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Cold Forging: Types, Uses, Process and Benefits

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Introduction

This article takes an in depth look at cold forging.

This article covers topics such as:

  • What cold forging is and how it works
  • Cold forging benefits & disadvantages
  • Hot forging vs. cold forging
  • The metals and equipment/machines used
  • Cold forging applications
  • And more...
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Chapter One – What is Cold Forging and How Does It Work?

Cold forging is a metal forming process in which bar stock is inserted into a die and compressed into another enclosed die at ambient temperatures or below the metal's austenite threshold.

This method is remarkably efficient and cost-effective for mass production of components. Cold forging can be classified into procedures like cold, warm, and hot forging, employing tools such as hammers, dies, or presses to shape and deform metal. It differs significantly from machining and casting by producing stronger and higher quality products.

Unlike warm or hot forging, cold forging shapes metal at room temperature by applying localized compressive forces. To achieve the desired outcome, the metal may be subjected to multiple dies or repeated strikes, depending on the part's design complexity.

Cold Forging Process

Chapter Two – How Cold Forging Works?

Cold forging, a crucial manufacturing method in the metal forming industry, offers substantial cost savings and efficiency improvements for mass production of metal parts. This innovative process dramatically reduces labor needs and eliminates many secondary machining steps, minimizing waste and streamlining the production workflow. Advanced cold forging techniques enable manufacturers to produce components at high speeds—often exceeding 1,000 units per hour—which significantly lowers the cost per piece for OEMs and suppliers. By leveraging sophisticated cold heading and press technology, metal coils are automatically fed into high-precision cold forging machines, resulting in efficient throughput and superior quality assurance.

The end products manufactured using cold forging technology demonstrate outstanding surface finish and enhanced dimensional accuracy, as clearly illustrated in the image below. With optimized grain structure and minimal material loss, parts produced through cold forging exhibit superior mechanical properties—including increased tensile strength, wear resistance, and longevity—making them ideal for critical automotive, aerospace, electronics, and construction applications. The range of available cold forging processes enables production of durable, corrosion-resistant, and reliable fasteners, shafts, gears, and complex custom components, meeting diverse user requirements and industry standards.

The Cold Forging Process

Step 1: Lubricant

Before the cold forming process initiates, the workpiece—often a steel or aluminum billet or wire—is typically coated with an anti-sticking lubricant. This step is essential for two main reasons: it prevents galling and adhesion between the metal and die, and it reduces tool wear during high-pressure deformation. Lubricants also facilitate smoother material flow and help to control frictional heat generated during the process, which can reach temperatures between 250°C to 450°C—though still below the recrystallization point of most ferrous and non-ferrous metals. The type and application of forging lubricants vary by manufacturer, with some using advanced phosphate or polymer coatings tailored for specific alloys or manufacturing requirements. While lubrication is a standard best practice, certain high-speed automated cold forging lines may utilize alternative die coatings or surface treatments to maximize throughput and tool life.

Forging Lubricants

Step 2: Feeding the Metal Coil

Next, the chosen metal coil or rod—often cold-drawn steel, copper, brass, or alloyed aluminum—is introduced into the forging machine, precisely positioned over a specially machined die cavity designed to form the intended part geometry. Most cold forging dies consist of two or more segments: a stationary die beneath the workpiece and a movable upper die attached to a hammer or press ram. This configuration enables precise control over part dimensions, surface texture, and internal structure. Automated coil feeding systems ensure consistent material supply and alignment, optimizing production consistency and minimizing setup time—a key consideration for customers seeking rapid turnarounds and high repeatability in custom component manufacturing.

Metal Piece Insertion

Step 3: The Stroke

The heart of the cold forging process is the controlled application of high compressive force through mechanical, hydraulic, or pneumatic means. State-of-the-art cold forging presses use a shaft or slide mechanism equipped with a precision hammer, which descends with immense power onto the workpiece—typically within a few milliseconds. This rapid deformation technique creates dense, uniform material structures while maintaining tight tolerances and repeatable dimensions. Some part geometries may require multiple progressive strokes or sequential dies (multi-stage cold forming) to achieve complex shapes, threaded features, or unique profiles without excess flash or unnecessary machining. The choice of stroke mechanism directly affects productivity, energy consumption, and finished part quality—relevant factors for manufacturers comparing cold forging vs. hot forging or CNC machining alternatives.

