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Introduction Terminology Processes Benefits Material Characteristics Applications Steps to Manufacture Coatings and Lubricants
The information and data presented herein are typical or average values and are not a guarantee of maximum or minimum values. Applications specifically suggested for material described herein are made solely for the purpose of illustration to enable the reader to make his/her own evaluation and are not intended as warranties, either express or implied, of fitness for these or other purposes.
Isaac Garretson U.S. Patent for nail cutting & heading machine
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
Cold Forming:
Applications:
for example:
The wire is fed in through the cut-off die to a wire stop. The cut-off knife shears the blank.
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.
Typical 1-Die/2punch 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
Metallurgical Effects
Grain flow Improves strength, hardness, toughness & fatigue resistance
Material Savings
Materials - Characteristics
Material Description
Tensile strength of mild steel with 1/3 the weight. Ex: 2024 Alloy of Cu & Zn. Tough, rustproof. Relatively inexpensive. Ex: 274 Yellow Brass High corrosion resistance. Expensive. Ex: 110 Electrolytic Tough Pitch Approximately 2/3 Nickel, 1/3 Cu with small amounts Fe. High strength, resistance to heat and corrosion. Ex: NiCu400
Tensile (ksi)
Yield
Formability
Aluminum Alloys
55
50
Excellent
5.0
Brass
60 min
40 min
Excellent
6.0
Copper
35 40
10 35
Excellent
6.5
Nickel Alloys
80 min
60 min
Excellent
18.0
Materials - Characteristics
Material
Typical max Description Tensile as annealed Typical max Cost Index Tensile w/ Formability 50% cold Steel = 1 work
Low carbon Low carbon Medium carbon Medium carbon Medium carbon low alloy
55 65 70 85
62 98 108 157
1 1 1 1
4037
83
166
Fair to Good
1.5
Materials - Characteristics
Material 410 430 302HQ 305
Typical max Typical max Cost Index Tensile w/ Formability Description Tensile as Steel = 1 annealed 5% cold work Martensitic Stainless Steel Ferritic Stainless Steel Austenitic Stainless Steel Austenitic Stainless Steel Austenitic Stainless Steel
78 75 75 83
90 86 83 93
A-286
95
120
95
135
Fair to Poor
Poor
6.5
12.0
brake parts ball joints & steering parts starter pinions oxygen sensors constant velocity joints manifold bolts engine valves gears fasteners for assembly
Appliance Industry
bolts, nuts screws tapping, window, roofing, deck transmission gears similar parts for automotive rivets, fuselage engine bolts fasteners - landing gear, interior
Aerospace
Equipment
Material
Part
Equipment
Material
Part
Cold Heading
Room Temperature No heat
Warm Heading
Forming of heated slugs at temperatures from: 550 950 C (1020 1740 F)
Hot Heading
Forging temperatures from 950 1250 C (1740 2300 F)
Warm Heading
550 - 850oC 1020 - 1560oF
Hot Heading
>950oC >1740oF
Blue Brittleness Problem
Room temp
Austenitic Steels
Aluminum alloys
Room temp
Room temp
Not applicable
Brass alloys
Room temp
Not applicable
Cold
Room
Warm
Hot
accuracy formability material energy costs surface quality tolerances grain structure heat treatments machining
550 - 950oC 950 - 1250oC 1020 1740 1740oF 2300oF high good low restricted good good restricted large variety large variety low moderate high high good low close closer low good good variable few few definite least less necessary
Relative Load
Raw Material
Heat Treatment
Surface Treatment
Cold Forming
Formed Part
Metal Removal
Heat Treatment
Metal Removal
Finished part
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
Steps to Manufacture
Heat Treatment of Raw Material Benefits
Improves ability of deformation Reduces hardness
Steps to Manufacture
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
Steps to Manufacture
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
Steps to Manufacture
Surface Treatment Pre-coating
carbon
zinc phosphate
stainless
potassium sulfate lime
Drying
approx. 250oF/ 120oC
Metallic Coating
copper plating
Steps to Manufacture
Surface Treatment
Non-metallic coatings
molybdenum disulfide MoS2 Soaps
sodium stearates calcium stearates
Steps to Manufacture
Cold Forming Single stage presses Multi stage presses
up to 5 or 6 stages, as many as 8
Steps to Manufacture
Heat treatment after Cold Forming
Annealing
relieve stress re-crystallize normalize
Hardening
increase the hardness after forming
Steps to Manufacture
Metal Removing Hard Surfaces
turning grinding honing lapping
Soft Surfaces
turning drilling milling
Steps to Manufacture
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
Types
precoat lime copper plating zinc phosphate molybdenum disulfide oxalate
Lubricant
Water Pre-coat: phosphate, lime, oxalate Lubricants: Soaps, Oils
Cold Forming
Thread rolling Cutting/slotting
Oils
Metal removal coolant: Emulsion, Solution, Oil Metal removal coolant: Emulsion, Solution
Sources:
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)
Thank you for your interest in cold forming of wire. More information about Carpenter is available on this website including technical datasheets and articles, Products and Markets. Visit Product Literature to request a free copy of Heading Hints: A Guide to Cold Forming Specialty Alloys. To contact Carpenter, call 1-800-654-6543 in the U.S. or refer to the Contact Us page for the location nearest you.