Cold Headed Conversions

Cold Headed Conversions

Let us help convert your costly machined components to reap the benefits of high volume efficiencies of cold formed/cold heading processes. Cold Headed Conversions are currently machined components converted to cold formed components yielding the highest possible savings for your products.

Examples of parts that are very good candidates for cold headed conversions are: Contacts, pins, shafts, collared studs, parts in brasssteel and aluminum. -Even your tight tolerance machined parts can be achieved with or without secondary operations.

Advantages of Cold Heading/ Cold Forming

  • Improved product performance. Cold heading rearranges the grain structure increasing shear strength performance.
  • Can provide substantial material savings due to reduced scrap.
  • Achieves savings due to higher speed processes.

Case Study

We converted 2 separately machined and then assembled parts into a single cold formed part resulting in savings to our customer of 45%, Abbott is a solutions-oriented manufacturing company and so we specialize in providing value-added technical support that improves quality and significantly reduces costs.

These are factors that helped this particular project become a success. Featuring a threaded stud with multiple diameters and a large cloverleaf shaped head; this part was previously a two-piece assembly consisting of separate screw machined parts that were press fit together in a secondary assembly process. Utilizing the latest cold heading technology, we built a single-piece part, stronger, more resistant to wear, and far less expensive than the original.

The cold heading process was carried out on high-speed automated equipment that transforms wire or rod into a near net-shaped part with repeatable tolerances. Constructed from steel, we used high-speed, multi-blow cold heading machine and a series of dies and punches to form the desired geometry. We transferred the parts to a CNC machine to secondarily machine to achieve a tolerance of ±0.001 on the head diameter and reduce the shafts for thread rolling.

During cold heading material is bent, allowing axial grain flow to follow the geometry of the part and strengthen the metal through cold working. When compared to a more conventional screw machining process, this cold heading process approach takes advantage of the natural strength profile of the material, as opposed to cutting through the grain which weakens it. Furthermore, the cold heading approach produces no chips or waste, the only scrap comes from material removal during the light secondary machining. Substantially less waste of material occurs compared to the large amount of scrap losses of screw machining which contributed to the big savings.

When completed, the part featured overall dimensions of 0.810" in diameter x 1-5/16" in length and a RoHS compliant zinc finish. These photographs illustrate the "before" and "after" as well as the progression of this large-headed part with multiple diameters. By initiating a quality and cost analysis for converting this component to cold heading, we delivered a better product at a dramatically lower cost. If you are interested in discovering which of your parts can be converted to cold heading, please contact us for a consultation.

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