Vertical Cold Forging of Industrial Parts

Forming of the bulk metals can be catagorized like cold forming, hot forming, warm forming. These three methos has their own advantages and disadvantages. They are all formed by the force of the pressess. 
Mostly Industrial parts like fasteners, bolt ,nuts and gears are produced by cold forging method. Its called cold forging because the process is on room temparetures in the process heat ( temperature which may amount to several hundered degrees) occurs by the changing of the shape because of the deformation. Coldforming is an economical process because of the production rates , dimensional accuracy,material saving , and surface quality of the work material. We can separete cold forging in two which cold extrusion and forming. These two basic methods some times combined in one step. The cold extrusion can be catagorized in three.
 1. Forward Extrusion 
 2. Backward Extrusion
 3. Combined extrusion

Fig. 1 Extrusion Types
The Loads in the extrusion process are extremly high. The important facts for the punch material is compressive strenght and for the die material tensile stregth and wear resistance. In the selection of the tool materials these facts must be considered. In theextrusion over loads occures because of the stractural change ofthe workpieces. In backward extrusion the loads appears much more than the forward extrusion. Also n backward extrusion the wear tensions occures on punch. You can see the analysis of FMEA Methods with Simufact program in forward extrusion carbide die.

Schuler , Kiserrling, Invernizzi press, vs.  are most known vertical cold forging press in Europe. They have multiple machines started from one step to  transfer presses . Vertical presses can be catagorized as ;
1.Hydrolic press
2.Crank Press
3.Toggle press
4.Fricsion Screw Press
5.Drop Hammer
6.Power Hammer
Complex parts can be formed in one blow from a billet or a preformed parts. Diamensional accurancy surface quality ,special shapes ,thin wall sized  parts can be shaped with vertical forging machines. Forming are made to size the workpiece with min machening allowance. It reduced mechanical stress and stress corrosion of some metals. 

The die materials need max tougness for forging, and high wear resistance for extrusion parts. Toughness and extrusions needs are extremly satisfaied with Tungsten Carbide family. The dies with mass production need carbide for productivty and diamentional accuarancy. Thats why we recomend Carbide grades for cold forming G40/G50/G55/G6O and for cold extrusion G30/G40 The grain size of the carbide material is playing an important position in cold forging . you need to be carefull abouth grain size for your needs otherwise its difficult to achive the goals.

Lubricants act as parting agets between the workpiece and the forging die. It also provide insulating film layer on the die surface that reduces heat transfer between billet and die. Die life incresed lessed by the thermal craks. TKO Tooling established in 2010 and now a day supporting 50 customers for more than 150 finished cold forming  Dizayn , Simulation, Tooling and production consaltant in Fastener, Aerospace and Military Industries with 18 year experience . We accept our customer complex parts drawings  and we dizayn them according to their machine.Our services is; 
1. Dizayn of cold forming parts acc.  to your preses .
2. FMEA Simulation study with Simulfact program.
3. Production consaltunt for Fastener Co. Like lean manufacturing , Supply chain managenent  

Date : 08.11.2018