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Cold Forging Services ___

✅ Exceptional Precision Machining: Achieving tolerances as tight as 0.000039 inches.
✅ Quality Assurance: Maintaining a qualified rate of 99.3%.
✅ Minimum Order Quantity: Orders accepted for quantities as small as 1 piece.
 

What is 

Cold Forging?

2. Cold Forging Die
Cold forging is a collective term for processes such as cold heading, cold die forging, cold extrusion, and other plastic forming methods.
It is an efficient manufacturing process that deforms metal by placing the workpiece between dies and tools while applying compressive forces at room temperature. This process not only changes the shape of the material but also enhances the performance of the forged parts through the refinement of grain size.
This process is also known as precision forging with near net shape. Therefore, the final products need little or no final machining after a precision forging.

What is 

Cold Forging Tooling? _____

Cold forging tooling refers to the various tools and components used in the cold forging process, aimed at producing high-quality, precision-engineered parts.
At U-Need, you benefit from our expertise in crafting high-quality, custom cold forging tooling tailored to your unique production needs. Our dedicated engineering team works closely with you to create tooling that enhances your efficiency, precision, and performance, ensuring that your components are produced to the highest standards.
3. Cold Forging Tooling
4. Essential Tooling Components in a Cold Forging Die Set

Essential Tooling Components 

in a Cold Forging Die Set _____

A cold forging die system typically consists of several key components, each serving a specific purpose in the forging process. The core tooling includes:
☆ Punch (Upper Die / Male Die)
The punch shapes the material by exerting force during the forging process, creating precise contours and dimensions in the workpiece.
☆ Die (Lower Die / Female Die)
The die receives the workpiece from the punch, ensuring an accurate final shape. It forms the counterpart to the punch, allowing the workpiece to take on the desired profile.
☆ Ejector Pin (Ejector Sleeve / Knockout)
This component expels the forged part from the die after the process is complete, preventing damage and ensuring efficient operation.
☆ Shearing Die
The tool is designed to cut material into specific shapes or sizes. It typically uses a sharp blade that applies a shearing force to separate the material.
☆ Trimming Die
A separate die used in a subsequent operation to shear off the flash or excess material (e.g., in backward extrusion).
☆ Ram (Stress Rings / Pre-stressed Casing)
The ram applies consistent pressure during the forging, providing stability and strength to the forging process for optimal results.
☆ Anvil (Bolster Plate / Die Holder)
The anvil supports the die and punch system, maintaining alignment and stability throughout the forging operation, ensuring reliability and efficiency.

Material Selection for Cold Forging Die Sets

Choosing the right material is crucial for achieving optimal performance and longevity, influenced by factors such as the type of forged material, production volume, and required durability.
Our die material science is not a one-size-fits-all solution; rather, it is a precise calculation tailored to address your specific challenges.
High-Grade Tool Steels (e.g., SKD11, SKH51)

High-Grade Tool Steels (e.g., SKD11, SKH51)

These materials are the industry standard, offering an optimal balance of hardness, toughness, and wear resistance through heat treatment.
6. Carbides

Carbides (e.g., Tungsten Carbide)

They are used for extremely high-volume production or for forging abrasive materials. Carbides offer superior wear resistance, though they come at a higher cost and may exhibit lower impact toughness.
7. Powder Metallurgy Steels

Powder Metallurgy (PM) Steels (e.g. Vanadis 4E, Vanadis 8)

The materials provide a more homogeneous microstructure, resulting in better dimensional stability and wear performance for complex dies.

