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

1. The process of progressively forming a specified shape from metal wire without adding heat – using a replicated series of dies, hammers, and punches at high speed.

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.

• Tight Tolerances
• High Speed Production Rates
• Large Volume Capabilities
• Reduced Raw Material Waste
• Improved Physical Properties
• Reduction in Cost Vs Machining
• Capabilities Include a Large Range of Diameters
• Standard and non-standard configurations are made to the customer’s specifications
• Many secondary operations available to complete fully customized parts

Cold Heading Basics

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.

Progression

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.

Basic Forming Techniques

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

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.

Extrusions

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.

Secondary Operations

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.

• Thread Roll
• Drill and Tap
• Knurling and Grooving
• Stamping
• Heat Treat
• Plating
• Grind and Shave
• Metal Finishing & Polishing
• CNC Milling
• Flatten
• Pierce

 Grandeur Fasteners – Cold Headed Products

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 1975, 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!

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Phone: 479-489-5168
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The manufacturing world has changed over the years. Thanks to new manufacturing methods, we are moving towards a more efficient and affordable world.

Bolts are the essential parts used in manufacturing, regardless of the industry. The cold Heading process creates these bolts at a more commercial level. This article will discuss the cold heading process and its basics to make it more straightforward for readers. Let’s begin.

Cold heading is one of the two most popular methods used in the manufacturing industry. It helps manufacturers create simple bolts if they have a piece of metal.

The other method used in this approach is called screw machining, which cuts the bare metal until the professionals have a simple screw/ bolt-type design. Once this basic design is in place, the manufacturers can add further threads.

Because of so many different steps involved in the Process, there’s a lot of metal waste in the cold heading process. There’s over a 35% pocket range difference that you may experience in this regard.

This cost generally increases if the manufacturers do not recycle any of the metal wasted in the Process. By using the wasted metal, the companies can easily create fasteners for much more affordable rates and make the business profitable.

The cold heading process usually forces a metal piece without wasting or removing any metal used. An easier way to understand the process is to think it has form moulding.

However, in this case, the moulding is done with metal. The main reason bolt and fastener manufacturers use cold heading is that it minimizes the raw material waste from the process.

What does the Process Require?

To create bolts and fasteners with the cold heading, the professionals need to use a specific machine and utilize it throughout the Process. The suitable machine for cold heading depends on the material used in manufacturing, as some machines may be more beneficial than others.

Moreover, the manufacturers must also consider the final type of fastener they wish to have by the end of the Process.

Basics of Cold Heading

Cold heading, also called cold forming, is a step-by-step method for metal formation. With these metals, one can get net-shaped similar parts in their final designs. Slug, one of the most common products from cold heading, is created by cutting from a coil material that runs continuously.

Multiple mighty hammers and dies work within the cold heading process. This way, there’s little to no wastage from the Process, and the final products are much more pocket-friendlier than others. The best part is that with the cold heading, the final volume of the slug is pretty similar to the starting volume.

Because the Process uses a die, there’s a consistent design instead of cutting it down in parts from the blank. With the cold heading process, the final products are more robust, have smoother surfaces and have better graining surfaces at the end.

On the other hand, conventional methods like metal cutting are slower and can waste up to 60% of raw material in the manufacturing process.

Consequently, the cold heading is a better choice than machining, which is best for commercial production, and its efficiency remains accurate (up to +/- .002″ without any other operations).

Progression

Progression is a step-by-step process used in manufacturing that makes the final product more efficient. The Process begins with a slug, and the products become more and more accurate in the final look. It would help if you had more progression for specifically tailored fasteners than simple ones. The simpler fasteners may only require 1 or 2 blows from the machine.

However, the progression is not the same for each step. Each product type has a specified number of dies, punches and hammers. These designs focus on unique specifications, depending on the needs.

Moreover, the design progression also varies based on the raw materials used for the fastener production. For instance, softer metals, such as Copper, Aluminum, don’t require much processing. They are more accessible to mould and can be prepared quickly.

However, harder metals such as Stainless Steel or nickel alloys require more punches, dies and processing to get the right product from them.

Essential Techniques Used in Cold Forming

Cold forming or cold heading processes are pretty simple in most cases. If we talk about the processes used in cold forming, extrusions and upsets are the two main approaches used in the process.

The main principle of these methods is to apply sufficient force on the metal sections, which requires various dies. Therefore, each process requires a specific number of hammering, processing, and hammering with specifically designed machines.

Upsets

Upsets are the primary approach used in cold heading in today’s commercial manufacturing. In this process, the slug reduces height, and its starting diameter is more significant. With the upset technique, you can create a part’s head and assist with open tooling.

The choice between tooling options may vary based on the shape and location of the upsets. For example, the main parts of the upsets can have various diameters and designs. The manufacturers may also use multiple upsets with different designs throughout the setting.

Extrusions

Extrusion is the second most common method used in cold forming. The cold heading process has two different sub-categories based on their final design. Let’s discuss this.

Forward Extrusions

The material is run through a more minor diameter system in the forward extrusions, increasing its length. In this approach, the raw material may be in the tooling ultimately or to some extent.

Backward Extrusions

There’s a penetrating punch or a pin in backward extrusions through which the metal flows. The metal may need to be in a die or punch insert throughout this step. With the backward extrusion, professionals may typically create a hole or opening into the metal.

Cold Heading is a popular method used in industrial manufacturing. It is mainly used for creating screws, bolts and fasteners. However, cold heading provides a more persistent, innovative, and cost-effective alternative. It helps reduce raw material wastage and optimize the overall process.

What is Cold Heading?

Basics of the Cold Heading ProcessCold Heading Process - Clark Engineering