Jul. 21, 2025
Minerals & Metallurgy
The cold heading process usually forces a metal piece without wasting or removing any metal used. An easier way to understand the process is to think it has form moulding.
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However, in this case, the moulding is done with metal. The main reason bolt and fastener manufacturers use cold heading is that it minimizes the raw material waste from the process.
To create bolts and fasteners with the cold heading, the professionals need to use a specific machine and utilize it throughout the Process. The suitable machine for cold heading depends on the material used in manufacturing, as some machines may be more beneficial than others.
Moreover, the manufacturers must also consider the final type of fastener they wish to have by the end of the Process.
Cold heading, also called cold forming, is a step-by-step method for metal formation. With these metals, one can get net-shaped similar parts in their final designs. Slug, one of the most common products from cold heading, is created by cutting from a coil material that runs continuously.
Multiple mighty hammers and dies work within the cold heading process. This way, there’s little to no wastage from the Process, and the final products are much more pocket-friendlier than others. The best part is that with the cold heading, the final volume of the slug is pretty similar to the starting volume.
Because the Process uses a die, there’s a consistent design instead of cutting it down in parts from the blank. With the cold heading process, the final products are more robust, have smoother surfaces and have better graining surfaces at the end.
On the other hand, conventional methods like metal cutting are slower and can waste up to 60% of raw material in the manufacturing process.
Consequently, the cold heading is a better choice than machining, which is best for commercial production, and its efficiency remains accurate (up to +/- .002″ without any other operations).
Progression is a step-by-step process used in manufacturing that makes the final product more efficient. The Process begins with a slug, and the products become more and more accurate in the final look. It would help if you had more progression for specifically tailored fasteners than simple ones. The simpler fasteners may only require 1 or 2 blows from the machine.
However, the progression is not the same for each step. Each product type has a specified number of dies, punches and hammers. These designs focus on unique specifications, depending on the needs.
Moreover, the design progression also varies based on the raw materials used for the fastener production. For instance, softer metals, such as Copper, Aluminum, don’t require much processing. They are more accessible to mould and can be prepared quickly.
However, harder metals such as Stainless Steel or nickel alloys require more punches, dies and processing to get the right product from them.
Cold forming or cold heading processes are pretty simple in most cases. If we talk about the processes used in cold forming, extrusions and upsets are the two main approaches used in the process.
The main principle of these methods is to apply sufficient force on the metal sections, which requires various dies. Therefore, each process requires a specific number of hammering, processing, and hammering with specifically designed machines.
Upsets are the primary approach used in cold heading in today’s commercial manufacturing. In this process, the slug reduces height, and its starting diameter is more significant. With the upset technique, you can create a part’s head and assist with open tooling.
The choice between tooling options may vary based on the shape and location of the upsets. For example, the main parts of the upsets can have various diameters and designs. The manufacturers may also use multiple upsets with different designs throughout the setting.
Extrusion is the second most common method used in cold forming. The cold heading process has two different sub-categories based on their final design. Let’s discuss this.
The material is run through a more minor diameter system in the forward extrusions, increasing its length. In this approach, the raw material may be in the tooling ultimately or to some extent.
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There’s a penetrating punch or a pin in backward extrusions through which the metal flows. The metal may need to be in a die or punch insert throughout this step. With the backward extrusion, professionals may typically create a hole or opening into the metal.
Cold Heading is a popular method used in industrial manufacturing. It is mainly used for creating screws, bolts and fasteners. However, cold heading provides a more persistent, innovative, and cost-effective alternative. It helps reduce raw material wastage and optimize the overall process.
There are two ways to make a bolt or screw out of a piece of round stock. First, there is screw machining, that cuts excess metal away from a piece of bar stock until what remains is the shape you want. These fasteners start out with a bar stock size equal to the largest diameter of the fastener being made. This process produces a fastener with scrap material left over. The second method, cold heading, forces a piece of wire stock into the desired shape without removing any metal. When finished, the fastener will be produced without wasted material.
Screw machined parts are made by lathes or CNC’s (computer, numerical controlled machines). Cold heading is done by a variety of cold heading machines. It involves moving metal through a series of dies to form the part to its desired shape.
Cold heading machines use a coil of wire and form the wire into desired parts at very high rates of speed allowing the cold-headed parts to be made very quickly and economically. The process begins by loading a large coil of wire in front of the cold heading machine. The wire is purchased in a condition called spherodized anneal. This special condition allows the material to be formed without cracking.
The wire is then pulled through a wire draw box to change the stock diameter to the specific diameter required to manufacture the fastener. Running the wire through a draw box makes the wire shape very round with a tolerance of .001. This is very important to holding size on the final parts after it is cold headed. A wire straightener can also be added which will align the wire prior to going into the cold heading machine. Straightening the wire is especially important on long parts.
After the wire has been successfully drawn to size, the wire enters the inside of the cold heading machine. The wire goes through a cut-off die and continues until it reaches a wire-stop. Once it reaches the wire stop, a cut-off knife moves across the wire, cutting it off to a specific length. This is referred to as the cut-off slug.
The slug is then placed in front of the heading die by the cut-off knife. Once the slug is in the proper position in front of the heading die, a series of punches are used to strike the part. This is how a cold-formed fastener is processed.
At Bossard, we use cold heading to cut down on waste material. We believe this is a better solution because it eliminates costs for our customers and improves overall productivity.
Cold Heading Terms:
Cut-off: A specific length of wire that is cut off from a coil of wire prior to going into the heading die.
Heading Die: A stationary piece of tooling that has the specific geometry for the part machined into its cavity used to form parts.
Punch: A piece of tooling that moves, striking the cut-off slug to upset material and push it into the heading die.
Knockout Pin: (used for two purposes)
Diameter of Upset: The amount of material that can be upset to form a head of a fastener. A length of wire equal to its diameter. The term “1 diameter of upset” only moves a small amount of material to form the head of a fastener. The term “4 ½ diameters of upset” involves moving a lot of material to form the head of a fastener. The larger the diameter of upset – the larger the head diameter can be made.
Upsetting: Striking an object on its end causing the existing diameter to increase in size.
Extrusion: Forcing into a die causing the diameter to become smaller
Grain Flow: The grain flow of the existing material is either interrupted (as in machining) or uninterrupted (as in cold heading). A part that has an interrupted grain flow is weaker than a part with uninterrupted grain flow. Cold-formed parts are stronger because the internal grain structure follows the contour of the part.
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