The traditional machining of parts requires the use of a lathe to form the parts out of a large block of metal material. While this time-tested process can produce the desired result, it does come with certain disadvantages. For example, machining generates a high volume of waste material, which makes it inefficient and less cost-effective. The machining process also tends to be slow, which can make it difficult to keep up with a demanding production schedule.
Many manufacturers are discovering the benefits of cold forming vs. machining in terms of increased efficiency and reduced costs. Cold-forming manufacturing entails the use of specialized equipment that forms the metal parts via a precise combination of high speed and high pressure. The cold-forming process enables the much faster production of smaller parts, while also resulting in much less material waste than machining.
What Are the Advantages of Cold Forming over Traditional Machining?
Cold forming can result in savings of as much as 50 to 100 percent when compared to traditional machining. Other important benefits include increased hardness and tensile strength, improved reproducibility and interchangeability, and the ability to handle higher stress and die loads. Additionally, cold-formed parts are less susceptible to contamination than machine components, which can result in higher overall quality. Lastly, cold forming is more economical than traditional machining – meaning, we can produce hundreds of high-quality components at a fast pace that is not possible with machining. This makes the most of your time and dollar investments.
What Are The Different Types of Cold Forming?
The various types of cold forming techniques include:
- Forward extrusion: The most common cold-forming method, forward extrusion involves punching the metal through a hole in the die to create a smaller cross-section in the slug.
- Backward extrusion: Similar to forward extrusion, with the difference being that the metal is punched backward around the press’s punching mechanism to create a cup shape or blind hole.
- Combined extrusion: Can implement forward and backward extrusion simultaneously during forging.
- Upsetting: Forces the metal outward from the die to create a diameter that is larger than the starting diameter of the metal blank.
The Use of Secondary Machining During Cold-Form Manufacturing
Cold forming and machining do not have to be mutually exclusive processes. There are a number of secondary machining techniques that can be implemented in conjunction with cold forming to enhance its effectiveness. Examples include shot peening for further surface cleaning and deburring, abrasion blasting to remove surface contaminants, immersion washing for enhanced cleaning and e-coating for additional surface protection.
STS Intelli Offers Innovative Micro Cold-Forming Services
As one of the top cold-forging companies in the industry, STS Intelli offers a wide range of high-quality micro cold-forming services that can offer a cost-effective alternative to traditional machining. We also offer a variety of secondary machining processes that can provide the perfect complement to our cold forming solutions. We implement the latest cold forming technology to deliver the high-quality results that will exceed your expectations.
Contact us to learn more about the benefits of cold forming vs. machining and how cold-forming manufacturing can help you lower your production costs. We’ll also be happy to provide a no-obligation micro cold-forming services quote.