COLD HEADING

FOR

FASTENER MANUFACTURE
BY
MANGESH R. WARAY

COLD HEADING
COLD HEADING
DEFINITION
Metal forging process used for rapidly
producing enlarged (upset) sections on a
piece of rod or wire held in a die

COLD HEADING
PROCESS CHARACTERISTICS
• Extrusions without draft
• Range of Tolerance: IT6 to 15
• Normal range: IT9 to 12
• Finished workpieces have improved
• Grain structure
• Mechanical properties
COLD HEADING
PROCESS CHARACTERISTICS
• High productivity
• Full quality control
•Process monitoring & methods of SPC
• High material yield
• Reduced material cycle

COLD HEADING
PROCESS CHARACTERISTICS

• Finished surfaces are smooth with

uniform accuracy

• All ductile metals

COLD HEADING
COLD FORGING TECHNIQUES

COLD HEADING
COLD HEADING
COLD HEADING
COLD HEADING
COLD HEADING
COLD HEADING
STAGES IN COLD FORGING

• Billet/preform production - by cropping,

shearing or machining
• Upsetting to form a ‘cheese’
• Annealing to restore maximum ductility
• Lubrication
• Cold forging
• Finish machining

COLD HEADING
COLD HEADING
SINGLE DIE HEADING PROCESS
• Cut off, the wire is sheared off in pieces
with same cubic volume as the final
fastener blank shape
• Preform, a blow is delivered to the
fastener blank, transforming it into a
fastener preform, or cone blow
• Finish blow, a second blow reforms the
one or preform into the final fastener
geometry
• Eject, or kick out
COLD HEADING
STAGES IN FASTENER Mfg.

COLD HEADING
SHAPES SUITABLE

Ideal parts geometry results in:

• Smooth & uniform fibre structure
generally parallel with the die walls
• Uniform & even distribution of forging
stresses around the die
• Maximum die life without
catastrophic failure

COLD HEADING
MATERIALS

• Low carbon steel

• Low carbon alloy steel.
• Non-ferrous - Al, Cu, Mg, Pb, Ti, Zn, Sn,
Ni & their alloys

COLD HEADING
ADVANATAGES
• Precision cold forging of materials offers
the net/near net shape production of simple
or complex geometry parts
• High accuracy gives savings on account of
material & energy (no finish machining
needed)
• CAD can be used to optimize strength to
weight ratio
COLD HEADING
ADVANTAGES
• Yield & break strength increased
• Harder surface & more favorable
material structure
• Results in smoother surface, suitable for
surface treatment, such as zinc plating

COLD HEADING
PRECAUTIONS TO BE TAKEN
WHILE SELECTING MATERIAL

COLD HEADING
 PRECAUTIONS TO BE TAKEN WHILE
SELECTING MATERIAL
•The bolt plating material is usually the
limiting factor on maximum service
temperature

• Carbon steel & alloy steel are unsatisfactory

(become brittle) at temperatures below -65 F
(-54 0C)

COLD HEADING
PRECAUTIONS TO BE TAKEN WHILE
SELECTING MATERIAL
•Series 400 SS contains only 12 % Cr &may
corrode in some environments
•Contact of dissimilar materials can create
galvanic corrosion, a major problem
•Hydrogen embrittlement is a problem with
most common methods of plating, unless
special procedures are used

COLD HEADING
 DIE DESIGN
FOR

COLD FORGING

COLD HEADING
RULE 1
Limit of length of
unsupported stock
that can be upset in
one blow without
injurious buckling
is not more than 3
times the diameter
of the bar

COLD HEADING
RULE 2
Length of the stock more than 3 times bar
diameter can be successfully upset in one
blow, provided the diameter of the upset
made is not more than 1.5 times bar diameter

COLD HEADING
RULE 3
In an upset
requiring more than
3d in length when
the diameter of the
upset is 1.5d, the
amount of
unsupported stock
beyond the face of
the die must not
exceed 1d of the bar
COLD HEADING
MATERIALS FOR DIE BLOCKS

• Heat resistant
• Adequate strength
• Low wear rate
•Machinability
•Typical material: Carbide

COLD HEADING
GOVERNING FACTORS FOR
MACHINE SELECTION

COLD HEADING
• Volume of the stock required in
the finished forging
• Size of the stock used
• Maximum dimension of the
finished forging
• Number of blows necessary to
complete the forging

COLD HEADING
DESIGN OF BOLT (CASE STUDY)

COLD HEADING
Material Class: 8.8

COLD HEADING
Material class 8.8 stands for
• 8 x 8 = 64 640MPa yield strength
• 800MPa ultimate tensile strength
• Carbon steel with additives (e.g.
Boron, Mn, Cr) quenched & tempered

COLD HEADING
STAGES IN MANUFACTURING A
FASTENER

COLD HEADING
Volume of Bolt: 4130 mm3
Volume of Head: 2945.24 mm3
Length of wire required: 29 mm
using 13.5 wire

COLD HEADING
 Why  13.5 & not 7.9 wire?
Extrusion ratio with  13.5 = 24.29%
with  7.9 = 90.1%
Permissible limit  70 %

COLD HEADING
 Why  13.5 & not 7.9 wire?
Upset ratio with  13.5 = 70.84%
with  7.9 = 90%
Permissible limit  70 %

COLD HEADING
Company visited
• Mini Nuts
Bangalore

COLD HEADING
CONCLUSION
To conclude we can say that this is a
very cost effective process as compared
to other manufacturing processes for
fasteners, as…….

COLD HEADING
THANK YOU

COLD HEADING