Cold-Formed Headed Stud Production for Higher Strength Shanks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing headed studs through cold forming are inefficient in enhancing the strength properties of the studs in a structurally simple and cost-effective manner.
Innovation Solution
A method involving pre-drawing and multiple drawing steps followed by pre-upsetting and final upsetting to form a head stud, with specific deformation ratios to enhance strength properties, and optionally incorporating an aluminum ball for improved weldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cold forming with single upset is used, then manufacturing process is simple, but strength properties of headed stud are insufficient
Solution Approach 1:
The manufacturing process is segmented into multiple distinct steps: pre-drawing to reduce diameter, cutting to separate wire sections, and finish-upset to form the head. This segmentation allows each step to be optimized independently, with the pre-drawing step creating a refined grain structure that enhances strength properties in the final product.
Solution Approach 2:
The pre-drawing step is performed as a preliminary action before the final upset operation. This preliminary reduction of diameter creates a refined material structure and eliminates defects that would otherwise compromise strength, thereby enabling the subsequent upset to produce a headed stud with superior mechanical properties.
2Productivity
If wire section is cut and conveyed to another tool, then head section can be fully upset, but manufacturing efficiency decreases
Solution Approach 1:
The method merges the pre-drawing and cutting operations into a single integrated process step. The pre-drawn wire is cut to length, and the head is formed in one upset operation, eliminating the need to convey wire sections between multiple tools. This integration streamlines the manufacturing flow and improves productivity.
3Manufacturing precision
If pre-drawing is performed to predetermined diameter, then shank portion is pre-formed, but additional processing steps are required
Solution Approach 1:
Pre-drawing is performed as a preliminary action to reduce the wire diameter to a predetermined size and pre-form the shank portion with improved grain structure. This preliminary processing enhances manufacturing precision by creating a refined base material before the final upset operation, while the integrated process design minimizes the addition of complex equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in headed studs with increased strength properties and improved weldability, maintaining or enhancing structural integrity and performance.
Implementation Method 1
the head bolt is formed from a wire portion by cold forming and the head portion is produced by upsetting
Implementation Method 2
a wire having a predetermined starting diameter is reduced by means of a pre-drawing machine to a predetermined pre-drawing diameter in order to pre-form the shank portion
Data Source
AI summary
The invention relates to a method for producing a head stud having a shank portion and a head portion by cold forming, wherein a wire having a predetermined starting diameter is reduced by means of a pre-drawing machine to a predetermined pre-drawing diameter in order to pre-form the shank portion of the head stud, wherein a wire portion cut from the pre-drawn wire is finish-upset at a longitudinal end in order to form the head portion of the head stud, and wherein after pre-drawing and before finish-upsetting, the pre-drawn wire portion is reduced by drawing to a predetermined diameter in order to form the shank portion of the head stud.