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 materials 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 parts

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 parts

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

Hot Rolling Water