MET 203

Manufacturing Processes I
Mechanical Engineering

Cold-Working Processes
Technology

Fall 2005 Wolfgang J. Sauer

 What you will learn in this lecture
• What are the advantages of cold-
working processes
• How cold heading/upsetting work
• The advantages of hydrostatic
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extrusion
• How to control fracture in
shearing operations
• How to achieve tooling cost
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reductions
• What are the limitations in wire
drawing
 Advantages
• Cold forming processes are generally used
to produce semi-finished goods.
• Strain hardening acts to increase the
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strength of the material, so cheaper,weaker

starting materials may be selected.
• By properly positioning the last anneal, a
final product can be produced with a
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specified amount of cold work.

• Surface finish and dimensional precision are
quite good.
 Cold-Working Processes
• Squeezing Processes
– Rolling
– Thread Rolling
– Forging
– Extrusion
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• Bending
• Shearing
– Simple Shearing
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– Piercing and Blanking

• Drawing and Sheet Metal Forming
– Wire Drawing
– Sheet Metal Drawing
Mechanical Engineering
Technology Cold Heading
 Cold Forging
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Cold forging can produce parts with minimal amount of scrap.

 Grain Flow in Cold Forging

This spark plug body was

cold forged. The section
shows the favorable grain
flow which increases part
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strength.
Dimensional accuracy is
good, so little or no
secondary machining is
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needed.
Mechanical Engineering
Technology Preform Steps in Cold Forging
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Production of Cold-Formed Bolts

Mechanical Engineering
Technology Hydrostatic Cold Extrusion
Mechanical Engineering
Technology Extrusion Profiles
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Video Credits: The video clip on this page was taken from the
SME Sampler DVD that accompanies our textbook.
Sheet Metal Forming
 Blanking & Piercing
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Simple blanking with a punch and die

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Video Credits: The video clip on this page was taken from the
SME Sampler DVD that accompanies our textbook.
Shearing Operations
Mechanical Engineering
Technology Shearing Operation
 Changing the State of Stress
Obtaining a smooth edge in
shearing by putting the metal
in localized compression and
a squeezing ejector.
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Stock skeleton after

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shearing, showing the

compressed indentation.
Mechanical Engineering
Technology Fine Blanking
Mechanical Engineering
Technology Components of Blanking Dies
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Die Set with Alignment Posts
Mechanical Engineering
Technology Self-contained Subpress Tooling
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Technology Compound Die
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Technology Progressive Blanking Die
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Technology Inclined Blanking Press
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Technology Mechanical Press Drives
 Wire Drawing
a) Principle of
operation
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b) Die design
 Wire Drawing – Die Design
a) Schematic process
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b) Draw bench
 Tube Drawing
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a) without mandrel b) stationary mandrel

c) Floating mandrel d) moving mandrel