Differences between Cold Heading 

and Cold Die Forging ____

Cold heading and cold die forging are both cold forging processes that take place at room temperature, yet they differ in several key aspects.
No. Item Cold Heading Cold Die Forging
1 Machine Uses a multi-station cold heading machine arranged horizontally. Typically employs vertical presses.
2 Dies Dies consist of a male die (like a punch) and a female die (like a heading die). A single die is used, followed by pressing with a second closed die.
3 Process Involves pressure processing with little or no cutting of the metal. A cold bulk metal forming process that utilizes compressive forces.
4 Performance Improves the mechanical properties of metal parts. Enhances the strength and integrity of the final part with higher dimensional accuracy.
5 Raw Material Uses materials such as alloy steels, aluminum, brass, bronze, copper, stainless steel, and nickel alloys. Typically employs aluminum and its alloys, copper and its alloys, low carbon steel, medium carbon steel, and low alloy structural steel.
6 Material Type Primarily uses coiled wire or rods. Uses slugs, bars, billets, coils, or beams.
7 Workpiece Type Upsetting deformation of smaller workpieces. Compressional deformation of larger workpieces.
8 Application Ideal for producing bolts, screws, nuts, rivets, pins and other standard fasteners. Widely used in various industries, including electric vehicles, aerospace, construction, and off-road equipment, such as brake parts and starter pinions.
9 Example of Bolt The hexagonal head is formed. The diameter of the rod is reduced.
10 Sample 9. Cold Heading Parts 10. Cold Die Forging parts

How does Cold Forging Work? _____

By applying significant pressure at room temperature, cold forging reshapes metal without extensive heating, ensuring minimal waste and faster production times. Taking cold heading as an example, this process effectively forms fasteners with precision and efficiency.
  • Firstly
    Firstly
    The wire is fed from the mechanical coil through a pre-straightening machine, where the straightening rollers align the wire, while the feeding rollers ensure proper advancement. Once straightened, the wire moves directly into the shearing die, where the cutting blade automatically cuts it to the designated length.
     
    01 Straightening Rollers - Feeding Rollers - Die Cutting Blade - Shearing Die - Adjusting Screw
  • Secondly
    Secondly
    The cut wire is sent to the heading die and aligned with the center of the first punch die, where the first punch creates a stable shape, achieving approximately 70% of the final form.
     
    02 Heading Die & First Punch
  • Thirdly
    Thirdly
    The die set moves upward, while the first punch case shifts to the right.
     
    03 Die set - the first punch case
  • Fourthly
    Fourthly
    The second punch case moves upward, while the screw second punch (also known as the screw header punch or second header punch) forms the head of the blank into a programmed shape. At this point, both the screw head and screw drive are fully formed.
     
    04 screw second punch - screw header punch - second header punch
  • Finally
    Finally
    The pin ejects the screw blank without rolling thread.
     
    05 ejector pin - screw blank without rolling thread
ADVANTAGES

Advantages of Cold Forging

Cold forging offers numerous advantages since it takes place without heating the metal beforehand.
✅ Higher Productivity
Conventional processes (such as machining or other fabrication methods) typically involve multiple processes to finish a part. In contrast, cold forging is often a single-pass forming process that deforms the material into the desired shape, making it ideal for high volumes production.
✅ Material Savings
Cold forging is designed to minimize waste by eliminating unnecessary material loss. Each billet is precisely the amount of material required for the final part, resulting in no wastage.
✅ Cost Reduction
Cold forging is more economical than other process because it is a net-shape and near-net-shape process that requires little to no finishing. Additionally, the dies used in cold forging have a longer lifespan compared to those used in hot processes, which leads to fewer replacements.
✅ Improvement of Part Integrity and Strength
A key benefit of cold forging is its ability to significantly enhance the strength and integrity of the final part. The high compression forces in the cold forging process rearrange the grain structure of the metal, increasing impact strength, yield strength, tensile strength, and structural integrity.
✅ Enhanced Appearance and Surface Finishing
Cold forging is a precision forming process that achieves high dimensional accuracy and an attractive appearance, so it does not require post-processing steps like removing burrs, grooves, or striations. This makes it optimal for achieving excellent surface finishes.
✅ Eco-friendly
Cold forging is likely the most eco-friendly process of its kind. By using less material, it produces less scrap. Compared to heat-based processes, cold forging significantly reduces energy consumption.
APPLICATIONS