Upsetting Cold Forging Stroke

Flash

Step 4: Part Removal

Once the metal component is fully formed, efficient part removal becomes critical for maintaining workflow and avoiding production bottlenecks. In modern high-volume cold forging facilities, automated systems—such as conveyors, pick-and-place robots, or pneumatic ejectors—remove finished parts from the die without manual intervention, reducing costs, minimizing human error, and enabling seamless integration with downstream quality inspection or packaging lines. Automation ensures repeatability and traceability, key metrics for industries requiring strict adherence to ISO 9001 or IATF 16949 quality standards.

Part Removal

Step 5: After Shaping

Handling and post-processing requirements depend on part complexity and final specifications. Simple cold-forged parts—such as nuts, bolts, or washers—may be trimmed to remove minor excess material (flash) and sent directly to finishing or shipping. For more intricate components, additional die operations, secondary forming, precision punching, or rolling may be required to achieve tight tolerances, special grooves, threads, or other engineered features. Automated die transfer systems allow components to move swiftly between processing stations, maximizing output and reducing lead times. For large or heavy forgings, material handling equipment such as forklifts, hi-los, or overhead cranes transport components to their next destination. Throughout these processes, producers often perform real-time inspection and measurement, utilizing statistical process control (SPC) and non-destructive testing (NDT) to assure zero-defect quality essential for mission-critical industries.

When evaluating cold forging services, buyers should consider the manufacturer’s technological capabilities, equipment range (such as multi-station presses and progressive die systems), material expertise, available secondary operations (like heat treating, plating, or coatings), and compliance with industry standards. Comparing cold forging with alternative processes—such as hot forging, CNC machining, or metal stamping—helps clients select the best solution for their application, balancing factors like cost, part performance, production speed, and customization flexibility. Requesting samples, reviewing case studies, and visiting supplier facilities further ensures informed purchasing decisions and optimal supply chain reliability.

Leading Manufacturers and Suppliers

    Mouse Over Company Names to see their previews

    Chapter Three – What are the Benefits of Cold Forging?

    This chapter explores six key benefits of cold forging, a highly efficient and innovative metal forming process used extensively in manufacturing industries such as automotive, aerospace, electronics, and construction. Cold forging offers numerous advantages over traditional hot forging and machining methods, positioning it as a preferred choice for high-volume, precision-driven production.

    • Cost effective manufacturing
    • Faster production cycles
    • Environmentally friendly solutions
    • High production output and scalability
    • Wide choice of metals and alloys

    Below, you’ll find in-depth details on why cold forging is valued in modern manufacturing, comparisons with other metal forming processes, and how its specific benefits can translate to cost savings, higher quality, and sustainable production. Whether you are evaluating cold forging versus hot forging or considering the best technique for custom components, this section will help clarify how cold forging fulfills various user intents in sourcing or purchasing precision metal parts.

    Cost Effective Manufacturing:

    Cold forging is exceptionally cost efficient due to its elimination of high-temperature heating equipment, intricate tooling, and expensive extra finishing operations. By working metals at or near room temperature, the process saves substantial energy costs typically incurred by furnaces, induction heaters, or kilns required in hot forging. In fact, cold forging delivers up to a 70% reduction in raw material waste compared to machining techniques, supporting lean manufacturing principles and material yield optimization.

    Unlike many subtractive metalworking processes, cold forging uses near-net-shape forming, resulting in minimal scrap and achieving tight tolerances in the finished part immediately after processing. Only minor post-processing or deburring may be necessary, driving significant labor cost savings. As a result, cold forging provides excellent value for industries seeking volume production of bolts, fasteners, shafts, and custom precision components.

    Cost of Cold Forging

    Faster Production Cycles:

    Cold forging technology enables rapid, continuous production due to its streamlined workflow where raw material blanks are inserted directly into the automated forging press. Modern machinery and robotics have made it possible to fully automate feeding, forming, and ejection of finished parts, thereby reducing downtime, operator involvement, and cycle times.

