What exactly is Cold Heading? Let’s begin by defining the general term along with the basic principles of involved in the cold heading process.
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Cold Head·ing
/kōld/ /‘hediNG/
verb
Simply put: cold heading is feeding wire into a machine, cutting it into pieces, and hammering on it. The material is not heated or machined, but formed into its desired shape at room temperature. The ability to form material instead of removing it deems this process extremely efficient and cost effective when manufacturing large quantities.
At Grandeur Fasteners, we design and fabricate our own custom tooling and manufacture nearly all fastener forms including multiple upset configurations, customized head shapes, and substitutions for multi-part assemblies. Converting your supply needs to cold heading can benefit in many ways.
Cold heading (or cold forming) is a method of forming metal in progressive steps into net shaped or near net shaped parts. Starting with a slug, which is cut from a continuous coil of wire material; the cold heading machine uses a series of powerful hammers and dies to form a part. This process creates very little to no waste, offers significant material cost savings, and the volume of the starting slug is about the same as the finished part. The net volume remains the same since the material is being formed into the die, rather than cut from the blank. The cold heading process creates a stronger part, with smooth continuous surfaces while enhancing the grain flow of the material.
In contrast, metal cutting operations are typically slow and can generate as much as 60% waste.
Cold heading is more efficient than machining, allowing rapid production of large quantities while maintaining tolerances as close as +/- .002″ without secondary operations.
A progression is the process of developing gradually towards a more advanced state. Starting with the slug, each step of the progression forms the material closer and closer to its’ final shape. Intricate fasteners often require a longer progression than simple fasteners, as many simple fasteners may be completed in 1-2 blows from a cold heading machine.
Progressions are not the same for every part. Each type of fastener or component has its’ very own series of punches, dies, and hammers which have been engineered to a unique specification. Material requirements also play a role in how the progression is designed. Softer metals will form more readily (e.g. Copper, Aluminum) while harder metals (e.g. Stainless Steel, Nickel Alloy) may require multiple blows to achieve its’ final form.
Upsets and extrusions are two basic types of techniques used in cold headed manufacturing. These techniques involve the controlled forming of a material by applying enough force for the material to fill a voided space within a die. Each die is engineered accordingly, to produce the proper amount of material movement throughout the progression.
Upsets are the most common and basic technique used in cold heading today. An upset is formed when the slug is reduced in height and the starting diameter is increased. This technique is often used to create the head of the part, and may be formed with open tooling, between tooling, or enclosed tooling – depending on the upset location and shape. Integral parts may require multiple heads and diameters. To achieve these complex configurations, different upsets are incorporated throughout the part’s progression.
Another common cold heading technique is called an extrusion. There are two types of extrusions: forward extrusions, and backward extrusions.
Forward extrusions force the material through a smaller diameter orifice, thereby reducing its diameter and increasing its length. The starting material may be partially or totally contained in the tooling before the start of this type of extrusion.
Backward extrusions force material to flow around a penetrating punch or pin while being contained in a die or punch insert. This extrusion is typically used to form a hole or cavity inside a part.
Complex fasteners and components often require secondary operations to produce finished parts. These operations cannot be performed on a cold heading machine and are complimentary to the cold heading process.
Cold heading was originally created to manufacture fasteners. However, given today’s technological advancements and research, cold headed parts, fasteners, and components can be found in thousands of various products and structures around the world. This process is continuously being developed for new applications, allowing a growth in manufacturing and a reduction in cost for manufacturers.
Since , we have continuously improved our process while finding new ways to help our customers reduce cost. As the leading and best cold headed supplier in the industry, Grandeur manufactures customer specific and highly specialized fasteners with unmatched quality. If your fastener or component needs require something special, whether in material or design, then Grandeur Fasteners may be a great fit for you. Contact us today to request a quote or inquire if cold heading is right for you!
For more Cold Heading Quality Wire Supplierinformation, please contact us. We will provide professional answers.
In the world of manufacturing, precision is everything. When it comes to the art of cold heading, precision transforms into a masterpiece. Cold heading is a specialized cold forming process that shapes metal wire into intricate components by hammering and forming it through dies and punches—all without applying heat.
This article explores the secrets of cold heading manufacturing, focusing on a streamlined 3-step process that ensures excellence at every stage: a production floor for precision crafting, a quality testing station to ensure flawless results, and advanced vision sorting for the highest level of consistency. We'll also highlight specialties such as cold extrusion, fasteners, rivets, and miniature fasteners that showcase the versatility of this manufacturing method.
Whether you're a manufacturer seeking a reliable solution for producing specialty bolts, screws, or other metal components, or simply curious about the technology behind the process, this guide is for you. Let’s dive in and reveal the secrets of cold heading manufacturing.
The foundation of exceptional cold heading manufacturing lies in a well-defined and efficient process. This 3-step approach—spanning precision crafting on the production floor, rigorous quality testing, and advanced vision sorting—ensures every component meets the highest standards of accuracy and reliability.
The journey begins on the production floor, where metal wire is transformed into components using state-of-the-art cold heading machines. These machines apply immense force to form metal wire into desired shapes without heating the material, ensuring superior structural integrity. The process relies on precision dies and punches, meticulously crafted to meet specific design requirements. Whether it’s crafting standard fasteners, rivets, or intricate miniature fasteners, the production floor sets the stage for consistent and efficient output.
After the components are crafted, they undergo rigorous quality testing to ensure they meet exacting standards. The quality testing station is equipped with advanced tools and techniques to measure dimensions, durability, and overall performance. Each component is scrutinized to ensure it adheres to specifications, leaving no room for defects. This step not only guarantees customer satisfaction but also enhances the reliability of the final product.
The final step involves vision sorting, where cutting-edge technology ensures every piece meets strict criteria. Vision sorting systems use high-resolution cameras and sophisticated algorithms to inspect components at the micro-level. These systems identify even the slightest imperfections, ensuring only flawless products reach the customer. Vision sorting is particularly critical for industries that demand high precision, such as aerospace, automotive, and electronics.
In addition to cold heading, this process incorporates a range of specialized manufacturing techniques that expand its capabilities:
A method of shaping metal through compression, cold extrusion complements cold heading by enabling the creation of highly intricate and elongated components. This process is ideal for producing parts with complex geometries and superior strength.
From standard bolts and screws to custom rivets, the versatility of this manufacturing process ensures that components are both durable and cost-effective. Cold heading’s ability to minimize material waste makes it an excellent choice for high-volume production.
For industries like electronics and medical devices, where size and precision are paramount, cold heading offers the perfect solution. Miniature fasteners crafted through this process deliver unmatched reliability even at the smallest scales.
The benefits of cold heading manufacturing go beyond its precision and efficiency:
By shaping components without heat, cold heading enhances structural integrity and reduces the risk of material deformation.
The process minimizes material waste and optimizes production efficiency, delivering a competitive edge for manufacturers.
Cold heading is a sustainable option that reduces energy consumption and material waste.
Cold heading manufacturing is more than just a process—it’s an art form that combines precision, craftsmanship, and advanced technology. With a robust 3-step process and a wide array of specialized capabilities, this method offers manufacturers a reliable, efficient, and eco-friendly way to produce high-quality metal components.
Whether you're looking for standard fasteners, custom rivets, or intricate miniature fasteners, the cold heading process delivers unmatched quality and precision. Ready to learn more? Contact us today to explore how cold heading can elevate your manufacturing needs.
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