Advantages: Compared to traditional methods of machining and cutting processes performed by machinery, low volume manufacturingcold forming miniature metal parts can be achieved through time cost savings, reduced waste of resources, faster process development and better quality of finished parts.
Cold forming, also known as cold heading or cold forging, is a manufacturing and metalworking process that forms miniature metal parts, such as connector pins, without heating or cutting excess material. Cold forming is performed by feeding a predetermined diameter coil into a cold collector and cutting it to the desired length. The cut sheet metal is then transferred through a series of punches and dies that form, bend, join and shape the part to create the desired final shape. High-pressure dies are used with a force or tonnage appropriate to the type of metal and the custom part manufacturersize of the desired end product. The process does not require heating and the metal ultimately retains its original length, width and thickness (or flatness).
In conventional machining, a bar of a particular raw material is cut into a shape. Although the starting material may be close to the final size, it needs to be cut to achieve the final size and shape to produce excess material. This process involves high heat and subsequent cooling, which can stress the metal and affect its structural integrity. Many metals are suitable for cold forming, including gold, nickel, copper, steel, brass and aluminum.
Cold forming offers the following key advantages over traditional processing techniques:
Cold forming can be accomplished at a much higher rate of production development. Using through this traditional process, production rates we can range between 150-400 pieces per minute. This time sensitive production brings additional cost management savings and allows the company to achieve a quick response to analyze customer service needs; cold formed products can be quickly supplied to students for assembly with short lead times.
Secondary processes such as deburring, welding, bending, punching and undercutting are eliminated as the tooling helps to obtain the desired end product shape.
Cold forming produces zero material waste and cost savings, reducing the amount of precious metals required and eliminating post-production waste disposal.
It is a more environmentally friendly process because removing heating and cooling from the equation reduces energy use. Using cold forming technology helps companies reduce their carbon footprint, which is becoming increasingly important as more companies implement higher environmental standards to comply with regulations or corporate initiatives.
Finally, cold forming produces stronger, finished parts with higher quality requirements, which helps corporate suppliers can create quality educational final parts that manage to run longer in the field. Because cold forming does prototype machining servicesnot appear to interrupt the grain structure or flow of the raw material, the finished part is designed with a greater degree of material integrity. The greater product development strength offered by cold forming developments is critical in the high reliability analytical market and in electronic technology products used in harsh operating system environments where part integrity is critical to performance studies under stress.
Cold formed parts offer significant advantages to manufacturers in terms of end product quality. These parts typically have more accurate dimensions because they are not exposed to any heating processes that cause the metal to shrink or expand. This is a significant advantage in the field of nanoscale or nano-scale microelectronics, where components can be just a few millimeters in size. A variety of components can be manufactured by cold forming, including connector pins, electrical contacts, sockets, fasteners, rivets, and custom parts. Shapes that can be completed by this process include bends, holes, flattening and press fits. Secondary processes can add threads, ridges, knurling, grid patterns, rings, and letters.
A variety of standard and custom parts can be manufactured using the cold forming process. Cold forming manufacturers can also offer secondary manufacturing processes including rolling, machining, bending, pressing, fastening, and plastic molding. Plating and other surface treatments can be used to create the final product. Cold forming specialists can work closely with part designers and original equipment manufacturers to design a complete product that performs well, has a long service life, and meets time and cost requirements. The end result should be an excellent product with a good service area.
Related Hot Topic
Is there a lack of machine operators?
Manufacturing businesses have long struggled with the lack of skilled workers in this field. Less and less skill is emerging to replace the current workforce of NC programmers and machinists as they prepare to retire.
Low volume manufacturing: what is it?
Low-volume manufacturing involves producing (you guessed it) a small number of parts; some businesses are capable of managing anywhere between 10 and 100,000 parts. This capacity can thoroughly validate a product's design and manufacturing processes while bridging the gap between prototyping and full-volume production.
Who is the largest producer?
leading nations in terms of manufacturing production With a manufacturing output of nearly $2.01 trillion, China dominates the world (see Table 1). The United States ($1.867 trillion), Japan ($1.063 trillion), Germany ($700 billion), and South Korea ($372 billion) are the next largest economies after that.