Cold formed Specials
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Engineered Fastening Cold Formed Specials

Unsurpassed Expertise Advancing technology has been the cornerstone of our success for over 50 years. When Camcar developed the Raycarl® process, it was considered the most significant breakthrough in cold forming technology in over 100 years. Today, we continue to lead the industry though continuing research and investment in new technology, unsurpassed expertise and strict attention to detail. STANLEY Engineered Fastening manufactures the high-quality, costefficient components your applications demand. ­Quality • Improved strength and reliability through work hardening and an...

Cold Forming Processes & Capabilities Dies and Punches Cold forming uses forces greater than a metal‘s elastic limit to form shapes without causing scrap material. extrusion punch First the material, in wire form, is drawn into the header, and is cut off at the desired length. Next, a series of engineered dies and punches are used to form shapes by upsetting or extruding the cut-off. One Die, Two-Blow Process The two-blow cold forming process allows upsets and extrusions to be achieved on the same component. The first blow provides the rough shape, while the second blow forms the final...

Cold Forming Processes & Capabilities Multiple-Die Forming Through multiple-die forming, the final shape is achieved in stages. Multiple-die headers have more dies and punches on each machine to allow for: • increased areas of reduction • forming unique shapes such as multiple diameters on one component • large head to shank ratios • possible elimination of secondary operations such as drilling, turning and trimming Current technology includes off line set-up, computer-controlled tool loading, and trimming capabilities within the header. Multiple-Die Progression Through multiple-die...

Candidates for Cold Forming Any one of the following criteria make a part a strong candidate for cold forming: Round or concentric extrusions, for shafts or threading; multiple diameters are possible • Large head to shank ratio • Part is longer than 1-1/2 times its largest diameter • Part has multiple diameters • High production quantities needed • Raw material is a large portion of part‘s total cost • Part has fine surface finish requirements • Strength, hardness and ductility must meet certain requirements • Part requires a geometrical shape, a drive system or an extrusion External...

Cold Formed Equipment & Capabilities Materials Heat Treat Through continual development and modification of manufacturing techniques, STANLEY Engineered Fastening can cold form many unusual materials. This allows easy conversion from screw machining and other manufacturing methods. Several types of heat treatment are available to meet desired hardness, strength, and ductility characteristics, including: • Through hardening: entire part is hardened and tempered to desired strength level • Case hardening: surface hardness is raised to a level higher than the core hardness and the material the...

Cold Forming Equipment & Capabilities Secondary Operations Precision Machining Cold forming allows products to be manufactured to net or near net shape. STANLEY Engineered Fastening also offers a full line of precision secondary operations to meet more specific requirements. STANLEY Engineered Fastening has a wide array of equipment that allows multiple secondary operations with extremely tight tolerances to be performed. A single machine can perform up to 12 operations per part, including turning, grooving and drilling. Capabilities Include: Utilizing this precision equipment can be less...

From Screw Machining To Cold Forming Our wide array of cold forming processes allow even the most complex screw machined components to be converted to cold formed components. There are many reasons to switch: Cold forming provides stronger and more reliable parts. The cold forming process causes the raw material to work harden as it conforms to the desired shape, providing an uninterrupted grain flow that follows the contour of the part. • provides improved yield and ultimate tensile strength • provides greater fatigue strength, especially at critically-stressed corners Although these...

From Screw Machining To Cold Forming Cold forming can reduce scrap by 80% and more. Screw machining only removes material, so it requires bar stock to be as large as the largest diameter of the finished component, resulting in excessive scrap. Cold forming moves material, so the original wire stock can be significantly smaller. • requires less material • generates minimal scrap • minimizes scrap handling and removal costs This is especially important with expensive raw materials. The cold formed cut-off (right) is often significantly smaller than the screw machined blank (left) required to...

Success With Cold Formed Components Material Capabilities Fulfill Requirements Application: Airbag mount assembly Component: Attachment pin Original process considered: Die-casting Needs/Problems: During prototyping, it was determined that the die-cast material could not meet the mechanical performance requirements of the application. STANLEY Engineered Fastening Solution: Cold forming 10B21 material, followed by secondary machining Customer Benefits: • Provides a strong, reliable component Reduced Material Costs Application: Automotive brake assembly Component: Piston rod Original process...

Success With Cold Formed Components Internal Rolled Threads Provide High Precision Fit Application: Motorcycle wheel assembly Component: Internally-threaded fastener for attachment of wheel spokes to tire rim Original process used: Cold formed part with cut-tapped hole Needs/Problems: Cut-tapped hole could not meet automation requirements STANLEY Engineered Fastening Solution: Cold formed blank with squared end, TORX PLUS® Drive recess, and hole. Internal threads were rolled instead of cut. Customer Benefits: • Increased thread quality • Decreased assembly line rework due to threading...