Mike McNulty
Editor, Fastener Technology International
Cold Forming
Every issue of Fastener Technology International (FTI) magazine contains one or more Roundup Articles on various technology subjects, and in a recent issue the subject of cold forming was covered in a multi-page article featuring editorial contributions from several suppliers of the relevant equipment and services. Many of these suppliers will be on hand at the International Fastener Expo 2024 in Las Vegas, NV, USA, where visitors will be able to see cold forming machinery and tooling suppliers as well as discuss the latest innovations with industry experts. Here are some excerpts from the article:
What Can Your Heading and Forging Machines Do?
Ing. Enrico Brigatti, Chief Commercial Officer, SACMA Limbiate S.p.A., Limbiate (MB), Italy, says, “Today the variety and the quantity of metal fasteners produced by cold forming of wire rod is impressive. Almost all of screws, bolts and nuts are made with that technology, but not only. The name of the process evokes itself the capacity to form a lot of special parts, solid or hollow, with a complex shape, to be used in the most important industry fields, automotive first. Cold forming is not just the simple heading of its debuts in the early fifties. By sophisticated multiple die presses, dedicated materials, accurate tooling, it becomes possible to produce parts that only few decades ago no one could imagine obtaining from wire. If we add the advantages coming from a high productivity, optimal use of raw material, consistency of precision, the success and the spread of this technology appears logical and motivated. Our mission is to offer to the producers of cold formed parts the best possible equipment with effective solutions, keeping at the same time the well-known robustness and reliability of SACMA machines. In 2024, SACMA is proposing the new KSP12, a fully re-designed successor of the iconic KSP11, an 1D2B header with thread rolling, suitable for production of screws, self-tapping and metric, from diameter 3mm to 8mm. The machine was enthusiastically accepted by our loyal customers and by new too.” www.sacmagroup.com
CNC Radial Crimper for Precision Cold Forming Operations – Specializing in Nut Crimping
David C. Willens, Ph.D., Director, Research & Development, Kinefac Corporation, Worcester, MA, USA, says, “Kinefac supplies the high precision RP-10 CNC KINECRIMP radial forming machine for specialized secondary cold forming operations. Engineered with a focus on compact footprint and energy efficiency, the RP-10 is adept at performing cold-form crimping operations to create hexagonal, square, and rectangular shapes, as well as crimps, on precision automotive and aerospace components and self-locking fasteners in a variety of materials and high strength alloys. With a 10-ton force capacity the RP-10 can perform radial form operations on shaft ends and nut sizes from M4 to M18 in fast cycle times. Its versatility is enhanced by quick-change capability, allowing seamless setup for two, three or four die/crimp configurations. Achieving a die position accuracy of 10-microns is facilitated by a servo-electric roller screw and low-friction wedge actuation system. Components to be formed are placed on the central support tooling and are automatically lowered into the forming area by a fast-acting electric servo ball screw actuator. Upon completion of the cold forming process, the components are automatically raised to the unload position. The RP-10 CNC KINECRIMP comes standard with the ability to form components by a programmed die penetration position and speed or by a programmed die force and speed for the most sensitive thin-wall applications. Part load/unload raised and forming position is also programmable through the HMI. The system has the capacity to store and recall up to 500-part programs, facilitating seamless workflow management. Quick-change die-form inserts and part support tooling further expedite change-over times, ensuring efficiency part to part. Kinefac offers the RP-10 CNC KINECRIMP with various automation options including vibratory bowl feed with robot or high-speed pick-and-place units. Higher forming tonnage capacities are also available upon request.” www.kinefac.com
Cutting Edge Solutions: Demystifying Cold Forming Cutoff Methods
Jesse Maga, Cinco Industries, Huntley, IL, USA, says, “Cold forming is the cornerstone technique in the production of bolts and screws due to its efficiency and ability to produce parts with exceptional strength and precision. Employing room temperature deformation to shape metal, the first step of this process is often the most critical stage. The cutoff, a step that significantly influences the quality and consistency of the final product, consists of two primary methods: bushing cutoffs and open knife cutoffs. Each technique offers a unique approach to slicing the metal stock to precise lengths, preparing it for subsequent forming operations. A bushing cutoff utilizes a shearing action within a guiding bushing, ensuring high precision and minimal material deformation. Conversely, an open knife cutoff employs a direct slicing action, prioritizing speed and operational flexibility. The fundamental differences between these cutoff methods and the technological and operational nuances that delineate them illuminate the advantages of bushing cutoffs. Underscoring their contributions to the manufacturing of high-quality bolts and screws, and their role in enhancing the overall efficacy of cold forming processes. Simple reliable machines like the Chun Zu CNH-6L offer reliability and cost-effectiveness for the American market. Leveraging bushing cutoffs and a proven ‘One Die Two Blow’ concept, the Chun Zu CNH-6L offers superior dimensional accuracy, reduced burr formation and operational efficiencies discussed earlier. Its design philosophy is to streamline the manufacturing process by forming both the head and shank of the bolt or screw in a single station, and robust construction with high-quality components to ensure an extended service life and minimal downtime for maintenance.” www.cinco-ind.com
White Paper: The Differences Between Cold Headed and Machined Solid Pins
Christie L. Jones, Director of Marketing, Vice President, SPIROL International Corporation, Danielson, CT, USA, says, “Solid pins are available in multiple configurations, and are commonly used for aligning, joining and assembling multiple components. They are also used for specific functions such as locating components, hinging, tamper-resistant fastening, etc. Two common manufacturing methods used to produce solid pins are cold heading and machining. Cold heading and machining both produce high quality, consistent parts, yet it is important to understand the differences between the two manufacturing processes when designing a solid pin for an assembly. This is because the manufacturing method directly impacts the design specifications including tolerances, geometry and the specific grade of material that can be assigned to the solid pin. Ultimately it is these factors coupled with the setup and cycle time of the production machine that will determine the total installed cost of the pinned assembly.” www.spirol.com
Visit www.fastenertech.com to read the entire article in the April/May 2024 issue.
