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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
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.
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
3 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
4 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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
5 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Applications:
For example:
1 Die/2 blow
2 Die/3 blow
2 Die/4 blow
6 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
7 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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Basics of Cold Forming
9 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
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Basics of Cold Forming
21 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics 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
22 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
23 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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Basics of Cold Forming
25 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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
26 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Materials - Characteristics
Typical max
Typical max
Tensile w/ Cost Index
Material Description Tensile as Formability
50% cold Steel = 1
annealed
work
Medium carbon
4037 83 166 Fair to Good 1.5
low alloy
27 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Materials - Characteristics
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
28 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
29 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Automotive
Brake parts
Ball joints & steering parts
Starter pinions
Oxygen sensors
Constant velocity joints
Manifold bolts
Engine valves
Appliance Industry
Gears
Fasteners for assembly
30 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Aerospace
Rivets, fuselage
Engine bolts
Fasteners - landing gear, interior
31 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
32 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Equipment
Which machine
Which tools
Skill of personnel
Material
Formability
Incoming condition
Part
Accuracy
Tolerances
Additional treatments
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Basics of Cold Forming
Warm
Cold Heading Hot Heading
Heading
34 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
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
350 - 620oC
Brass alloys Room temp Not applicable
660 - 1150oF
35 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
120%
R e la t iv e L o a d
100%
80%
60%
40%
20%
0%
Cold Warm Hot
37 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
Basics of Cold Forming
Finished
Part
Steps to Manufacture
Raw Material
Wire/rod
Hot rolled
Cf/anl
Material in the softest condition
Optimum for cold forming
Anl/cf
Uniform volume
Uniform diameter
Specific incoming mechanical properties desired
Reduces hardness
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
42 | 2016 QuEST Global Services Pte. Ltd. Confidential
Basics of Cold Forming
Cold Forming
Single stage presses
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
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
Tool Design and Part Shape Development for Multi-die Cold Forming -
National Machinery Co.(1976)
50 | 2016 QuEST Global Services Pte Ltd. QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Confidential
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