COLD FORMING OF

METALS

Cold Forming of Metals

Cold forming: The forming of blank metal into a shape.
A variety of machines can be used for this operation

depending on the metal and desired end product.

Common machines used for cold forming include power
presses, metal shears, and press breaks.

Power Presses
Versatile machines that can be attached with different dies

to produce a variety of products

Safeguarding the point of operation of a press depends on

the die or tool component

type of press selected to power the die
method selected to insert materials, to remove parts, and to
dispose of scrap

Power Presses (Cont.)

Die or tool component design considerations:
material used
configuration of the finished part
method of feeding the material
method of removing parts
method of scrap disposal
ways to reduce noise

Power Presses (Cont.)

The safety of power press operations depends on:
adequately safeguarding the point of operation
properly training press operators
enforcing safe work practices
Setup and maintenance personnel must be trained to

assure their s.afety while working in or around a press

Primary Operations
Hazards include:
die setup
guard repairs
material handling
feeding stock into machines
part and scrap ejection

Point-of-Operation Safeguarding
Protecting personnel, including helpers, after the dies

have been installed, tested, and operated, and are ready

for production
Consider all hazards in the dies space that may crush,
cut, punch, sever, or otherwise injure personnel.
There are two basic categories of safeguarding at the
point of operation:
the guard
the device

Point-of-Operation Safeguarding (Cont.)

A guard, or barrier guard, is a physical barrier that

prevents access to a dies hazard during operation

If a barrier allows access to a dies hazard during operation, it is

not a guard; it is an inadequate enclosure.

An inadequate enclosure always requires using a device to form an
acceptable safeguarding system.

Point-of-Operation Safeguarding (Cont.)

There are several types of safeguarding devices for power

presses:
Two-hand control devices
Regulatory standards may specify safe distance for mounting controls.
Pull-back devices
Usually limited to secondary operations.
Restraints
Presence sensing devices

Point-of-Operation Safeguarding (Cont.)

Point-of-Operation Safeguarding (Cont.)

Metal Shears

Metal Shears (Cont.)

Safe operation guidelines
Be familiar with the shear and its capacity, controls, operating
modes, and safeguarding.
Keep blades sharp and clearance correct.
Keep work area clean and free of obstructions.
Do not place hands between the material and shear table.
Wear snug fitting clothes and appropriate PPE.
When leaving the shear, turn off the power.

Press Breaks

Press Breaks (Cont.)

The primary function of the press break is to cold-form

angles, channels, and curved shapes in metals.

Two power press break categories:
General purposemechanical and hydraulic
Special purposemechanical, hydraulic, and other drive

arrangements

Press Breaks (Cont.)

Press Breaks (Cont.)

Safeguarding press breaks
Install a point-of-operation guard, such as fixed barriers, die
guards, and other means that do not allow access to the point of
operation.
Install point-of-operation devices, such as presence-sensing
devices, gates, or movable barriers, pull-backs, etc.
Use safe-distance methods when guards/devices cannot be used.