This is a metalworking process that reshapes metal material into a specified form using a die for plastic deformation.

Heading is a metalworking process that reshapes metal material into a specified form using a die for plastic deformation. Which is commonly used in producing general screws compliant with the JIS standard. And heading is analogous to forging. Heading at regular temperatures is called cold heading while heading via the heating of metal is called hot heading. Kofuseibyo adopts cold heading. Coiled wire is used in the heading process. The wire is inserted into a die and pressed with a punch to perform the upsetting, forward extrusion, and backward extrusion process.

The expressions 1 Die 2 Blow and 2 Die 3 Blow are found in our website. The terms refer to the capability of headers, which means how many die shapes the header uses. A 1 Die 2 Blow header inserts workpiece into one die shape and strikes it with two different punches. A 2 Die 3 Blow header inserts workpiece into two die shapes and strikes it with three different punches. There are 5 Die 5 Blow and 8 Die 8 Blow headers capable of using many die shapes. The complexity of the parts being made rises with the number of die shapes, but so does the production cost. Heading machinery is commonly referred to as the header or parts former. There is no definite difference between the names, but parts former appears to be used more for heading machinery that can use many die shapes.

The rolling process reshapes blanks in dies via plastic deformation by spinning them within the dies.

The rolling process reshapes blanks in dies via plastic deformation by spinning them within dies. This process is used to production screw products. Parts are not always created through rolling alone. Blanks formed through other processes (cold heading in the case of Kofuseibyo) are also used in secondary processes. Examples include the screw thread, groove, knurling, and rounded end. There are a few different rolling methods, but the process used at Kofuseibyo involves flat dies method.

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  Screw Thread

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  Rounded End

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  Knurling (Diamond Pattern)

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  Knurling (Straight Pattern)

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  Groove

Here is the heading process using general cross recessed head screws.

1. 

   1. The wire is inserted into the heading machine.

2. 

   2. The wire is cut inside the machine.

3. 

   3. The pre-forming process is performed.

4. 

   4. The finish-forming process is performed. (A cross recess is formed in the head of a workpiece with the this strike to bring the headed blank to finished form)

5. 

   5. The screw thread is shaped through the rolling process.

Advantages

*Appropriate for mass production as a high processing speed allows for superior productivity.
*Possible to produce in large volumes using fewer machines.
*Almost no material is wasted as it is not cutting and therefore very little scrappage is created.
*Parts can be produced more cheaply than through other methods by aligning their specifications and requested amounts with the conditions and advantages of the process.
*The product is strengthened through work hardening (strengthening of metal by plastic deformation) and the absence of fiber material (fiber flow) cutting.

Disadvantages

*Must use of die entails initial costs and time for trial production.
*Machine setup and adjustments are time-consuming because headers are not computer numerically-controlled.
*All processes, from materials to aftertreatment, are designed for mass production, which is disadvantageous for small batch production.
*Physical limits to how materials can be reshaped by processing restrict shape and dimensional accuracy.
Heading parts similar to those shaped by the CNC lathe cutting process. The two processes can be compared on the following items.

We are flexible in response to customer demands.

We are flexible in response to customer demands, and an order volume will also vary with parts size. The empirical data shows that parts are desirably ordered by tens of thousands per month as a guide, to capitalize on the strengths of the heading process. However, we are adaptable to high-mix low-volume production and still happy to prepare parts to customer needs even if an order is below the guide. If your monthly consumption of parts is low, orders can be placed in bulk allowing a single production volume to be high for an alternative. Please feel free to contact us for details.

We most commonly use a steel for cold Heading called SWCH (Steel Wire Cold Heading).

We most commonly use a steel for cold heading called SWCH (Steel Wire Cold Heading). Depending on customer specifications, we may also use other materials including stainless steel for corrosion resistance, copper or brass for conductivity, or aluminum for lightness.