The CRES fastener has a threaded shank with an overall length of just 0.676 inch and a low profile 0.250 inch diameter oval head.
What is said to make the product unique 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 Sussex Wire’s in-house engineering team.
“The new part incorporates 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,” states Sussex Wire. “In addition, the finished part is clean and burr-free after forming, thus eliminating expensive and time consuming secondary operations.”
However, the major advantage compared to a part manufactured by machining 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.
