WINTER 2024

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168 THE DISTRIBUTOR’S LINK LAURENCE CLAUS HOW FASTENERS ARE MADE - PART 1: COLD HEADING from page 140 ¤ The surface is coated with top performing surface lubrication to prevent parts from galling in the tool that might prematurely destroy or render it inoperable. ¤ Dimensional variability has been reduced to a minimum. Cut-off The first operation in the cold heading machine is to cut off a piece of the continuous raw material wire or rod (See Figure 4). This is accomplished with a cutting knife that shears through the material. The more flat and square this sheared cut-off surface is the higher quality the final part will be. Since the surface is sheared it will be subject to some degree of irregularity. The more irregular the starting surface, the more likely that the point end will display cupping and irregularity. When working with small cut-offs such as those generated to form a nut, the surface is often drooping on one end or exhibiting severe irregularity and the first step or two in the process is to square up the cut-off (See Figure 5). Upsetting Heads are formed by upsetting, the first of the forming mechanisms possible in cold heading. Upsetting is essentially aggregating material from a smaller diameter to a larger diameter. On fasteners it is the way that we form heads, flanges, and collars. As with all the cold heading processes there are limitations on how much material can be moved with a single blow of the machine. Therefore, the upset feature on most parts is formed by striking the part more than once. Even the most basic cold forming process strikes the part twice and, thus, industry veterans often refer to these steps as the “first upset blow” and the “final upset blow” (See Figure 6). FIGURE 6: EXAMPLE OF ONE-DIE TWO-BLOW PART- MIDDLE PART IS FIRST UPSET BLOW AND RIGHTMOST PART IS FINAL UPSET BLOW FIGURE 4: EXAMPLE OF WIRE CUT-OFF (IRREGULAR SHEARED FACE) FIGURE 5: FIRST FEW PROGRESSIONS OF FLANGE NUT- LEFTMOST IMAGE IS CUT-OFF AND PROGRESSIONS TO RIGHT ARE STARTING TO SQUARE-OFF THE CUT-OFF Extrusion The second forming mechanism is extrusion. Extrusion is the movement of material in either a forward or reverse direction. There are three distinctly different extrusion processes that can be employed. An Open Extrusion is a forward extrusion process and results in going from a larger diameter to a smaller diameter (See Figure 7). In an Open Extrusion the portion of the tool where the extrusion is taking place is usually near the front of the tool. As such, the part is not entirely confined in either the punch or die and too much pushing pressure would likely buckle it. CONTINUED ON PAGE 176
INTERNATIONAL FASTENER EXPO MANDALAY BAY, LAS VEGAS, NV - OCTOBER 10-11, 2023 CONTINUED ON PAGE 171
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In the Winter 2024 issue of 6 DISTR
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WINTER 2024

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