Thursday, July 14, 2016
Blind Fasteners
Sure you know about cold forming rivets, but ever wonder how a blind rivet works? Most people think that it's some sort of magic, but in reality it is simply a design. I'm obviously joking, but here's a look inside the inner workings of the blind rivets and how they fasten.
Tuesday, May 26, 2015
Hot Forging Vs.Cold Forming
Hot forging and cold forging are two different processes for forming metal that deliver similar
results. The manufacturer will look at a number of criteria before choosing which type of forging is best for a particular application.
The Hot Forging Process (Also called Hot Forming)
Hot forging is the process in which the material must be heated significantly to be formed, thus the name. The average temperatures necessary for hot forging are:
Heating the material during hot forging raises the temperature above the recrystallization point of the metal. The extreme heat is necessary to avoid strain hardening of the metal during deformation. A type of hot forging called isothermal forging is useful in order to prevent the oxidation of certain metals, like super alloys. In isothermal forging, the process occurs in a highly controlled atmosphere, similar to that of a vacuum.
Hot Forging Considerations
Manufacturers commonly choose hot forging for the production of parts that have a greater influence in the technical arena. Hot forging is also recommended for the deformation of metal that features a high formability ratio. Other considerations for hot forging include:
1. Production of discrete parts
2. Low to medium accuracy
3. Scale Formation
4. Low stresses or low work hardening
5. Homogenized grain structure
6. Increased ductility
7. Elimination of chemical incongruities
Possible disadvantages of hot forging include:
Cold Forging (Also called cold forming or cold heading)
Cold forging deforms metal while it is below its recrystallization point. Cold forging is simplest when dealing with soft metals, such as aluminum but can be achieved with hard metals like steel too. This process is usually more cost effective than hot forging and the final product requires little, to no, finishing work. Often times, when aluminum has been cold forged into a desired shape, it is then heat treated to strengthen the piece, called "tempering."
The Cold Forging Process
Although the process uses the term cold, cold forging actually occurs at or near room temperature. The most common metals used for cold forging are usually standard or carbon alloy steels. A very common type of cold forging is called impression-die forging. During this impression-die process, the metal is placed into a die, typically a carbide die, that is attached to an anvil.
The metal is then struck by a hammer and forced into the die, forming the desired part. The hammer may strike the part multiple times rapidly to form the product.
Cold Forging Considerations
Manufacturers may choose cold forging over hot forging for a number of reasons. One reason being that cold forged parts require very little or no finishing work. Removing this step from fabrication process can save the manufacturer money. Cold forging also creates less contamination problems, and the final product features a better overall surface finish.
Other benefits of cold forging include:
Some possible disadvantages include:
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| Cold Forming Versus Hot Forging |
The Hot Forging Process (Also called Hot Forming)
Hot forging is the process in which the material must be heated significantly to be formed, thus the name. The average temperatures necessary for hot forging are:
- Up to 1150 degrees Celsius for Steel
- 360 to 520 degrees Celsius for Al-Alloys
- 700 to 800 degrees Celsius for Cu-Alloys
Heating the material during hot forging raises the temperature above the recrystallization point of the metal. The extreme heat is necessary to avoid strain hardening of the metal during deformation. A type of hot forging called isothermal forging is useful in order to prevent the oxidation of certain metals, like super alloys. In isothermal forging, the process occurs in a highly controlled atmosphere, similar to that of a vacuum.
