Cold Forging External Processing

Cold forging is a general term for metal processing such as cold die forging, cold extrusion, and cold heading. Generally, forging without heating the blank is what’s referred to as cold forging. The higher the temperature, the softer the metal, and the better it will be formed. At room temperature, the difficulty of metal forming is greater due to hardness.
To fill the mold with cold metal extrusion flow and to obtain parts without cracks or missing corners, it is necessary to exert huge pressure on the workpiece. You need to exert great pressure on the press, mold, and materials to deform the billet. The test is far beyond hot forging. Generally speaking, pure cold forgings are mostly symmetrical, the structure is not too complicated, and the safety parts can withstand huge pressure.
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The cold forging process is a precision plastic forming technology with unparalleled advantages in cutting processing. Here are some of the main advantages:
First, the production efficiency is super high, which is several times or even dozens of times that of the cutting process. It does not require heating, saves energy, and does not require deoxidation.
Cold forging is a net forming/near forming process, close to the actual part shape. This means high material utilization, reduced amount of secondary processing, and the amount of waste processed. Some of the parts subjected to stress are large, and the machining efficiency is either low or Cutting and forming are difficult and costly, so it must be realized by cold forging.
Cold forgings have good consistency and good dimensional accuracy. The workpiece has high mechanical properties, good surface quality, greater strength-to-weight ratio, and continuous grain flow.

The material requirements are high, and the comprehensive requirements for cold forging are very high. Metals with too high carbon content (carbon content less than 0.5%) cannot be processed, and it is difficult to process complex parts.

Molds require high-strength and high-quality alloy steel, and both materials and processing costs are very high. The blank needs to be accurately cut, and the diameter tolerance and length tolerance must be small. Even if the volume tolerance is a little bit larger, it may damage the mold and shoot fragments to hurt people.

 Cold forging design, process design, and mold design Conditions such as manufacturing, billet material, billet lubrication, cold forging equipment, automation equipment, and post-processing must strictly abide by very strict standards. If any link is not in place, stable production cannot be achieved.

Cold forging force, forming speed, closing time, temperature management (cooling speed, mold preheating and temperature adjustment, material preheating, etc.), lubrication management (lubrication amount, lubrication time, the proportion of additives, etc.), elastic deformation of molds and forgings’ various factors, such as thermal expansion, affect the quality of the final forging, and should not be taken lightly.

The amount of deformation of cold forging is limited, and the weight of forgings is generally between a few grams to 5KG. Cold forging can produce all kinds of symmetrical precision forgings used in various types of engine oil pumps and automobile transmission systems. It can also produce gearbox systems, brake systems, hydraulic systems, engineering machinery, hardware products, lighting accessories, bicycle accessories, and electrical appliances.

Europe, the United States, and Japan have generally adopted cold precision forging processes to produce low-carbon steel, medium-carbon steel, aluminum alloy, and alloy steel parts. The shapes of cold-precision forgings are also diverse, such as gears, racks, synchronous ring gears, radiator, electromechanical shell, and many others.