Custom Cold Forging

Custom Cold Forging is a manufacturing process involving the shaping of metal using localized compressive forces.

Of all structural metals and alloys, the aluminum alloys are the most readily forged to precise intricate shapes. There are a number of reasons for this: aluminum alloys are ductile; they can be forged with dies heated essentially to the same temperatures as the workpiece; they do not develop scale during heating; and they require lower forging pressures.

Cold forging takes advantage of the plasticity of metals at room temperature to shape them. Before this processing method was applied, metals were mainly finished by cutting. But cutting materials down from the start is time consuming and produces a large amount of shavings. That is why so much interest is being shown in cold forging, because this technique makes processing times shorter and does not produce shavings.

The forging process has few limitations to forming shapes and complex fin designs. A forged part is formed in two dimensions within the tool to create complex shapes without the need for secondary operations. Holes, chamfers, pins, elliptical fins, steps, etc. are created in the tool in a single operation.

Processes are flexible. Parts can be hit multiple times while staying in one die, or transferred from die to die to progressively form various geometries.

Baknor’s consistency is excellent because each part is made in the same die. Material is used at almost 100% efficiency. There is no scrap as found in machining. Because of the high productivity, the efficiency of material use, and the use of precise dies, cold headed and cold formed parts have significant cost and quality advantages.

The range of possible shapes is rather broad, including heads, threads, steps, knurls, chamfers, grooves, undercuts, and tapers.

Radius on cold formed edge.

Cold formed metal has natural radii on most corners and undercuts. This is a natural result of the material flow as it fills the die under the very high pressures used in cold forming. The resulting freedom from burrs and sharp edges, along with the increased tensile strength, can result in improved toughness and fatigue performance.

Quality Control

We can create a control plan and inspection frequency that suits your needs. We can even do 100% inspection if that’s what the application require

Materials that can be formed include, but are not limited to:

Alloy steels, Aluminum, Brass, Bronze, Carbon steels,

Copper, Lead, Nickel Alloys, Precious Metals, Stainless steels.

Cost Advantages

Cold forming results in the most efficient material utilization, especially important when manufacturing precious metal parts.
Cold forging of precision parts is a high speed efficient process. This makes it a very attractive alternative to screw machining or conventional machining.
Production speeds are 50 to 400 parts per minute, compared to 1 or 2 parts per minute in screw machining.
Material waste is close to zero, while in screw machining, material waste can be 70% or more.
As a result of the high production rates and yield, forging part prices are typically only 40-60% of machined part prices. If the material is very expensive, such as precious metals like gold, platinum, silver, and palladium, cold forming results in significant cost advantages.
Tooling cost is very reasonable. The most expensive tool sets, for multi-station headers, are typically only a few thousand dollars.

Technical Advantages

For metals that are very difficult to machine due to their poor chip-breaking tendencies, forging is often the best alternative. Examples include nickel, gold, pure copper, tantalum, palladium, and others.

Many metals benefit from the cold work imparted during this process. This results in strain hardening of the material and improved strength.

Take Advantage Of Baknor’s Custom Metal Fabrication.

Being globally cost competitive in the thermal management product area has also allowed us

to help customers consolidate their vendor base for custom metal fabrication.

This also includes various finishes even when cosmetics are critical.

Of If You Require Help In Dissipating Heat From Your Design

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Custom Cold Forging

Custom Cold Forging

Custom Cold Forging Advantages