Multi-step cold forming by EJOT®
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More economic efficiency – more flexibility – more options with EJOFORM®The increasing demands on modern manufacturing facilities, regarding process capability, product quality and economic efficiency can only be met by exact coordination between the respective production processes. Every additional production step extends the processing time and thus increases costs especially for storage. For this reason the fastening technology industry demands innovative and reliable fasteners, which offer multiple benefits compared to conventional screws. |
EJOFORM® products, produced by EJOT in a multi-step cold forming process, meet these various demands in an optimal way. With this technology and up to six forming steps, a section of wire is formed to a complex fastening element, e.g. brackets, stop bolts, distance bush or adjusting element. EJOFORM® parts are more than just the mechanical connection of multiple components. They are the result of engineering which is consequently geared towards the specific application and a technology superior to a metal-cutting process.
Since the forming process is usually not material separating, but instead done by a plastic shaping of the raw material, a rethinking in regards to the component details is necessary. The high forces and speeds of the forming process require details of the various versions of edges, radii or the inside processing of components compared to the metal-cutting process. The special laws of cold forming always require an overall consideration of the dimensions and tolerances, with knowledge of the corresponding forming steps and methods.
Especially during the early phase of the component design the success of the product as well as the complexity of the production is defined. For this reason an early involvement of the EJOT engineers offers excellent possibilities to fully utilise the various cost saving potentials.
The eco-friendly character of the cold-massive forming offers additional benefits, especially compared to the metal-cutting process. Important criteria to reduce costs are, amongst others, a decisively higher output of the heading machines compared to ordinary turning / milling processes as well as much lower raw material and tool wear and tear costs. Even material cost savings of up to 80% - depending on the product design - are realistic.
For the cold-massive forming process one-time tool costs have to be considered. The specially designed tools are necessary because the high forces which occur during the forming have to be transmitted. These costs amortise very quickly though with adequate production volumes. The long lifetime of the forming tools therefore causes a much flatter increase of the cost curve compared to alternative production methods (see fig. 1).
Compared to metal-cutting or die-casting processes the user of EJOFORM® products gets a custom-made collection of various functions:
- 100% coordination to the application
- Simplification of the assembly
- Reduction of material and inventory cost
- Multiple use