    High-speed cold forging equipment can produce complex components within fractions of a second, dramatically increasing throughput for automotive, electronics, and consumer goods manufacturing. This efficiency makes cold forging an optimal solution for businesses requiring just-in-time (JIT) inventory, reliable supply chain fulfillment, and scalable mass production.

    Faster Production

    Eliminates Possible Negative Reactions:

    Traditional metalworking methods can introduce material defects such as porosity, fatigue, and grain boundary weaknesses due to thermal cycling or inconsistencies in heating. Cold forging addresses these issues by processing metals at ambient temperatures, greatly reducing the risk of unwanted metallurgical reactions. The result is a forged component with a dense, uniform grain structure that enhances both strength and fatigue resistance.

    While cold forging improves many mechanical properties and minimizes risks like micro-cracking, it is essential to note that the process may pose its own challenges, such as increased die wear for very hard materials or limitations for highly complex part geometries. Nonetheless, the process is widely adopted for critical safety components and high-tolerance parts due to its material integrity.

    Porous Structures

    Increased Quality and Long Service Life:

    Cold forged parts are known for their superior mechanical properties, such as higher tensile strength, improved fatigue resistance, and enhanced dimensional stability. The forging process strengthens the metal’s grain flow, resulting in parts that can endure high stress, heavy loads, and repeated cycling—even under extreme conditions. Unlike machined parts that may exhibit weak points at cut surfaces, cold forged products exhibit continuous, uninterrupted grain structure for maximum reliability and longevity.

    Custom Cold Forged Parts

    Retention of Precision Part Tolerances:

    Cold forging delivers consistent, repeatable, and tight tolerances throughout an entire production run, assuming proper die maintenance. This high degree of dimensional accuracy is critical for industries such as automotive, aerospace, and electronics that demand uniformity across large production batches. Every forged component emerges nearly identical to the prototype, making the process ideal for mass-producing precision fasteners, connectors, pins, and bearing components.

    Part Tolerances

    Design Freedom for Complex Components:

    Cold forging offers exceptional design flexibility for manufacturers and engineers. Advanced die technology enables the creation of intricate shapes, complex geometries, and customized contours—all in a single forming operation. This comparative design freedom reduces the need for costly secondary machining, drilling, or finishing steps, streamlining the manufacturing process and supporting faster product development cycles.

    More manufacturers are choosing cold forging for innovative applications, leveraging its capacity to produce parts with features such as undercuts, flanges, and threads, which may be challenging or impractical with other metalworking methods.

    Cold Forging Design

    High Production Output & Scalability:

    Cold forging enables manufacturers to achieve high production rates, often exceeding 50 pieces per minute and, with optimized automation, up to 400-450 pieces per hour. The actual output may be influenced by factors such as part complexity, material hardness, and die design. This high throughput makes cold forging a strategic choice for OEMs, fastener manufacturers, and suppliers seeking scalable solutions and rapid fulfillment of bulk orders.

    Cold Forging Output

    Wide Choice of Metals and Alloys:

    Cold forging is compatible with a broad spectrum of metals, allowing manufacturers to tailor parts for specific mechanical properties, corrosion resistance, and performance. Commonly cold forged metals include carbon steel, alloy steel, and stainless steel for high-strength industrial applications, as well as softer metals like aluminum, brass, and copper for electrical and decorative uses. Material selection is based on required specifications, end-use applications, and cost considerations, making cold forging extremely versatile.

    Variety of Cold Forged Bolts in Various Metals

    This image showcases a diverse array of cold forged bolts made from copper, brass, aluminum, and steel. Each material is chosen to match application-specific needs such as tensile strength, electrical conductivity, or corrosion resistance. By offering broad material compatibility, cold forging is an optimal process for industries seeking durable, reliable components with tailored physical and mechanical properties.

    In summary, cold forging stands out for its cost efficiency, speed, environmental benefits, and capacity to deliver consistently high-quality metal parts for diverse manufacturing requirements. Whether comparing cold forging vs. hot forging or evaluating the best production method for your application, understanding these benefits is essential for making informed sourcing and purchasing decisions.

    Chapter Four – What are the differences between hot forging and cold forging?

    The primary distinction between hot forging and cold forging lies in temperature: cold forging deforms metals at room temperature, creating strain and stress, whereas hot forging involves heating the metals before shaping them.

