During the cold forming process, coiled metal wire is fed into a machine and precisely sheared to length. The cut pieces called blanks are then moved through several sequential extrusion and upsetting stations. There, they are pushed into progressive carbide dies at room temperature using nothing but sheer power and high speed. This forces the metal to be formed into its desired final shape which is retained upon die removal.
A multi-station machine processes blanks at all stations simultaneously, each in a different stage of development. With every stroke of the machine, a finished part is ejected from the last die. In parallel, a new blank is being sheared to an engineered length and fed into the first die. This enables production rates to hit hundreds of parts per minute, leaving machining processes far behind when it comes to speed.
Some components may not lend themselves to the cold forming process, for instance due to incompatible shapes. Yet, our state-of-the-art cold forming machinery allows us to produce ever more complex components with incredible accuracy. Even when secondary machining operations are additionally applied, cold forming as the base manufacturing process still often proves to be the most cost-effective solution.
- Economies of scale because of high production rates
- Increased strength due to grain structure rearrangement
- Design versatility by using multiple progressive dies
- Little to no waste thanks to mitigation of material removal