Cold Forming Overview and Reference Guide

Cold Forming: A Definition

Cold Forming pertains to multiple processes where metal is moved / worked at room temperature by:

• Upsetting or Heading: Perpendicular Flow
• Extrusion: Parallel Flow
• Rolling: Displacing

Cold Formed Dimension Tolerances

• Upset in Dies: ± 0.004 in. (0.10 mm)
• Open Upsets: ± 0.015 in. (0.38 mm)
• Length: ± 0.020 in. (0.50 mm)
• Extruded or Sized: ± 0.002 in. (0.05 mm)

Cold Formed Surface Finishes

In General: 8 – 63 micro (0.020 – 1.6 micrometers)
Factors affecting surface finish:

• Condition of the material to be formed
• Type of cold working
• Forming lubricant
• Finish and condition of tooling

Secondary Machined Dimension Tolerances

• Diameters: ± 0.004 in. (0.10 mm)
• Length: ± 0.006 in. (0.15 mm)
• Groove Width and Depth: ± 0.004 in. (0.10 mm)
• Higher Cost: ± 0.002 in. (0.05 mm)

Secondary Grinding in Production

Common Total Tolerances: ± 0.001 in. (0.025 mm)
Obtainable Total Tolerances: ± 0.0005 in. (0.00127 mm)

Cost Savings with Cold Forming

• Material Savings
• High Production Rates
• Added Strength
• Consistent Quality: Because only good quality material can withstand cold forming

Selecting the Right Part for Cold Forming

• Economic Order Quantity: Production volume must offset set-up and tooling costs.
• Radii and Fillets: Avoid sharp corners and allow generous radii and fillets.
• Eliminate Assemblies: Choose parts that can be combined into a single cold formed
  piece.

Higher Quality of Cold Formed Parts

• Strength and Wear: Increased properties due to uninterrupted grain flow.
• Impact, Fatigue, and Shear Strength: Increased due to controlled grain flow.
• Smooth, Burnished Finish: Resulting from tooling surface, eliminating some secondary machining.

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Thank you,
The Federal Group USA