    Hot vs Cold Forging

    The critical factor in the temperature range is the austenite stage. Cold forging occurs below this stage, while hot forging involves heating the metal to temperatures beyond the austenite phase.

    Choosing cold forging vs hot forging depends on:

    • A fabricators equipment and machining: Producers specialize in one process or the other to maximize the use of their equipment.

      Hot Forging

      Cold Forging

    • Customer demand: During the design phase of part development, engineers make the decision regarding the best process to produce their designs since cold and hot forging have their limitations.
    • Types of part produced: Many times the restrictions regarding the choosing of the right process is determined by the design of the part since specific parts can only be hot forged while others are perfect for cold forging. The designs of cold forged parts are simple without intricate details while hot forging can produce pieces with extremely precise small minute features.

      Cold Forged Parts

    • Lower cost requirement: Whenever possible, manufacturers choose cold forging since it requires less equipment and does not including heating, which significantly lowers the overall cost of production.

    Hot forging

    Hot Forging Furnace

    Hot forging is conducted at very high temperatures, which helps prevent strain and hardening while reducing the stress flow and energy required to shape and deform metals. After cooling, the metals retain their new shape. The forming process typically involves hydraulic, pneumatic, or mechanical presses.

    Characteristics of hot forging:

    Dies or molds:

    One of the significant costs associated with hot forging is the production of dies and molds. These are made from high-strength steel designed to endure the extreme temperatures, resist fatigue, and possess the necessary ductility, toughness, and tensile strength.

    Hot Forging Die or Mold

    Forms of hot forging:

    While many hot forging techniques are similar to those used in cold forging, additional methods include gas forming, die quenching, draw forming, and isothermal forging.

    Gas Hot Forging

    Temperature of the metal:

    The process type determines the metal's temperature during shaping. In certain methods, the metal is fully melted and either poured into a mold or forced through a die. In other processes, the metal is annealed and then shaped under compression and pressure using a die or mold.

    Hot Forging Temperature

    Hazardous environmental factors:

    The primary drawback of the heating process in forging is the significant amount of pollutants generated, which varies depending on the type of furnace used. This issue has been a persistent challenge since the early days of the industrial revolution and continues to be a concern for manufacturers. The video below illustrates the volume of fumes produced.

    100 Ton Hot Forging Press

    Heating metals:

    To forge parts, metals must be heated beyond the austenite stage, which typically requires temperatures above 300°F and can reach into the thousands of degrees. Achieving these temperatures necessitates the use of large furnaces or kilns.

    Heated Metal

    Time involved:

    Hot forging involves a complex process that includes heating the metal, shaping it, and then cooling it. While the actual stamping, deforming, or shaping may take about the same time as cold forging, the heating and cooling phases require careful management and can extend the overall process duration.

    Results of hot forging:

    Heating and cooling metals enhance their strength, toughness, and ductility, though they can reduce hardness. During cooling, metals may warp or change shape, and these potential issues should be considered during the engineering phase.

    Scaling:

    Hot forging can result in oxidation, leading to scaling that discolors the metal's surface and complicates finishing processes.

    Scaling

    Cold forging

    The key difference between cold forging and hot forging lies in the temperature used. Hot forging involves heating the metal above its austenite stage, which alters its microstructure and eliminates internal stress, making it more ductile. In contrast, cold forging does not involve heating, allowing the metal to maintain its original strength and microstructure.

    The characteristics of cold forgings are as follows:

    Temperature of shaping:

    In cold forging, metals are shaped at room temperature, below their austenite stage. This approach reduces costs by eliminating the need for expensive furnaces and heating equipment.

    Temperature of Shaping

    Speed:

    Production speeds vary from seven pieces per minute for low-volume machines to up to 400 pieces per minute for high-volume systems.

    Equipment:

    Cold forging utilizes specialized machines that perform operations such as squeezing, bending, shearing, and drawing. The cost of this equipment varies widely based on its technology and size.

    Cold Forging Press

    Cost:

    Cost savings in cold forging are primarily due to material efficiency and production speed. Material savings arise from minimal scrap production, with reductions of up to 70%. Additionally, the rapid production rate significantly lowers the cost per unit.

