This document discusses cold forging and precision cold forged progressive stamping techniques. It provides examples of using these techniques to produce high-quality 3D metal parts for applications such as electronics components, power tools, hard disk drives, and automotive components. Cold forging allows producing parts with precision flatness, sharp edges, corners, and material thickness control. It provides benefits over conventional techniques like die casting, sintering, and machining, including higher production efficiency, part strength, and dimensional accuracy while reducing costs and waste. Simulation software is used to design cold forging processes and tools.

1. Interplex Solution
Cold Forging

2. Precision Cold Forged
Progressive Stamping

3. What is the Concept?
COLD FORGING
 Ironing / Upsetting
 Extrusion / Trimming
CONVENTIONAL STAMPING
 Blanking / Drawing / Forming
 Piercing / Bending
PRECISION COLD FORGED STAMPING
Blanking/ Drawing/ Forming / Piercing / Bending
Ironing / Upsetting /Extrusion / Trimming
3D PARTS
Machine Part to Cold Forge Part
Precision Cold Forged Progressive
Stamping

4. 3-D forming capability
Precision Forming of
1) Flatness/Parallelism
2) Sharp edges
3) Corners
4) Material Thickness: 2.0 – 3.6 mm
Precision Cold Forged Progressive
Stamping

5. Forging – Material “Thickening” to 2x raw material thickness
Cross Sectional View
Precision Cold Forged Progressive
Stamping

6. Merits:
 High quality 3D parts produced
 High efficiency
 High accuracy & repeatability in parts replacements
 Longer tool life
 3-D precision cold-forging
OPU
VCM for HDD
Precision Cold Forged Progressive
Stamping

7. Earphone part
Die casting Cold Forging Stamping
Material: SPCC
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Trimming d. Cut off
Process innovation:
Utilizing cold forging instead of die-casting, we
realized:
a. Improved Production efficiency
b. Improved strength
Upsetting
Precision Cold Forged Progressive
Stamping

8. Application : Power Tool
Material : S65C
Old Process : Sintering & Machining
New Process : Cold Forged Stamping
Precision Cold Forged Progressive
Stamping

9. Gear Detail
Electric Tool
Sintering Cold Forging Stamping
Material: S65C
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Trimming d. Drawing
Process innovation:
Utilizing cold forging instead of sintering, we
realized:
a. Improved Part Strength
b. Reduction in cost of > 60%
Precision Cold Forged Progressive
Stamping

10. Application : Motor
Material : SPCC
Old Process : Sintering
New Process : Cold Forged Stamping
Merit : Improve production efficiency
: Improved strength Section Detail
Precision Cold Forged Progressive
Stamping

11. Disc Clamp for HDD
Fine Blanking Cold Forging Stamping
Material: A1050
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Forming
d. Trimming e. Cut off
Process innovation:
Utilizing cold forging instead of fine blanking, we
realized:
a. Improved Part Strength
b. Shorter lead time for Mass Production
Precision Cold Forged Progressive
Stamping

12. Application : HDD Disc Clamp
Material : A6061(铝镁合金）
Old Process : Assembly by two parts
New Process : Cold Forged Stamping plus minimum machining
Main Merit : Improve production efficiency & Reduce the cost
Precision Cold Forged Progressive
Stamping

13. Vertical & Horizontal
Cold Forging

14. Stamping
Cold Forging
Production
Machining /
Thread Roll
Heat-treatment
Plating
Final Assembly
Simulation / DFM
FullProduction/QA/Sale&Marketing/R&DSetup
Typical manufacturing
processes for Cold Forged
components
Vertical & Horizontal Cold Forging

15. Horizontal Forging
Vertical Forging
Vertical & Horizontal Cold Forging

16. 1. High Mass Production Speed (SPM 80-400)
2. Net / Near net shape to eliminate or reduce
secondary operations
3. Consistency / dimensional accuracy
4. Quality / surface finish
5. Low Material wastage & Elimination of scrap
6. Improvement in mechanical properties,
greater strength to weight ratio, unbroken
grain flow.
Benefits of Cold Forging
Vertical & Horizontal Cold Forging

17. Vertical & Horizontal Cold Forging

18. Cold Forging Process Simulation
SIMULATION RESULT
(DFM / PROGRESSION)
UG NX2 Delta-Mesh
DEFORM 3DTM
FORGE 2D TM
PAM-STAMP™
MATERIAL
STAMPING
& COLD
FORGING
FRICTION
PRESS

19. Progression Example--- Engine Components
Combination use of Horizontal Forming + Vertical Forming
Vertical & Horizontal Cold Forging

20. Vertical & Horizontal Cold Forging

21. Progression Example for Cold Forging Process
Vertical & Horizontal Cold Forging

22. Step 3 Step 4 Step 8 Step 9
(Machining to complete
the part – 5% on Diameter)
Anneal&
Bonderizing
Anneal&
Bonderizing
Anneal&
BonderizingStep 6Step 1
(Hollow Blank)
Anneal &
Bonderizing
Step 3
1st Pre-Forge
Step 4
Cut Out Outside
Flange
Anneal &
Bonderizing
Step 6
Forge Internal
Gear
Anneal &
Bonderizing
Step 8
Forge External Gear
End of Cold Forge
Step 1
Blanking
Step 9
Machining
One piece Pinion Gear design for
Safety Seat Belt.
Old Process – Full Machining
New Process – Forging + Min. Machining
Vertical & Horizontal Cold Forging

23. Simulation
Process
Forming Tools
Laser WeldingStamping Blank
2 Pieces Pinion Gear design for Safety Seat Belt
Combination of Stamping + Forming +
Piercing + Laser Weld

24. Sample Products for Cold Forging

25. Sample Products for Cold Forging

26. Cold forged components for Automotive application
Sample Products for Cold Forging

27. Thank You
http://www.interplex.com/cold-forging