coldforming

Cold forming is a group of metalworking processes in which a workpiece is shaped by plastic deformation at or near room temperature, rather than at high temperatures used in hot forming. Because the metal is not heated significantly, energy consumption can be lower, and components can exhibit improved surface finish and dimensional accuracy.

Common methods include cold heading or cold forging, which forms heads on fasteners; cold extrusion; cold drawing; cold rolling; stamping; bending and punching. In cold heading, a blank is upset or upset-formed in a die by high pressure to create heads or shapes with minimal machining. Cold extrusion forces material through a die opening to create hollow or complex profiles. Cold drawing reduces cross-section by pulling the material through a die; this is common in wire and tubing production. Cold rolling reduces thickness in sheet metal to achieve tight tolerances and a smooth surface; strain hardening increases strength. Stamping covers punching, blanking and forming operations. Bending and other forming operations create bends and shapes without significant heating.

Materials commonly used include ductile metals such as carbon steel, stainless steel, aluminum, copper, and brass. The main advantages of cold forming are higher strength from work hardening, improved surface finish, tighter tolerances, and lower energy usage since no furnace heating is required. Disadvantages include tool wear and higher tooling costs, risk of cracking if the metal is overly work-hardened, residual stresses, and limitations on the extent of deformation in one operation.

Applications span fasteners, automotive components, plumbing fittings, electrical hardware, and household hardware.