    Environmental factors:

    This machine from Stalcop, shown below, operates with no emissions or pollutants. It is fully enclosed and self-contained, eliminating carbon and other pollutants since heating of the metal is not required.

    Cold Forge from Stalcop

    Results of cold forging:

    The diagram below illustrates how cold forging realigns the grain structure of metals to match the flow of the final part. This process reduces porosity fatigue, enhances shearing strength, and minimizes risks to material integrity. While the metal becomes stronger and more resilient through straining, it also loses ductility and becomes more brittle.

    Forging

    Forging True Grain Flow

    Scaling:

    Before forging, it is crucial to remove any scaling, such as rust or corrosion, that may have developed during storage. Failure to do so can result in the part exhibiting similar deterioration issues as seen in hot forging.

    Rusted Sheet Metal

    Finishing:

    Minimal finishing is needed with cold forging. Once a part is processed, it is ready for use or shipping with little to no additional work required.

    Cold Forged Steel Lugs

    Disadvantages of Cold Forging

    Cold forging is not without its drawbacks. As with any production method, it has its own limitations and constraints that should be considered before selecting it for your next project.

    • Only simple shapes and designs in high volumes can be produced. Unique, unusual, or intricate patterns cannot be cold forged. Deformation levels and shaping grades are limited, and cold forged metals have less ductility.

      Cold Forged Shapes

    • The alteration of the grain structure of a metal gives it extra strength but may produce residual stress.
    • Certain methods of cold forging require heat treatments to eliminate possible cracks or creep hardening.

      Heat Treatment

    • There is a limitation to the types of metals that can be cold forged. Ones with low ductility and sensitivity to strain hardening should not be chosen since they lose their ductility and will break under tensile stress. Only metals with a hardness of HRC 44 on the Rockwell scale can be used.

      Hardness Ratings

    • Production processes require a great deal of force to produce the necessary compressive force and pressure. Though the addition of hydraulics and pneumatics has decreased the size of the equipment, it has not eliminated the amount of power the machines consume.

      Cold Forging Press

    • Tools, dies, and molds have to be specially designed as well as sturdy and strong enough to be able to endure the constant repetitive force. The beating that cold forging tools endure requires that they be replaced frequently.

      Dies

    Chapter Five – What are the different processes involved in cold forging?

    Technological advancements and progress in metal processing have led to the creation of various cold metal shaping and forming techniques. While each method caters to specific needs, they are all optimized for efficient and rapid production, often eliminating the need for additional finishing steps.

    The eight most widely used cold forging methods include:

    • Bending
    • Cold rolling
    • Closed die
    • Drawing
    • Extrusion
    • Open die
    • Ring forging
    • Swaging

    While the following descriptions offer a foundational understanding of the various cold forging methods, it's important to note that other processes exist, which will be covered later in this chapter.

    Another crucial factor in cold forging is the type of lubricant used. Common choices include zinc phosphate or various polymer coatings. Despite being performed at room temperature, the bending and shaping actions can raise the metal's temperature. The right lubricant helps prevent errors, reduces the likelihood of the workpiece sticking to the die, and extends the lifespan of the tools.

    Forging Lubricants and Coatings

    Lubricant manufacturers offer a variety of products to fit each type of cold forging process. Pictured are graphite lubricants, but graphite free types are available as well as calcium aluminate, aluminum fluoride, and phosphate coatings.

    Common cold forging methods:

    Bending

    Bending involves using a press and die to force the workpiece against a shaping tool, a process also known as pyramid rolling. This method is sometimes employed to prepare a piece for subsequent cold forging processes. The workpiece is deformed along a single axis to achieve the desired angle.

    Cold Forge Bending

    Cold rolling

    Rolling is a forming process where metal is passed through a pair of rotating rollers for plastic deformation caused by compressive force. The compressive stresses produce friction between the rolls and the metal stock‘s surface. It is commonly used for the processing of steel.

    Bulk Deformation Processes

    Closed Die

    In closed die forging, the workpiece is shaped by successive mechanical blows after it has been placed between two die halves. Since the hammer strikes the workpiece multiple times, some producers refer to closed die forging as drop forging. As the metal is struck, it flows into the cavities of the die changing it to the shape of the die.