Applications of Cold Forging

Cold forging is appreciated for its ability to produce strong, lightweight, and precise components, making it suitable for a wide range of applications across various industries.
✅ Automotive Industry
Components: Gears, shafts, bolts, and connectors are often cold-forged for their strength and precision.
Fasteners: High-volume production of nuts, bolts, and screws.
✅ Aerospace Industry
Structural Components: Parts that require high strength-to-weight ratios, such as brackets and fittings.
Engine Parts: Components that must withstand high-stress conditions.
✅ Construction Industry
Structural Hardware: Reinforcement bars (rebars), anchors, and brackets used in building structures.
Fasteners: Various types of screws and bolts for construction applications.
✅ Electronics
Connectors: Cold forging is used to create precise connectors for electric components.
Casings: Components for electronic devices requiring intricate shapes and high durability.
✅ Consumer Products
Household Items: Parts for appliances, tools, and furniture that require good mechanical properties.
Metal Components: Decorative items or components requiring detailed shapes.
✅ General Manufacturing
Custom Parts: Manufacturers use cold forging for creating custom shapes and designs tailored to specific needs.
High-Volume Production: Ideal for mass production of parts with consistent quality.
✅ Medical Devices
Surgical Instruments: Components requiring high precision and cleanliness (e.g., surgical tools).
11. bolts-screws- nuts-rivets-pins- and-other- standard -fasteners

Unlock Precision with 

Our Cold Forging Solutions _______

At U-Need, we take pride in our expertise in cold forging and the development of high-quality cold forging tools tailored for this advanced process. Committed to excellence and innovation, we deliver precision-engineered components that meet the highest industry standards.
Partner with us to unlock the full potential of your projects through cold forging. Elevate your products with the strength and reliability of our expertly crafted components.

FAQs _____

  • What Are the Materials Used in Cold Forging?

    Cold forging requires materials with low deformation resistance and good plasticity at room temperature. Common materials include:
    * Aluminum and its Alloys: Known for their lightweight and excellent machinability.
    * Copper and its Alloys: Valued for their conductivity and corrosion resistance.
    * Low Carbon Steel: Offers good ductility and formability.
    * Medium Carbon Steel: Provides a balance between strength and ductility.
    * Low Alloy Structural Steel: Used for its enhanced mechanical properties and toughness.

  • What Are the Recrystallization Temperatures of Various Metal Materials?

    According to metallurgical theory, the recrystallization temperature of different metal materials is vary. The following table summarizes the lowest recrystallization temperature:

    Metal Lowest recrystallization temperature (°C)
    Iron (Fe) 360~450
    Copper (Cu) 200~270
    Aluminium (Al) 100~150
    Tin (Sn) 0
    Lead (Pb) 0
    Tungsten (W) 1200

    Based on the data in the table, the forming processes for tin and lead, which have recrystallization temperatures of 0°C, cannot be classified as cold forging, but rather as hot forging. In contrast, the forming of iron, copper, and aluminum at room temperature can be considered cold forging.

  • What is Cold Heading?

    Cold heading is a pressure processing that involves little or no cutting of the metal. It is a metalworking process that creates plastic deformation of the metal using molds - typically consisting of a male die (such as a punch) and a female die (like a heading die) - under the influence of external force. The process typically produces the required parts or blanks. Cold heading is ideal for the production of bolts, screws, nuts, rivets, pins and other standard fasteners.

  • What is a Header Die?

    A header die is a fundamental tool of cold forming process. It is used to shape the screw head and includes various types such as carbide heading dies, shearing dies, die cutting blades, screw first punch die, screw second punch die, as well as pins. Moreover, the selection of the materials for the header die is crucial, as its service life depends significantly on the quality of the tungsten steel used.
Injection Molding
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U-Need Precision Machinery Co., Ltd.
  +86 0769 23225585
 +86 15916761371
  contact@uneedpm.com
  Room 401-1, Building 4, SongHuZhiGu Research Center, No.6 Minfu Road, Liaobu Town, Dongguan City, Guangdong Province, China
523425

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