Cold Forging? Cold Forming? Or Cold Heading?
Cold forging is a manufacturing method that involves producing components such as pinions, gears, bushings, and, specifically in the automotive market, ball joints, stem ends, inner/outer sleeves, silent-blocks and transmission parts, all of them obtained from wire rod materials. It’s a highly versatile and efficient process, offering numerous benefits, including significant cost savings and reduced environmental impact.
However, despite these advantages, the technology faces a surprising challenge: it doesn’t have a universally agreed-upon name. Through this article, we will speak about how companies across the globe debate whether to refer to it as Cold forging, Cold forming, or Cold heading, and which is the role that Ecenarro S.Coop plays in this art.
A Technology With Multiple Names
Different companies and regions have adopted various names for this technology. For example, some manufacturers use Cold Heading to distinguish the process from Cold Stamping, which involves sheet metal deformation. Others alternate between Cold Forging and Cold Forming, depending on their industry or location.
At Ecenarro S.Coop., we have embraced the term Cold Forming to describe not only our core technology but all the industrial processes that are developed in both our sites, Spain and Mexico. You can check them all and surf our multiple technical threads on the Ecenarro Web.
In the United States, for example, the term Cold Heading is common due to its British origins, while in Canada, on the other hand, Cold Forging is more prevalent. Across much of Europe, where this technology was born, Cold Forging tends to be the favored term. The confusion is akin to the scenario described in Dewey Bunnell’s classic song, “A Horse with No Name,” which explores a quest for clarity in a chaotic world. Perhaps we, too, are navigating a similarly ambiguous landscape with “a technology with no name.” Manufacturers often resort to using all three terms interchangeably on their websites to ensure that they are understood by a global audience.
What Do Experts Say? Cold Forming, cold forging or cold heading?
In technical and scientific circles, Cold Forming is the most widely accepted umbrella term for all processes that involve the plastic deformation of metals at room temperature. This encompasses a wide range of techniques, including forging, stamping, foiling, drawing, and rolling.
However, the term cold heading has a long history, particularly in the fastener industry. Companies producing bolts and screws frequently perform an operation called “upsetting,” where the wire rod is compressed to create a larger projected area, such as a screw head. Over time, this operation became so closely associated with the industry that “cold heading” became a widely used name for the entire process.
To establish a more standardized terminology, one of the most credible authorities in this field is the International Cold Forging Group (ICFG). As described on their website, they define cold forging as follows: “Cold forging is a common industrial process in which metal workpieces are plastically shaped by suitably contoured dies to form a final desired shape. The process itself is a predominantly compressive one in which the workpiece is squeezed between the dies. Cold forging is an important process being used in many industries, for example the automotive industry in which a huge annual tonnage of cold forged components are used.”
Ecenarro: Innovating in Cold Forging Through Cooperation
With over 60 years of experience, we specialize in manufacturing high-performance components using this sustainable and cost-effective process. Our expertise extends to integrating additional secondary cold forming operations, such as wire drawing and thread rolling, under the comprehensive Cold Forming umbrella. We also incorporate complementary processes like washing, machining, grinding, and automatised sorting to ensure precision and quality at every stage.
At Ecenarro S.Coop., as part of Mondragon Corporation, the world’s largest Co-op, we are guided by deeply rooted cooperative values that prioritize collaboration through cooperation. We cultivate long-term partnerships with our employees, suppliers, and clients, recognizing that trust and teamwork are the foundation of sustained success. Innovation and continuous improvement thrive within this cooperative framework, driven by the collective expertise and dedication of all stakeholders.
Our commitment to sustainability is inseparable from these cooperative principles. We prioritize energy efficiency, waste reduction, and the use of environmentally friendly materials, integrating these priorities across every stage of our operations. By aligning environmental stewardship with economic performance, we not only deliver cost-effective solutions for our clients but also contribute to a shared mission of reducing our environmental footprint and fostering a more sustainable future.
You can get more detailed information about all these topics on the Ecenarro Web, the Ecenarro Blog, or you can subscribe to our Youtube and LinkedIn channels, or to the Newsletter, which we strongly recommend if you want to get the most fresh and recent news regarding the Cold Forming, Cold Forging or Cold Heading process, in the automotive and all other mobility related sectors. There you will receive information related to tools, materials, products, markets and, of course, technology. As an example, here are the top 5 benefits of Cold Forging process:
Top 5 Benefits of Wire Rod Cold Forging
Regardless of the terminology, wire rod cold forging has earned its place as a cornerstone technology in modern manufacturing. Its advantages include:
- Cost Efficiency.
- Improved Mechanical Properties.
- Energy Savings.
- Enhanced Precision and Consistency.
- Environmental Benefits
Regional Variations and Industry Trends
As mentioned earlier, regional preferences play a significant role in the naming conventions for Cold Forging technology. In North America, industries with British roots, such as fastener manufacturing, continue to favor Cold Heading. Meanwhile, in Europe, where diverse manufacturing sectors have adopted the technology, Cold Forging is often seen as the most comprehensive term.
Industry specialization also influences terminology. For example, automotive manufacturers may prefer Cold Forging to emphasize the compressive nature of the process, while other sectors might lean toward Cold Forming to highlight the broader range of metal deformation techniques involved.
But the name is not THE challenge
While the debate over terminology persists, the real challenge lies in mastering the complexities of cold forging technology itself. This process involves highly sophisticated engineering and requires a deep understanding of material science, die design, and metal behavior under compressive forces.
Studies have demonstrated that optimizing the cold forging process requires precise control of various parameters, including material selection, friction, lubrication, and tool geometry. Material behaviour during deformation is influenced by factors such as strain rate and temperature rise due to internal friction, even in supposedly “cold” conditions. For instance, research has shown that localized heating can occur during high-speed forging operations, which alter the properties of the tools if not properly managed.
In summary, while agreeing on a universal name for cold forging may be desirable, the true focus should remain on overcoming the technological challenges that define the process. Only through continuous research and innovation can companies fully unlock the potential of cold forging for high-performance, sustainable manufacturing.
As part of our ongoing mission to educate and support our partners, Ecenarro S.Coop is continuosly updating a section on our website dedicated to blog entries that delve into the art and science of cold forming. These articles will offer in-depth guidance on designing products specifically for this technology, covering essential considerations such as material grades, geometric tolerances, and process optimization.
We understand that designing for cold forming requires careful planning, and our blog will also showcase how Ecenarro can provide expert consultation to guide you through every step of the process. Whether you’re exploring the potential of cold forming for the first time or looking to refine your designs, our resources aim to support your success with practical advice and proven insights.
If you need more information, please contact us through our website, LinkedIn, Youtube or Newsletter.
A Look to the Future
As global manufacturing evolves, the need for clear and consistent terminology in cold forging technology remains essential. Organizations like the ICFG are working to promote standard definitions, which can help industries and researchers communicate more effectively across borders. At the same time, companies like Ecenarro S.Coop. continue to innovate, pushing the boundaries of what cold forging can achieve.
Our hope is that, in time, the industry will converge on a single, widely recognized name for this technology. Until then, we will continue to champion the term Cold Forming Developed by a Cooperative Company — a testament to both our expertise and our cooperative values.
If you’re interested in discovering how Ecenarro S.Coop. can benefit your business, we invite you to explore our website and contact us for more information. Whether you’re in the automotive, aerospace, machinery, or other sectors, we are ready to help you harness the power of cold forging to drive your success.