    Closed Die Process

    Drawing

    Drawing involves pulling the workpiece through a die using tensile force applied at the die's exit. This process reduces the cross-sectional area of the workpiece while increasing its length. The resulting metal components achieve tighter dimensional tolerances compared to those produced by rolling.

    Drawn Process

    Extrusion

    In cold extrusion, a billet or slug is pushed through a die under compressive force that shapes it into the profile of the final part. After extrusion, the piece is cut to the desired length and either prepared for shipment or sent for additional processing. The compressive force in cold extrusion can reach up to 20,000 kN (approximately 2007 tons), and the process can be performed in forward, backward, or both directions.

    Forward extrusion involves pushing the metal forward through the die.

    Forward Extrusion

    Backward extrusion involves pushing the metal into the die in reverse, creating holes or cups with a thicker bottom compared to the sides.

    Backward Extrusion

    Lateral extrusion applies force sideways, perpendicular to the extrusion direction, to add a secondary feature to the profile.

    Open Die:

    Open die forging uses two flat dies that lack a pre-cut profile. The workpiece is progressively shaped through multiple processes, allowing for a wide variety of shapes and sizes. This method is commonly used for large metal components that demand high structural integrity. Deformation is achieved by repositioning the workpiece throughout the process.

    Squeezing, or sizing, is a specific type of open die forging where force is applied over a short distance to achieve precise dimensional finishes.

    Open Die Process

    Ring forging

    Ring forging involves creating a circular workpiece with a central hole, resembling a donut shape. As the pierced piece is rotated, it is hammered and compressed. This process results in seamless rings with precise diameters and excellent strength.

    Ring Forming

    Swaging

    Swaging, also known as radial forging, involves deforming a workpiece to ensure that two parts fit together precisely. It is an automated and highly reliable process. There are two main types of swaging: tube swaging and radial swaging. Tube swaging resembles extrusion, where the workpiece is pushed through a die. Radial swaging, on the other hand, uses a hammer to press the workpiece through two or more dies.

    Swaging

    When searching for a cold forging manufacturer, you'll encounter more methods than the seven discussed here. Understanding these basic methods will enable you to engage knowledgeably with producers and interpret industry terminology effectively.

    As with any advanced production technique, cold forging continues to evolve with the development of new methods and technologies. Automation and robotics are increasingly significant factors, transforming the industry rapidly. Consulting a forging specialist can help you identify the process that best meets your requirements.

    Chapter Six – What types of equipment and machines are used in cold forging?

    Cold forging equipment is available in three main types: hydraulic, pneumatic, and mechanical. While some suppliers focus on just one variety, most offer a range of options based on price and operational needs. Modern machines often incorporate technology and automation, as illustrated by the servo cold forging press from Marvel Machinery shown below. Part designs are typically created using engineering software like CAD.

    There are requirements that machines must meet in order to be used for cold forging.

    • Force - Cold forging processes depend on a tremendous amount of force. The equipment connected with it must be capable of absorbing that force and dissipating it.
    • Balance - Machines have to be statically and dynamically mass balanced to reduce vibrations and enhance performance.
    • Endurance over time - Regardless of the method of cold forging, each requires powerful repeated force. For a machine to last, it has to be able to endure that force.
    • Multiple operations - Modern cold forging or forming machines, called headers, complete one to several operations during one process. This is necessary since there is a limited amount of deforming that can be performed with one stroke.

    Types of cold forging equipment:

    Hydraulic die forging hammer

    The hydraulic die forging hammer is engineered to deliver maximum force with minimal investment. It can create a diverse range of impressions using various dies. This hammer operates on hydraulic principles, where an incompressible liquid is housed in a cylinder. When the liquid is compressed by a piston, it drives a shaft with the die attached downward onto the workpiece.

    Electro Hydraulic Closed Die Forging Hammer

    Screw press

    The screw press is suited for large deformations due to its slow pressing speed. It is effective for flashless dies and long rod forgings. Its design accommodates single-slot dies for bending and final forging operations. An electric motor drives the screw, which presses the die onto the workpiece.

    Screw Press

    C Frame High Speed Press

    The C-frame design is ideal for forming, punching, bending, and multi-pressing applications. Available in single or double crank configurations, these presses offer punch forces ranging from 110 to 400 tons and slide strokes between 110 and 280 mm. They can accommodate die heights from 435 to 600 mm and are suitable for producing small parts.

