Basics of Cold Forming

QuEST Global
Basics of Cold Forming
30th Dec 2016/ Virupaksha A M
©2016 QuEST Global Services Pte Ltd. The information in this document is the property of QuEST Global Services Pte Ltd. and may not be copied or communicated
to a third
1 | ©2016 QuEST Global Services Pteparty
Ltd. or used for any purpose
QuEST other thanConfidential
Global that for which|itTEG-TEM-013
is supplied without the written| Revision:
| 11-Feb-16 consent of 02
QuEST Global Services Pte Ltd.
| Template Confidential
Basics of Cold Forming – Training Material
QuEST TRAINING MATERIAL

Training Title#1 : Basics of Cold Forming
Author(s)#02: Virupakshi AM Email#03 :virupakshi.am@quest-global.com Date #04: 30/12/2016
Summary#05:
Cold forming is a manufacturing process by which metal is shaped without removing material. A simple blank is placed within a die and a punch is
pressed into the blank at ambient temperature. The blank then takes on the form of the punch and the die. Put more simply, cold-forming is making a shape
from material at room temperature, just like Plasticine when it is pushed into a mould. With appropriate force, metals such as copper, aluminium, brass and now
even stainless steel can be formed into the required shape.
In cold forming, the metal is stretched beyond its yield strength, so that it takes on and retains the exact shape of the mould, but without
adversely affecting its tensile strength. Unlike conventional machining, where the material removal processes cut across the grain structure of each part, cold
forming allows the grain structure of the material to follow the contours of the die or mould. As a result, the strength of the part is maximised along its length,
while internal surfaces take on a highly polished finish.
Cold forming is a fast, economical way to produce robust, complex components in a wide range of materials. The process is capable of delivering
precision engineered parts with up to 80% less scrap than machine processes. Coupled with faster lead times, better surface finish and improved mechanical
characteristics, cold forming offers an opportunity for manufacturers across the industry to take advantage of enhanced component quality while also reducing
costs.
Revision Description Date

01 New Release 30th Dec 2016
2 | ©2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Training Details
Topics:
• Introduction
• Terminology
• Processes
• Benefits
• Material Characteristics
• Applications
• Steps to Manufacture
• Coatings and Lubricants
Introduction to Cold Forming
History and Development of Cold Forming
 March 23, 1794

 Josiah Pierson – “Cold Header” Rivet Machine
 November 16, 1796

 Isaac Garretson – U.S. Patent for nail cutting & heading machine
 Cold Forming Terminology
 Cold Forming terms:
 Cold Heading:
 Cold forming process in which the force of the punch must exceed the material’s elastic limit to cause
plastic flow
 Elastic limit = yield strength
 Forging operation without the heat
 Cold Extrusion
 Decreasing the diameter of the blank by pushing it through a smaller hole
 Reduces 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
 The wire is fed in through the cut-off die to a

wire stop.
 The cut-off knife shears the blank.
 The cut-off knife transfers the blank to

the heading die.
 Now the blank is ready to receive the first

punch operation.
 Proper cut-off of blank is critical.
 Blank mass equals mass of finished part.
 Upsetting of a fastener head is

accomplished by using one of these 4
methods.
 Typical 1-Die/2-punch method is common in

producing headed fasteners.
 The first blow combines coning with shank
extrusion.
 Coning is a partial head upset.
 The second blow finishes the head shape.
 Knockout pin acts as a blank support,

during heading operation.
 Then ejects finished part.
 Rule of thumb:
• Unsupported pin not to exceed 8D
• Supported pin is recommended over
8D
Open Extrusion Trap Extrusion
30% area reduction 75% area reduction
 Examples using trap extrusion and

open extrusion.
7 Station Cold Forming Process
 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
• Heading improves the finished part’s

grain structure by making it conform to
the flow of the design.
• The machined diagram shows how the

