length. This is referred to as thecut-off slug.
The slug is then placed in front of the heading die by the cut-off knife. Once the
slug is in the proper position in front of the heading die, a series of punches are
used to strike the part. This is how a cold-formed fastener is processed.
WORKING OF HEADER MACHINE
2.SLOTTING
WORKING OF SLOTTER
3.THREADING
WORKING OF THREADING MACHINE
4.HARDENING

Hardening is process in which steel is heated to a temperature above the

critical point, held at this temperature and quenched (rapidly cooled) in
water, oil or molten salt baths.
If a piece of steel is heated above its upper critical temperature and plunged
into water to cool it an extremely hard, needle-shaped structure known as
martensite is formed.
In other words, sudden quenching of steel greatly increases its hardness.
After hardening steel must be tempered to:
1. Reduce a brittleness,
2. Relieve the internal stresses, and
3. Obtain pre-determined mechanical properties.
TEMPERING

Tempering consists of heating a hardened steel to a temperature below eutectoid

temperature and keeping it at that temperature for a specified time to reduce brittleness
followed by air cooling.
The aim of tempering is to decrease brittleness of hardened steel.
The steel, after hardening, contains martensite which is accicular and is very brittle. It
cannot be used as such. Hence it is essential to temper it to make it less brittle.
During tempering, the martensite hardness may also get reduced to some extent.
During tempering, martensite changes to low carbon martensite and then to equilibrium
phases (ferrite and cementite) resulting in reduction in brittleness.
The internal stresses also get reduced making steel less brittle.
5.ZINC ELECTROPLATING
Zinc Electroplating is a process in which a layer of zinc is bonded to steel in
order to protect against corrosion.
The process involves electroplating, running a current of electricity through a
zinc solution with a zinc anode and steel conductor.
Zinc electroplating maintains a dominant position among other electroplating
process options, based upon electroplated tonnage per annum.
Electroplated finishes are coatings of pure or allied metals by means of DC .
It is the reversed process produced in a battery. Electricity is generated by
means of ionic dissolution of metals in a battery .In the case of electroplating
processes metals are deposited from a ionic solution by means of an electric
current .
Electroplating processes follow Faradays law.
Electroplated zinc is widely used for coating steel parts for corrosion
protection.
THANK YOU

Submitted by
Tushar Sukhija (CO13156)
Vicky Kumar(CO13157)