Cold Forging | Precision Cold Forged Progressive Stamping

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  • Interplex Solution Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • What is the Concept?

    COLD FORGING Ironing / Upsetting Extrusion / Trimming

    CONVENTIONAL STAMPING Blanking / Drawing / Forming Piercing / Bending

    PRECISION COLD FORGED STAMPINGBlanking/ Drawing/ Forming / Piercing / Bending

    Ironing / Upsetting /Extrusion / Trimming

    3D PARTS

    Machine Part to Cold Forge Part

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • 3-D forming capability

    Precision Forming of 1) Flatness/Parallelism2) Sharp edges3) Corners4) Material Thickness: 2.0 3.6 mm

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Forging Material Thickening to 2x raw material thickness

    Cross Sectional View

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Merits:

    High quality 3D parts produced

    High efficiency

    High accuracy & repeatability in parts replacements

    Longer tool life

    3-D precision cold-forging

    OPU

    VCM for HDD

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Earphone part

    Die casting Cold Forging Stamping

    Material: SPCC

    Operation: (Progressive Die)

    a. Cutting b. Upsetting c. Trimming d. Cut off

    Process innovation:

    Utilizing cold forging instead of die-casting, we realized:

    a. Improved Production efficiency

    b. Improved strength

    Upsetting

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Application : Power Tool

    Material : S65C

    Old Process : Sintering & Machining

    New Process : Cold Forged Stamping

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Gear Detail

    Electric Tool

    Sintering Cold Forging Stamping

    Material: S65C

    Operation: (Progressive Die)

    a. Cutting b. Upsetting c. Trimming d. Drawing

    Process innovation:

    Utilizing cold forging instead of sintering, we realized:

    a. Improved Part Strength

    b. Reduction in cost of > 60%

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Application : Motor

    Material : SPCC

    Old Process : Sintering

    New Process : Cold Forged Stamping

    Merit : Improve production efficiency

    : Improved strength Section Detail

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Disc Clamp for HDD

    Fine Blanking Cold Forging Stamping

    Material: A1050

    Operation: (Progressive Die)

    a. Cutting b. Upsetting c. Forming

    d. Trimming e. Cut off

    Process innovation:

    Utilizing cold forging instead of fine blanking, we realized:

    a. Improved Part Strength

    b. Shorter lead time for Mass Production

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Application : HDD Disc Clamp

    Material : A6061(

    Old Process : Assembly by two parts

    New Process : Cold Forged Stamping plus minimum machining

    Main Merit : Improve production efficiency & Reduce the cost

    Precision Cold Forged Progressive Stamping

    http://www.interplex.com/http://www.interplex.com/

  • Vertical & HorizontalCold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Stamping

    Cold Forging Production

    Machining / Thread Roll

    Heat-treatment

    Plating

    Final Assembly

    Simulation / DFM

    Full

    Prod

    uctio

    n / Q

    A/ S

    ale

    & M

    arke

    ting

    / R&D

    Set

    up

    Typical manufacturing processes for Cold Forged components

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Horizontal Forging

    Vertical Forging

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • 1. High Mass Production Speed (SPM 80-400)

    2. Net / Near net shape to eliminate or reduce secondary operations

    3. Consistency / dimensional accuracy

    4. Quality / surface finish

    5. Low Material wastage & Elimination of scrap

    6. Improvement in mechanical properties, greater strength to weight ratio, unbroken grain flow.

    Benefits of Cold Forging

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Cold Forging Process Simulation

    SIMULATION RESULT(DFM / PROGRESSION)

    UG NX2 Delta-Mesh

    DEFORM 3DTM

    FORGE 2D TM

    PAM-STAMP

    MATERIAL

    STAMPING & COLD

    FORGING

    FRICTION

    PRESS

    http://www.interplex.com/http://www.interplex.com/

  • Progression Example--- Engine ComponentsCombination use of Horizontal Forming + Vertical Forming

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Progression Example for Cold Forging Process

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Step 3 Step 4 Step 8 Step 9(Machining to complete

    the part 5% on Diameter)

    An

    nea

    l &

    Bon

    der

    izin

    g

    An

    nea

    l &

    Bon

    der

    izin

    g

    An

    nea

    l &

    Bon

    der

    izin

    gStep 6Step 1

    (Hollow Blank)

    Anneal &Bonderizing

    Step 31st Pre-Forge

    Step 4Cut Out Outside

    FlangeAnneal &

    Bonderizing

    Step 6Forge Internal

    GearAnneal &

    Bonderizing

    Step 8Forge External GearEnd of Cold Forge

    Step 1 Blanking

    Step 9Machining

    One piece Pinion Gear design forSafety Seat Belt.

    Old Process Full MachiningNew Process Forging + Min. Machining

    Vertical & Horizontal Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Simulation

    Process

    Forming Tools

    Laser WeldingStamping Blank

    2 Pieces Pinion Gear design for Safety Seat Belt

    Combination of Stamping + Forming + Piercing + Laser Weld

    http://www.interplex.com/http://www.interplex.com/

  • Sample Products for Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Sample Products for Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Cold forged components for Automotive application

    Sample Products for Cold Forging

    http://www.interplex.com/http://www.interplex.com/

  • Thank You

    http://www.interplex.com/cold-forging

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    Slide Number 1Precision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingPrecision Cold Forged Progressive StampingVertical & HorizontalCold ForgingVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingCold Forging Process SimulationVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingVertical & Horizontal Cold ForgingCombination of Stamping + Forming + Piercing + Laser WeldSample Products for Cold ForgingSample Products for Cold ForgingSample Products for Cold ForgingThank Youhttp://www.interplex.com/cold-forging