    C Frame Double Crank Press

    Pneumatic power press

    The pneumatic-powered press is capable of handling all die pressing functions. It features a pneumatically operated friction clutch and brake. The press's power is generated by an air compressor, which uses air pressure in a cylinder with a piston to drive the forging hammer onto the workpiece.

    Pneumatic Power Press

    Mechanical cold press

    Among the various cold forging machines, mechanical presses are becoming less common due to their need for substantial size to generate the required force. They use a flywheel to store energy from a motor. When activated, the flywheel drives the hammer or ram onto the die. Although it can deliver power over multiple rotations, the press must pause to allow the motor to recharge the flywheel before resuming its cycles.

    Mechanical Press

    Among the various types of cold forging equipment, hydraulic and pneumatic presses are the most prevalent due to their compact size, adjustable force capabilities, and programmability. When evaluating production options, it's important to consider the types of equipment available from a producer, as modern and well-maintained equipment is more likely to yield higher-quality parts.

    Chapter Seven- Who are the leading manufacturers of cold forging machines?

    Numerous machines are available for cold forging, and they play a crucial role in modern industry. Cold forging allows for the cost-effective and efficient production of high-strength metal components used in sectors such as automotive, hand tools, and military hardware. Below, we highlight some prominent brands of cold forging machines used in the United States and Canada:

    Hatebur - Model: HF-series

    Hatebur's HF-series machines are renowned for their high-speed precision forging, advanced automation, and multi-station design. These features enable the efficient production of complex metal components with exceptional accuracy.

    Sakamura USA - Model: SACMA Cold Formers

    Sakamura USA provides SACMA Cold Formers, known for their versatility, precision, and high productivity in cold forging. These machines offer precise control over forging parameters and can produce a diverse range of components efficiently.

    National Machinery - Model: FORMAX Plus

    National Machinery's FORMAX Plus machines are distinguished by their advanced servo-driven technology, rapid tool change capabilities, and energy-efficient operation. These features enhance precision and productivity in cold forging applications, ensuring high-quality component manufacturing.

    Carlo Salvi - Model: CF-Series

    Carlo Salvi's CF-Series machines are renowned for their high-performance cold forging capabilities. They provide exceptional control over force and displacement, feature rapid tool change systems, and incorporate advanced monitoring and control technologies.

    Nakashimada Engineering Works - Model: NBF-series

    Nakashimada Engineering Works offers the NBF-series machines, which are celebrated for their sophisticated cold forging technology, accurate parameter control, and rapid production speeds. These attributes ensure both high efficiency and dependability in the manufacturing of components.

    Keep in mind that details such as specific models, features, or components may have changed since my last update. For the most current information on the latest cold forging machines and their capabilities in the United States and Canada, it’s best to check with the manufacturers or relevant industry resources.

    Chapter Eight– What are the different types of forged metals?

    Cold forging offers a wide array of choices when you are choosing a metal for a project. The different varieties include hard metals such as carbon steel, alloy steel, and stainless steel. Aluminum, brass, copper, silicon, and magnesium are soft metals that can be used. The one requirement for any metal is that it has a hardness of 44 HRC or lower on the Rockwell scale.

    Copper

    Copper is highly suitable for cold forging due to its excellent ductility and malleability. It can be easily shaped, bent, or stretched with minimal force, resulting in components that are resistant to corrosion and rust.

    Copper

    Aluminum

    Aluminum is a lightweight, non-ferrous metal with a low density. It melts at approximately 1220°F and is known for its malleability, as well as its resistance to rust and corrosion.

    Aluminum Sheets

    Carbon steel

    Carbon steel is an iron-carbon alloy, with its various grades determined by the carbon content. It is known for its outstanding strength and ductility.

    Carbon Steel

    Stainless steel

    Stainless steel is widely used for its corrosion resistance, aesthetic appeal, and strength. While the term "stainless steel" broadly refers to steel with these properties, it actually encompasses a range of grades, each defined by its specific alloy composition.