grain structure is weakened by cutting
operations.
Materials - Characteristics
Cost
Tensile Formabili
Material Description Yield Index
(ksi) ty
Steel = 1
Tensile strength of mild
Aluminum
steel with 1/3 the weight. 55 50 Excellent 5.0
Alloys
Ex: 2024
Alloy of Cu & Zn. Tough,
rustproof. Relatively
Brass 60 min 40 min Excellent 6.0
inexpensive. Ex: 274
Yellow Brass
High corrosion resistance.
Copper Expensive. Ex: 110 35 – 40 10 – 35 Excellent 6.5
Electrolytic Tough Pitch
Approximately 2/3 Nickel,
1/3 Cu with small
amounts Fe. High
Nickel Alloys strength, resistance to 80 min 60 min Excellent 18.0
heat and corrosion.
Ex: NiCu400
Typical max
Typical max
Tensile w/ Cost Index
Material Description Tensile as Formability
50% cold Steel = 1
annealed
work
1010 Low carbon 55 62 Excellent 1
1018 Low carbon 65 98 Good to Excellent 1
1022 Medium carbon 70 108 Good to Excellent 1
1038 Medium carbon 85 157 Fair to Good 1
Medium carbon
4037 83 166 Fair to Good 1.5
low alloy
Typical max Typical max
Cost Index
Material Description Tensile as Tensile w/ Formability
annealed Steel = 1
5% cold work
Martensitic
410 78 90 Fair 4.0
Stainless Steel
Ferritic Stainless
430 75 86 Fair 4.0
Steel
Austenitic
302HQ 75 83 Fair 4.5
Stainless Steel
Austenitic
305 83 93 Fair 4.5
Stainless Steel
Austenitic
A-286 95 95 Fair to Poor 6.5
Stainless Steel
Hi Temperature
Pyromet® 718 120 135 Poor 12.0
Alloy
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
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
Decision Process for Cold Forming
 Equipment
 Which machine
 Which tools
 Skill of personnel
 Material
 Formability
 Incoming condition
 Part
 Accuracy
 Tolerances
 Additional treatments
Production of Headed Parts
Warm
Cold Heading Hot Heading
Heading
Room Temperature Forming of heated Forging temperatures

No heat slugs at temperatures from 950 – 1250 °C
from: 550 – 950 °C (1740 – 2300 °F)
(1020 – 1740 °F)
Cold Heading Warm Heading Hot Heading
Carbon Steel
550 - 850oC >950oC
>0.3% carbon, >3.0% Room temp
1020 - 1560oF >1740oF
alloy
Blue Brittleness Problem
400 - 450oC
Austenitic Steels Room temp 550 - 850oC
750 - 840oF
1020 - 1560oF
Aluminum alloys 420 - 480oC

Room temp Not applicable
790 - 900oF
350 - 620oC
Brass alloys Room temp Not applicable
660 - 1150oF
General Aspects of Heading Methods
Forming Type Cold Warm Hot

Temperature Room 550 - 950oC 950 - 1250oC
1020 - 1740oF 1740 - 2300oF
Accuracy High Good Low
Formability Restricted Good Good
Material Restricted Large variety Large variety
Energy costs Low Moderate High
Surface quality High Good Low
Tolerances Close Closer Low
Grain structure Good Good Variable
Heat treatments Few Few Definite
Machining Least Less Necessary
Tooling Loads in Heading Operations
120%
R e la t iv e L o a d
100%
80%
60%
40%
20%
0%
Cold Warm Hot
Process Chain of Cold Forming
Raw Heat Surface Cold

Material Treatment Treatment Forming
Metal Heat Metal Formed

Removal Treatment Removal Part
Finished
Part
38 | ©2016 QuEST Global Services Pte. Ltd. Confidential

Steps to Manufacture
Raw Material
 Wire/rod
 Hot rolled
 Shaved - ‘seam’ free
 Cf/anl
 Material in the ‘softest’ condition
 Optimum for cold forming
 Anl/cf
 Uniform volume
 Uniform diameter
 Specific incoming mechanical properties desired

Heat Treatment of Raw Material

 Benefits
 Improves ability of deformation
 Reduces hardness
 Improves metal structure towards better forming
Heat Treatment of Raw Material

 Types of heat treatment
 Tempering to form spherical cementite
 Annealing
 To remove strain hardening
 To set the desired mechanical properties
 To normalize the microstructure

Surface Treatment
 Alkaline cleaning
 Warm 170o-190of/ 77o-88oc
 Cold rinsing
 Removes alkaline cleaner
 Acid pickling
 Sulphuric
 Hydrochloric
 Nitric/hydrofluoric
 Cold/warm/hot rinsing
 Removes acids

Surface Treatment
 Pre-coating
 Carbon
 Zinc phosphate
 Stainless
 Potassium sulfate
 Lime
 Drying
 Approx. 250of/ 120oc
 Metallic Coating
 Copper plating
 Non-metallic coatings
 Molybdenum disulfide – mos2
 Soaps
 Sodium stearates
 Calcium stearates
Cold Forming
 Single stage presses
 Multi stage presses

 up to 5 or 6 stages, as many as 8
 Secondary forming operations

 threading
 rolled
 machined

Heat treatment after Cold Forming

 Annealing
 Relieve stress
 Re-crystallize
 Normalize
 Hardening
 Increase the hardness after forming