Hot Forging Considerations
Manufacturers commonly choose hot forging for the production of parts that have a greater influence in the technical arena. Hot forging is also recommended for the deformation of metal that features a high formability ratio. Other considerations for hot forging include:
1. Production of discrete parts
2. Low to medium accuracy
3. Scale Formation
4. Low stresses or low work hardening
5. Homogenized grain structure
6. Increased ductility
7. Elimination of chemical incongruities
Possible disadvantages of hot forging include:
- Less precise tolerances
- Possible warping of the material during the cooling process
- Varying metal grain structure
- Possible reactions between the surrounding atmosphere and the meta
Cold Forging (Also called cold forming or cold heading)
Cold forging deforms metal while it is below its recrystallization point. Cold forging is simplest when dealing with soft metals, such as aluminum but can be achieved with hard metals like steel too. This process is usually more cost effective than hot forging and the final product requires little, to no, finishing work. Often times, when aluminum has been cold forged into a desired shape, it is then heat treated to strengthen the piece, called "tempering."
The Cold Forging Process
Although the process uses the term cold, cold forging actually occurs at or near room temperature. The most common metals used for cold forging are usually standard or carbon alloy steels. A very common type of cold forging is called impression-die forging. During this impression-die process, the metal is placed into a die, typically a carbide die, that is attached to an anvil.
The metal is then struck by a hammer and forced into the die, forming the desired part. The hammer may strike the part multiple times rapidly to form the product.
Cold Forging Considerations
Manufacturers may choose cold forging over hot forging for a number of reasons. One reason being that cold forged parts require very little or no finishing work. Removing this step from fabrication process can save the manufacturer money. Cold forging also creates less contamination problems, and the final product features a better overall surface finish.
Other benefits of cold forging include:
- Easier to impart directional properties
- Improved interchangeability
- Improved reproducibility
- Increased dimensional control
- Handles high stress and high die loads
- Produces net shape or near-net shape parts
Some possible disadvantages include:
- Easier to impart directional properties
- Improved interchangeability
- Increased dimensional control
- Handles high stress and high die loads
- Produces net shape or near-net shape parts
- The metal surfaces must be clean and free of scale before forging occurs
- The metal is less ductile
- Residual stress may occur
- Heavier and more powerful equipment is needed
- Stronger tooling is required
Thursday, May 7, 2015
Cold Forming Chess!
How do you know if your cold forming, fastener company employees aren't being utilized to there full potential? "Fastener Chess" is a great clue!
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| Fastener Chess |
Wednesday, April 29, 2015
What is Warming Forming
What is Warm Forming? By Dave Sader, April 29th, 2015
Warm Forming is the process of forming metal that has been heated to a temperature that allows
for greater malleability without causing adverse effects to the metal structure that is caused at
greater temperatures. Examples of these undesirable effects include re-crystallization, grain growth, and metallurgical fracture. The process allows the part to be successfully formed to final
tolerance, which eliminates the need for secondary machining operations. Material, geometry and
final specifications and tolerances are all factors that manufacturers look at to decide
temperatures used in warm forming operations. Temperatures for warm forging can range from
200-850 degrees C.
Oh, and if you're wondering why a cold forming website is talking about warm forming, don't worry about it... you think to much! They are closely related.
Warm forming along in conjunction with carbide dies has been used for decades, primarily in the aerospace industry due to the use of metals such as titanium. Originally induction heaters were added to machines for use in warm forging. Today, specialized machines like FORMAX use advanced technology designed specifically for warm-formed applications.
Possible applications for warm forming include:
Cold forming machines can be adapted or specially designed to be warm formers, where the following features may be added:
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| Warm Forming |
Warm Forming is the process of forming metal that has been heated to a temperature that allows
for greater malleability without causing adverse effects to the metal structure that is caused at
greater temperatures. Examples of these undesirable effects include re-crystallization, grain growth, and metallurgical fracture. The process allows the part to be successfully formed to final
tolerance, which eliminates the need for secondary machining operations. Material, geometry and
final specifications and tolerances are all factors that manufacturers look at to decide
temperatures used in warm forming operations. Temperatures for warm forging can range from
200-850 degrees C.
Oh, and if you're wondering why a cold forming website is talking about warm forming, don't worry about it... you think to much! They are closely related.
