The CRES fastener, just launched by Sussex Wire, has a threaded shank with an overall length of only 0.676in and a low profile 0.250in diameter oval head. What makes the product unusual is the incorporation of a reverse hex extrusion on the end of the shank opposite the head which is created completely by cold forming and thread rolling. The economy of cold forming coupled with the ability to create the hex socket without collapsing the reverse extrusion was achieved through innovative tool design by the company’s in-house engineering team, it is claimed.
The component is said to incorporate all of the benefits of cold forming, including high part throughput rates, significant cost economy, and 100% net shape, resulting in zero scrap or material waste. And in addition, the finished part is clean and burr-free after forming, thus eliminating expensive and time consuming secondary operations.
Sussex Wire says, however, that the product’s key advantage over a machined part is strength. Because of work hardening via cold forming and thread rolling, material hardness increased to 130,000 KSI from the original material tensile of 85,000 KSI, and the reverse hex was strengthened rather than weakened, as it would had it been machined, substantially improving integrity and durability, an important factor in mission critical applications such as aircraft and aerospace assemblies.
Sussex Wire utilises cold-forming and roll-forming technologies to shape metal wire and specialty alloys at room temperatures into highly engineered, precision, micro-miniature components faster and in a more cost-effective manner than traditional machining, stamping, metal injection moulding and casting methods can.
The Company claims to be one of a few in the world that can manufacturer miniature, precision, geometrically complex, cold forming of parts in quantities ranging from 10 million to over 1 billion per year.
