Interplex Solution Cold Forging

Precision Cold Forged Progressive Stamping

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

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

Forging – Material “Thickening” to 2x raw material thickness

Cross Sectional View

Precision Cold Forged Progressive Stamping

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

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

Application : Power Tool

Material : S65C

Old Process : Sintering & Machining

New Process : Cold Forged Stamping

Precision Cold Forged Progressive Stamping

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

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

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

Application : HDD Disc Clamp

Material : A6061(铝镁合金）

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

Vertical & HorizontalCold Forging

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

Horizontal Forging

Vertical Forging

Vertical & Horizontal Cold Forging

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

Vertical & Horizontal Cold Forging

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

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

Vertical & Horizontal Cold Forging

Vertical & Horizontal Cold Forging

Progression Example for Cold Forging Process

Vertical & Horizontal Cold Forging

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

Simulation

Process

Forming Tools

Laser WeldingStamping Blank

2 Pieces Pinion Gear design for Safety Seat Belt

Combination of Stamping + Forming + Piercing + Laser Weld

Sample Products for Cold Forging

Sample Products for Cold Forging

Cold forged components for Automotive application

Sample Products for Cold Forging

Thank You

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