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: Volume of Head: Length of wire required: using 13.5 wire

4130 mm3 2945.24 mm3 29 mm

COLD HEADING

Why 13.5 & not 7.9 wire?

Extrusion ratio with 13.5 = with 7.9 = Permissible limit 24.29% 90.1% 70 %

COLD HEADING

Why 13.5 & not 7.9 wire?

Upset ratio with 13.5 = with 7.9 = Permissible limit 70.84% 90% 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