Cold forming is a process where room temperature material is forced into a die,
or a pre-determined shape. As the forces are very high (500 ton), the material
cold flows into the die. Some of the key benefits of this process are that an
infinite number of shapes can be created and it can run at high speeds on the
order of hundreds of parts per minute. As the process is done at room temperature
and at high speeds, the process can be very efficient. Image's manufacturing
methods can provide custom shapes economically even at relatively low volumes
and can produce components that normally would not be economical through machining
from a solid bar.
Image performs cold forming at optimally efficient levels, controlling the flow
of the material and allowing it to instantly form without any waste. Through
this process, you can create studs and fasteners, and other components in a wide
variety of cold forged materials, including steel, stainless steel, aluminum,
bronze, silicon bronze, copper, etc.
COLD FORMING ADVANTAGES
The process can be used to create complex shapes with consistent quality. An assembly with two or more pieces can often be formed as a single piece.
It produces minimal scrap. As there is no cutting to achieve the desired form, cold forming produces almost zero scrap.
You have the ability to create stronger components. Cold working can raise the tensile strength of the component and create an uninterrupted grain flow. Additionally, since there is typically no cutting as in a screw machine process, there are no stress risers or fracture points.
The process offers high, repeatable output rates, producing more parts per hour
as it can fabricate components at speeds up to and many times over 120 parts/min.
Screw machining and other processes may manufacture components at speeds of 20-10
parts/min.
You can produce near net shapes for screw machining or grinding. Your designs,
which cannot be directly cold formed or those requiring very precise tolerances
(better than +/- .005), can be reduced by forming a blank which is very close
to the final component. It effectively reduces secondary processing operations
necessary to achieve finished component shapes, so scrap is reduced and secondary
operation time is kept to a minimum. Surface finish is greatly enhanced, offering
an attractive alternative to screw machined components.
You can create diverse shapes, such as parts with multiple diameters, extrusions,
blind holes, and through-holes. Eccentric and asymmetrical bodies are also possible,
as is large head-to-shank ratios without secondary machining.
Each of these features — alone or in combination — reduces your component's final cost.
VARIOUS COLD FORMING PROCESSES
Cold Heading
This process is popular for creating fasteners and works by using the force of a punch to access the end of a metal blank in a die. This process uses force rather than heat to achieve its goal.
One Die, Two-Blow Process
During the one die, two-blow process, extrusions and upsets are achieved on the same component. Rough shapes are provided by the first blow and the final shape is completed by the second blow.
Two Die, Three-Blow Process
Two die, three-blow offers added extrusion and impact as well as up to 4" diameters
of upset. This process provides more variety in shapes and increased head ratios
than processes that use one die.
Multiple-Die Forming
The final stage is accomplished in various stages during this type of process. As each machine involved has multiple-die headers with more punches and dies, this process provides: increased head-to-shank ratio; more original, unusual shapes; more reduction areas; as well as, the opportunity to do away with secondary operations, helping to save both time and money.
Multiple-Die Progression
This process also forms the final shape in various stages and can be completed in less than one second.
Multiple-Die Headers
Image Multiple-Die Headers can create customized components to your specifications. Some of the advantages of this process are the ability to create unusual shapes at a fast speed, efficient setup times, suitability for runs of all sizes, and the ability to create tight part tolerances that help cut down on the complexity and length of the overall manufacturing process.
CONTACT US
If you would like to submit a drawing to us, we can accept most neutral formats. For 2D drawings, we can read dwg, dxf, wmf, and emf. For 3D formats, we can read iges, step, stl, acis, and all parasolid formats. If you are unfamiliar with any of these formats, or prefer another, please let us know.
Please include a brief description with your drawing. Click here to e-mail.
Contact us to find out how Image can help you find solutions for all of your welding, fastening, and cold forming needs.
