The Advantages of Cold Heading in Parts Manufacturing

Cold heading, or cold forming, is a manufacturing process that dates to more than 75 years ago, although it has evolved considerably over that time. Cold heading, as the resource describes, is a manufacturing method best suited for high volume production.

One of the most important advantages of cold heading is the virtual elimination of scrap. In traditional machining operations, scrap can run north of 60% – a significant cost consideration that can substantially reduce the manufacturer’s and customer’s profitability. For metals that are difficult or expensive to recycle or reuse, and in market conditions in which raw material prices are at their highest, elimination of scrap can make cold heading the only economically viable choice.

High Production Volumes and Speed

Cold heading is ideal for high volume production runs. The initial setup time and cost for cold heading tools and equipment is high compared to other methods like machining. However, once the cold heading system is set up, pieces can be produced extremely quickly in very high volumes. Parts are formed at rates from 20 to over 300 pieces per minute depending on their size and complexity. This makes cold heading the preferred choice for large production runs in the hundreds of thousands or millions of pieces.

Improved Part Characteristics

The cold working of the metal during cold heading makes parts that are typically 20 to 40% stronger than a comparable machined part. This is because the grain structure and density of the metal is improved through cold working. Cold headed parts also have a better surface finish and dimensional accuracy and consistency versus machining. These characteristics are very important for many critical application areas like automotive, aerospace, medical devices and more.

One of the most important advantages of cold heading is the virtual elimination of scrap. In traditional machining operations, scrap can run north of 60% – a significant cost consideration that can substantially reduce the manufacturer’s and customer’s profitability. For metals that are difficult or expensive to recycle or reuse, and in market conditions in which raw material prices are at their highest, elimination of scrap can make cold heading the only economically viable choice.

Machine Safety Inspections

Operating powerful cold header machines demands strict safety protocols and practices. Thorough training and regular evaluations are necessary for all operators to ensure they follow safe operating procedures. The machines, along with their tooling, safety guards, and accessories, must undergo regular Machine Safety Inspection by ST&L or another reputable firm, to guarantee proper and secure functionality. System operators and maintenance staff should conduct daily safety checks before initiating any production run. Additionally, cold heading systems need comprehensive quarterly or annual safety inspections performed by qualified technicians, following guidelines set by the manufacturer and regulatory safety agencies. Adhering strictly to machine safety inspections and protocols is crucial for ensuring operator safety and preventing costly equipment damage or downtime.

Environmental Advantages

The metal forming process of cold heading is much more environmentally friendly versus processes like machining and casting. It generates no heat, smoke or chemical pollutants. Lubricants are used but they are fully contained within the heading machine and no discharge into the environment occurs. And the virtual elimination of scrap metal greatly reduces energy demands and landfill waste inherent to other production methods. This small environmental footprint allows manufacturers to reduce their carbon impacts and helps them achieve sustainability goals.

Cold heading has evolved into a superior parts production method for high volumes and critical applications. Its advantages over alternate manufacturing approaches lead to lower costs, better performing components, increased safety and reduced environmental impact. As cold heading technology continues to advance, its use will only expand across more industries and applications.

The accompanying resource presents a good overview of the advantages and potential limitations of this process.

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