Metal Removing
 Hard Surfaces
 Turning
 Grinding
 Honing
 Lapping
 Soft Surfaces
 Turning
 Drilling
 Milling

Surface Treatment
 Cleaning of parts
 De-phosphate
 Washing
 Acid to remove copper coating
 Corrosion protection
 Passivation – stainless steel
 Plating
 Zinc
 Chromate - cr+6 (hexavalent chrome) can be a problem

Coatings and Lubricants

Coatings
 Uses
 Prevent metal to metal contact with tooling, galling
 Act as a carrier for machine lubricants
 Types
 Pre-coat
 Lime
 Copper plating
 Zinc phosphate
 Molybdenum disulfide
 Oxalate

Lubricants
Types
 Soaps
 Calcium stearate
 Sodium stearate
 Drawing oils
 Metal-removing coolants
 Oil
 Emulsion
 Synthetics

Process Lubricant
Hot Rolling Water
Pre-coat: Phosphate, lime, oxalate

Drawing
Lubricants: Soaps, Oils
Cold Forming Oils
Metal removal coolant:

Thread rolling
Emulsion, Solution, Oil
Metal removal coolant:

Cutting/slotting
Emulsion, Solution

Additional references
• Heading Hints: A Guide to Cold Forming Specialty Alloys” - Carpenter

Technology Corporation (2001)
• “Steel Wire Handbook Vol. 3” – The Wire Association, Inc.(1972)
• “Tool Design and Part Shape Development for Multi-die Cold Forming” -
National Machinery Co.(1976)
• “Cold Forming 101” - Fastener Technology International (June 2005)
Thank You
©2016 QuEST Global Services Pte Ltd. The information in this document is the property of QuEST Global Services Pte Ltd. and may not be copied or communicated
to a third
51 | ©2016 QuEST Global Services party
Pte Ltd.or used for any purpose
QuESTother thanConfidential
Global that for which| itTEG-TEM-013
is supplied without the written
| 11-Feb-16 consent of 02
| Revision: QuEST Global Services Pte Ltd.
| Template Confidential

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QuEST Global

Basics of Cold Forming

30th Dec 2016/ Virupaksha A M

QuEST TRAINING MATERIAL

Revision Description Date

Introduction to Cold Forming

History and Development of Cold Forming

 March 23, 1794

 November 16, 1796

 Cold Forming Terminology

 Cold Forming terms:

 Cold forming machines - by the number of dies and blows

 The wire is fed in through the cut-off die to a

 The cut-off knife transfers the blank to

 Now the blank is ready to receive the first

 Upsetting of a fastener head is

 Typical 1-Die/2-punch method is common in

 Knockout pin acts as a blank support,

Open Extrusion Trap Extrusion

30% area reduction 75% area reduction

 Examples using trap extrusion and

7 Station Cold Forming Process

 Benefits of Cold Forming

 Advantages of Cold Forming

• Heading improves the finished part’s

• The machined diagram shows how the

1010 Low carbon 55 62 Excellent 1

1018 Low carbon 65 98 Good to Excellent 1

1022 Medium carbon 70 108 Good to Excellent 1

1038 Medium carbon 85 157 Fair to Good 1

Applications for Cold Formed Parts

Construction, Off-road equipment

Decision Process for Cold Forming

Production of Headed Parts

Room Temperature Forming of heated Forging temperatures

Cold Heading Warm Heading Hot Heading

Aluminum alloys 420 - 480oC

General Aspects of Heading Methods

Forming Type Cold Warm Hot

Tooling Loads in Heading Operations

Process Chain of Cold Forming

Raw Heat Surface Cold

Metal Heat Metal Formed

38 | ©2016 QuEST Global Services Pte. Ltd. Confidential

 Shaved - ‘seam’ free

39 | ©2016 QuEST Global Services Pte. Ltd. Confidential

Heat Treatment of Raw Material

 Improves ability of deformation

 Improves metal structure towards better forming

Heat Treatment of Raw Material

 Tempering to form spherical cementite

40 | ©2016 QuEST Global Services Pte. Ltd. Confidential

41 | ©2016 QuEST Global Services Pte. Ltd. Confidential

 Multi stage presses

 Secondary forming operations

43 | ©2016 QuEST Global Services Pte. Ltd. Confidential

Heat treatment after Cold Forming

44 | ©2016 QuEST Global Services Pte. Ltd. Confidential

45 | ©2016 QuEST Global Services Pte. Ltd. Confidential

46 | ©2016 QuEST Global Services Pte. Ltd. Confidential

Coatings and Lubricants

47 | ©2016 QuEST Global Services Pte. Ltd. Confidential

48 | ©2016 QuEST Global Services Pte. Ltd. Confidential