    Cold Rolled Stainless Steel

    Steels used for cold forging

    Low carbon steels with a carbon content of 0.1% to 0.25%. Cold forging improves strain hardening in steel removing the need for austenitization, quenching, or annealing.

    Steel Plates

    Metals Suitable for Cold Forging

    Data from website https://www.deringerney.com
    Suitable Alloy Cold Formability Characteristic
    Copper Excellent
    Gold, Silver and most of their Alloys Excellent
    Brass- Cartridge Brass Good
    Platinum, palladium, tantalum, and their alloys Most are cold formable.
    Titanium and its alloys Pure Ti and alloys with high ductility, yes, but alloys like 6-4 are only hot head able.
    Nickel and its alloys Pure Ni yes, alloys with room temperature elongation of 20% or more, yes.
    Iron and steels Pure iron, yes. Steels, depends on the steel. Many are cold formable.

    Considerations when choosing a metal:

    When selecting a metal for a project, thorough research is crucial. Different metals respond to plastic deformation and shaping in various ways. The chosen metal should meet the final use requirements and desired strength. Consulting with a forging expert can provide valuable insights to help you make an informed decision.

    Chapter Nine – What are the applications of cold forging?

    Cold forging is capable of producing components of various sizes with exceptional dimensional precision and structural accuracy. Its cost-effectiveness and rapid production speed have made it a preferred method in manufacturing.

    Cold forging meets the demands of modern industries because it:

    • Maximizes the use of raw materials: A key investment for any operation is raw materials, which is an essential and important element of cold forging and is carefully monitored.
    • Reduces costs: Since parts are rapidly produced, the cost per unit is very low making the final products more profitable and less expensive to produce.
    • Produces high quality parts: Cold forging increases the strength and durability of parts and products guaranteeing that they will last longer. The structure and characteristics of a shaped piece does not change providing excellent dimensional accuracy.

    Applications where cold forged parts are used:

    Automobiles

    Cold forging's exceptional strength, reliability, and cost-effectiveness make it highly appealing for the automotive industry. Cold forged components are used in high-stress areas due to their superior shock resistance. Parts such as drive trains, drive shafts, and struts or shocks benefit from this process. The diagram below illustrates various undercarriage components of a car that are manufactured through cold forging.

    Parts Cold Forged on a Car

    Hand Tools and Hardware

    Connectors like nails, bolts, rivets, and nuts have long been manufactured through cold forging. The process is favored by hand tool producers due to its ability to achieve tight tolerances and high dimensional accuracy, making it preferable to machining and other methods.

    Cold Forged Three Position Adjustable Pliers

    Military

    The military adheres to stringent specifications for hardware, often opting for cold forging in the production of shell casings, bullets, and other military equipment. This method ensures high reliability and performance under demanding conditions. The precise tolerances and strength of cold forged components make them ideal for military applications.

    Cold Forged Gun Barrel

    Gear Production

    Cold forging is used for gear production because it eliminates the need of cutting in gear shaping. Gears can be produced from billets that are less than 50 mm or shaped using coiled wire. Some annealing may be necessary to remove residual stress and work hardening. An important benefit of cold forged gears is how smoothly and quietly they intermesh.

    Cold Forged Gears

    Conclusion

    Progression of a Cold Forged Part

    • Cold forging produces metals with low tolerances and high dimensional accuracy at very low cost and high volumes.
    • Cold forging quickly and rapidly creates finished parts immediately available and complete.
    • Manufacturers will offer you a wide selection of processes to produce exactly and precisely the part you need using the most up to date and technically advanced equipment.
    • You will have a wide array of metals to select for the completion of your project from hardened steel and stainless steel to copper and aluminum.
    • You will find very few limitations to the number of products that you can have produced from stress withstanding components for your car to rivets, gears, and work tools.
    • When you compare cold and hot forging, you will find that cold forging takes less time and produces stronger and longer lasting parts and products.

    Leading Manufacturers and Suppliers

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      Table of Contents

      What is Cold Forging and How Does It Work?

      How Cold Forging Works

      The Benefits of Cold Forging

      Hot vs Cold Forging

      Cold Forging Processes

      Cold Forging Equipment and Machines

      Leading Manufacturers of Cold Forging Machines

      The Types of Forged Metals

      Cold Forging Applications

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