Cold Formed Specials
Complex Shapes
Semblex specializes in complex shapes and designs. No two applications may be alike and may require a functioning “special” to fulfill the demanding requirements.
Machine Capabilities
Multi-die heading capabilities range from 2 dies 3 blow headers for miniature screws up to 6 die 6 blow for large diameter products.
Drilling
In-House drilling supports a wide variety of parts and industries: From brake assemblies, vented fasteners, to specialized applications with critical requirements.
Screw Machine Conversions
Significant cost savings through scrap reduction (as material is moved not removed)
Improved product strength with cold forming process
Tight tolerances can be achieved
Parts Consolidation
Combines multi-piece components into one piece designs
Eliminates part numbers to be managed
Simplifies assembly process and reduces cycle time
Net Shapes Equal Net Savings
The Cold Forming Process
Cold Forming is the process of forming metal at ambient temperature to produce 'Net' or 'Near Net' Shapes resulting in material cost savings, increased production rates and consistent quality parts. Cold Forming produces shapes by the movement or shaping of material versus the removal of material so virtually no material is wasted. Because the shape is produced by manipulating volume the grain flow follows the part configuration which provides a higher resistance to fatigue and fractures resulting in a stronger part. The ever expanding Cold Forming Technology allows for increasingly complex configurations produced at very high rates thus reducing costs and improving design flexibility.
Adding Value to the Process with Secondary Operations
The Cold Forming Process can provide a wide range of 'Net' Shapes, allowing for optimum savings to the product and the assembly. When additional features or precision tolerances are required, the Cold Forming Process can complement the secondary processes to meet application requirements. This combination of processes provides high-quality, value-added products and enhanced performance.
Benefits
Cost
- Less material required
- Increased production rates
- Ability to form 'near net' shaped parts
- Potential part consolidations
- Stronger overall product
- Reduced scrap rates
- High-speed process
Quality
- Increased product strength
- Improved surface finish (up to 63 micro inches)
- Uninterrupted grain flow
Design
- Unique shapes and geometry are possible
- Non-symmetrical shapes and features can
- be created
- Large head-to-shank configurations
- Parts can be formed complete or near-complete, reducing process steps
- Tight tolerances can be maintained
- Allows for multi-piece assemblies to be made as a single-piece
Candidates
Large features relative to the shank or body of the part
Multiple sections or diameters
High production quantities
Material cost is a significant portion of the part's total cost
Applications with high dynamic loads
Designs that require complex shapes or extrusions
Tight tolerances and positional requirements
High surface finish requirements
Success Story
Application: Motorcycle Suspension Bolt
Opportunity:
- Material cost reduction using a process conversion while creating a stronger part.
Process:
- The original screw machine process required the use of bar stock the size of the largest diameter, which resulted in a large amount of material loss. Semblex could use less material cold forming the part while using a simple shaving operation to finish the angle and meet print requirements.
Benefits:
- 50% less material required.
- Higher production rates through the cold-forming process.
- Improved strength of part through work hardening and improved grain flow.
Assemblies
Discover cost reduction opportunities by working with Semblex and our partners to combine Cold Formed Specialty Components, fasteners, plastics, stampings, and other items into simple , complete assemblies.
Benefits Include:
Part consolidation
Vendor reduction
Outsourcing of simple components
Inventory reduction
Labor savings
Capabilities
Carbon Steel:
- Provides good formability, lower cost, good functionality, some hardenability
1010, 1018, 10B21, 1022, 1524
Medium Carbon Steel:
- Offers high strength, provides good formability, good hardenability
10B30, 1035, 1038, 1045, 1541
Alloy Steel:
- Offers high strength, good formability, increased hardenability
4037, 4140, 8640, 8740, B16
Stainless Steel:
- Provides improved corrosion resistance, improved strength through work hardening, resistance to exposure to elevated temperatures
302, 304, 305, 316, 410, 430, A286
Aluminum:
- Offers improved corrosion protection, weight reduction, and excellent formability. Some grades have hardenability
2024, 5056, 6061, 7075
Other:
Copper, Brass, Bronze
- Offers additional benefits for soldering and conductivity requirements while providing good formability
CDA 101, CDA 102, CDA 110, CDA220, CDA230, CDA260, CDA270, CDA651 (Silicon Bronze), CDA510/CDA521 (Phosphor Bronze)
Team Approach
At Semblex, Cold Formed Specialty Components are an important means to meet our customer's needs and exceed their expectations. We accomplish this not only with our equipment but with our team-driven approach. This approach starts with our team working with our customer to understand their needs and the application requirements. Our team's experience and process knowledge allow us to evaluate requirements and ensure the most stable, cost-effective processes are used. During this activity, we identify opportunities for cost savings and improve the product's performance. This lets us connect our customers' needs with the best, most cost-effective processes.
Data Sheet(s)
What is Cold Heading you ask? Discover...
The Cold Hard Facts of Cold Heading (722 KB)