Warm forming along in conjunction with carbide dies has been used for decades, primarily in the aerospace industry due to the use of metals such as titanium. Originally induction heaters were added to machines for use in warm forging. Today, specialized machines like FORMAX use advanced technology designed specifically for warm-formed applications.
Possible applications for warm forming include:
- Commercial Stainless Steels
- FA 286 SS
- High Carbon & Alloy Steels
- Inconel
- Titanium (6-2, 6-4)
Cold forming machines can be adapted or specially designed to be warm formers, where the following features may be added:
- High-Frequency Converter
- External Circuit / Transformer
- Buss Bar
- Induction Coil
- Cooling System
- Converter & Induction Coil
- Machine: Die Block, Induction Coil Bracket, & Die Lube
- Heater for Die Lube
- Wire Temperature Sensor (Pyrometer)
- Automated Blank Drop
- Blank or Feed Indicator
- Fire Suppression System
Tuesday, April 14, 2015
Cold Forming and Cold Heading Basics
Cold forming is a commonly used technique for rapidly forming metal parts such as screws, bolts and
many other fasteners. Cold forming, also called cold heading, uses force to strike a cold metal slug into a Cold Forming Die to shape parts. The force of the strike causes the metal to form into the desired shape inside the carbide die.
Cold forming begins with cutting the slug, also called a blank. The slugs are cut from a coil of round wire to the exact size needed. It is important for the volume of the slug to match the volume of the finished product, as the cold forming process doesn't add or remove any material. After the slug has been cut it is then placed into the carbide die (Cold Forming Dies) by “fingers” on a cold forming machine (or header). The slug is pushed into the die with one or more strikes. The final formed product is shaped by a combination of the carbide die and carbide punch. This strike action creates enough force to temporarily cause the metal become a liquid. This process creates a stronger part than if the metal was cut along the grain into the desired shape. A series of dies is often needed to form parts into the desired shape.
Most cold forming machines use one or two strikes to reach final form. After the part is formed an ejector pin is used to remove the product from the die. All of the operations completed by a cold heading machine are done at a rapid pace. Cold heading machines manufacture parts at such a high rate of speed that the process is invisible to the naked eye. Additional tasks can be completed by cold heading machines, such as trimming, piercing and sharpening.
What Materials Can Be Cold Formed?
Carbon steels
Brass
Lead
Stainless steel
Copper
Aerospace Alloys
Alloy steels
Bronze
Precious metals
Aluminum
Nickel Alloys
Obviously, this is a very brief description of cold heading and cold forming. We will continue with more in depth articles in the future.
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| The Cold Forming Process and a Cold Forming Machine |
Cold forming begins with cutting the slug, also called a blank. The slugs are cut from a coil of round wire to the exact size needed. It is important for the volume of the slug to match the volume of the finished product, as the cold forming process doesn't add or remove any material. After the slug has been cut it is then placed into the carbide die (Cold Forming Dies) by “fingers” on a cold forming machine (or header). The slug is pushed into the die with one or more strikes. The final formed product is shaped by a combination of the carbide die and carbide punch. This strike action creates enough force to temporarily cause the metal become a liquid. This process creates a stronger part than if the metal was cut along the grain into the desired shape. A series of dies is often needed to form parts into the desired shape.
Most cold forming machines use one or two strikes to reach final form. After the part is formed an ejector pin is used to remove the product from the die. All of the operations completed by a cold heading machine are done at a rapid pace. Cold heading machines manufacture parts at such a high rate of speed that the process is invisible to the naked eye. Additional tasks can be completed by cold heading machines, such as trimming, piercing and sharpening.
What Materials Can Be Cold Formed?
Carbon steels
Brass
Lead
Stainless steel
Copper
Aerospace Alloys
Alloy steels
Bronze
Precious metals
Aluminum
Nickel Alloys
Obviously, this is a very brief description of cold heading and cold forming. We will continue with more in depth articles in the future.
Wednesday, April 1, 2015
Cold Forming Industry New
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| Cold Forming Industry |
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