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Basics-of-Cold-Forming.pdf
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1 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template ©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 party or used for any purpose other than that for which it is supplied without the written consent of QuEST Global Services Pte Ltd. QuEST Global Basics of Cold Forming 30th Dec 2016/ Virupaksha A M
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2 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template QuEST TRAINING MATERIAL Training Title#1 : Basics of Cold Forming Author(s)#02 : Virupakshi AM Email#03 :virupakshi.am@quest-global.com Date #04 : 30/12/2016 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. Basics of Cold Forming – Training Material Revision Description Date 01 New Release 30th Dec 2016
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Topics: • Introduction • Terminology • Processes • Benefits • Material Characteristics • Applications • Steps to Manufacture • Coatings and Lubricants Training Details
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Introduction to Cold Forming History and Development of Cold Forming March 23, 1794 Josiah Pierson – “Cold Header” Rivet Machine November 16, 1796 Isaac Garretson – U.S. Patent for nail cutting & heading machine
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Cold Forming Terminology Cold Forming terms: Cold Heading: Cold forming process in which the force of the punch must exceed the material’s 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
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Applications: Cold forming machines - by the number of dies and blows • For example: 1 Die/2 blow 2 Die/3 blow 2 Die/4 blow
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming The wire is fed in through the cut-off die to a wire stop. The cut-off knife shears the blank.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming The cut-off knife transfers the blank to the heading die.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming 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.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Upsetting of a fastener head is accomplished by using one of these 4 methods.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Typical 1-Die/2-punch 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.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming 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
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Open Extrusion Trap Extrusion 30% area reduction 75% area reduction
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Examples using trap extrusion and open extrusion.
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming 7 Station Cold Forming Process
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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17 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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18 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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19 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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20 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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21 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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22 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Benefits of Cold Forming Advantages 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
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming • Heading improves the finished part’s grain structure by making it conform to the flow of the design. • The machined diagram shows how the grain structure is weakened by cutting operations.
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24 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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25 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming
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26 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Material Description Tensile (ksi) Yield Formabili ty Cost Index Steel = 1 Aluminum Alloys Tensile strength of mild steel with 1/3 the weight. Ex: 2024 55 50 Excellent 5.0 Brass Alloy of Cu & Zn. Tough, rustproof. Relatively inexpensive. Ex: 274 Yellow Brass 60 min 40 min Excellent 6.0 Copper High corrosion resistance. Expensive. Ex: 110 Electrolytic Tough Pitch 35 – 40 10 – 35 Excellent 6.5 Nickel Alloys Approximately 2/3 Nickel, 1/3 Cu with small amounts Fe. High strength, resistance to heat and corrosion. Ex: NiCu400 80 min 60 min Excellent 18.0 Materials - Characteristics
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Materials - Characteristics Material Description Typical max Tensile as annealed Typical max Tensile w/ 50% cold work Formability Cost Index Steel = 1 1010 Low carbon 55 62 Excellent 1 1018 Low carbon 65 98 Good to Excellent 1 1022 Medium carbon 70 108 Good to Excellent 1 1038 Medium carbon 85 157 Fair to Good 1 4037 Medium carbon low alloy 83 166 Fair to Good 1.5
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Materials - Characteristics Material Description Typical max Tensile as annealed Typical max Tensile w/ 5% cold work Formability Cost Index Steel = 1 410 Martensitic Stainless Steel 78 90 Fair 4.0 430 Ferritic Stainless Steel 75 86 Fair 4.0 302HQ Austenitic Stainless Steel 75 83 Fair 4.5 305 Austenitic Stainless Steel 83 93 Fair 4.5 A-286 Austenitic Stainless Steel 95 95 Fair to Poor 6.5 Pyromet® 718 Hi Temperature Alloy 120 135 Poor 12.0
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29 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Applications for Cold Formed Parts
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30 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template 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
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31 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Construction, Off-road equipment Bolts, nuts Screws – tapping, window, roofing, deck Transmission gears Similar parts for automotive Aerospace Rivets, fuselage Engine bolts Fasteners - landing gear, interior
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32 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Decision Process for Cold Forming
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33 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template 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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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Production of Headed Parts Cold Heading Hot Heading Room Temperature Forming of heated Forging temperatures No heat slugs at temperatures from 950 – 1250 °C from: 550 – 950 °C (1740 – 2300 °F) (1020 – 1740 °F) Warm Heading
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Cold Heading Warm Heading Hot Heading Carbon Steel >0.3% carbon, >3.0% alloy Room temp 550 - 850oC 1020 - 1560oF >950oC >1740oF Austenitic Steels Room temp 400 - 450oC 750 - 840oF Blue Brittleness Problem 550 - 850oC 1020 - 1560oF Aluminum alloys Room temp 420 - 480oC 790 - 900oF Not applicable Brass alloys Room temp 350 - 620oC 660 - 1150oF Not applicable
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Forming Type Cold Warm Hot Temperature Room 550 - 950oC 950 - 1250oC 1020 - 1740oF 1740 - 2300oF Accuracy High Good Low Formability Restricted Good Good Material Restricted Large variety Large variety Energy costs Low Moderate High Surface quality High Good Low Tolerances Close Closer Low Grain structure Good Good Variable Heat treatments Few Few Definite Machining Least Less Necessary General Aspects of Heading Methods
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37 | ©2016
QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Basics of Cold Forming Tooling Loads in Heading Operations 0% 20% 40% 60% 80% 100% 120% Cold Warm Hot R e la t iv e L o a d
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38 | ©2016
QuEST Global Services Pte. Ltd. Confidential Basics of Cold Forming Raw Material Heat Treatment Surface Treatment Cold Forming Formed Part Metal Removal Heat Treatment Metal Removal Finished Part Process Chain of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential 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 Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential Heat Treatment of Raw Material Benefits Improves ability of deformation Reduces hardness Improves metal structure towards better forming 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 Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential 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 Basics of Cold Forming
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42 | ©2016
QuEST Global Services Pte. Ltd. Confidential 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 Basics of Cold Forming
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43 | ©2016
QuEST Global Services Pte. Ltd. Confidential Cold Forming Single stage presses Multi stage presses up to 5 or 6 stages, as many as 8 Secondary forming operations threading rolled machined Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential Heat treatment after Cold Forming Annealing Relieve stress Re-crystallize Normalize Hardening Increase the hardness after forming Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential Metal Removing Hard Surfaces Turning Grinding Honing Lapping Soft Surfaces Turning Drilling Milling Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential 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 Basics of Cold Forming
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QuEST Global Services Pte. Ltd. Confidential Basics of Cold Forming Coatings and Lubricants Coatings 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
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QuEST Global Services Pte. Ltd. Confidential Basics of Cold Forming Lubricants Types Soaps Calcium stearate Sodium stearate Drawing oils Metal-removing coolants Oil Emulsion Synthetics
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QuEST Global Services Pte. Ltd. Confidential Basics of Cold Forming Process Lubricant Hot Rolling Water Drawing Pre-coat: Phosphate, lime, oxalate Lubricants: Soaps, Oils Cold Forming Oils Thread rolling Metal removal coolant: Emulsion, Solution, Oil Cutting/slotting Metal removal coolant: Emulsion, Solution
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template Additional references • 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) • “Cold Forming 101” - Fastener Technology International (June 2005)
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QuEST Global Services Pte Ltd. Confidential QuEST Global Confidential | TEG-TEM-013 | 11-Feb-16 | Revision: 02 | Template ©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 party or used for any purpose other than that for which it is supplied without the written consent of QuEST Global Services Pte Ltd. Thank You
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