A single-die dual-stage bolt cold header is a precision industrial apparatus designed to fabricate threaded fasteners, such as screws and bolts, through room-temperature metal deformation. This technique eliminates thermal energy input, enhancing material integrity and production speed.
The operational sequence is outlined as follows:
1. Wire Preparation and Segmentation
A coiled metal wire (commonly carbon steel or non-ferrous alloys) undergoes straightening via rollers to remove residual curvature. A servo-controlled feeder then propels the wire to a shearing unit, where it is segmented into volumetrically calibrated cylindrical blanks.
2. Initial Compression Stage
The blank is positioned within a unified die chamber. A primary punch, actuated by a mechanical drive system with a crankshaft mechanism, applies axial compressive force to initiate partial shaping. This step defines foundational features like the fastener's head profile or shank diameter, with the die restricting radial material dispersion.
3. Secondary Forming Phase
A secondary punch, integrated into the tooling assembly, executes a subsequent high-pressure strike to finalize the geometry. Complex elements-thread precursors, chamfered edges, or undercuts-are imparted during this phase. The dual-stage approach enables intricate designs while maintaining tooling simplicity and dimensional stability.
4. Component Ejection
Post-forming, an automated ejector expels the finished workpiece from the die. The component is then routed to auxiliary operations (e.g., surface finishing or quality inspection).
Technical Benefits
● Cycle Optimization: Concurrent dual-strike actions maximize throughput.
● Dimensional Consistency: Single-die architecture minimizes tolerance stack-up.
● Resource Efficiency: Near-net-shape production reduces scrap generation.
● Enhanced Metallurgy: Strain hardening during cold working elevates tensile strength.
The bolt cold header is pivotal for high-volume output of compact-to-midsize fasteners with standardized or moderately intricate configurations. Its energy-efficient operation and reduced tooling complexity solidify its role in automated manufacturing ecosystems.
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