6-Station Automatic Cold Heading Machine for High-Strength Fasteners & Custom Parts

6-Station Automatic Cold Heading Machine for High-Strength Fasteners & Custom Parts

The 6-station automatic cold heading machine is a high-efficiency, automated specialized machine tool within the forging and pressing machinery family. The cold heading process and the automatic cold former are essential means for the fastener industry to mass-produce various bolts, screws, rivets, and nuts.

Thanks to the advanced nature of cold heading equipment and the inherent advantages of the cold heading process (material savings, high production rates, enhanced mechanical properties), this machine is widely applicable across many sectors of the national economy. It is capable of producing fasteners and custom non-standard parts for industries including:

• Aerospace & Aviation

• Shipbuilding & Marine Engineering

• General Machinery & Industrial Equipment

• Rail Transportation

• Automotive Manufacturing

• Motorcycles & Bicycles

• Sewing Machines & Appliances

• Construction & Building Materials

• Furniture & Light Industry

• Daily-use Goods

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1. Main processing capabilities and technical parameters of the equipment
1.1 KD625 specifications

Whether you need high-strength structural fasteners or complex near-net-shape cold-formed components, this 6-station cold header delivers consistent quality, tight tolerances, and high output efficiency.

2. Why 6 Stations?

Each station performs a specific deformation step. The 6‑station design offers an optimal balance between complexity and productivity:

• Fewer stations (3–4) limit the shape complexity and are suitable only for simple parts.

• More stations (7–8) increase tooling cost and setup complexity beyond what most standard & custom parts require.

With 6 stations, the machine can produce:

• Complex socket head cap screws

• Shoulder bolts and step screws

• Semi-tubular and solid rivets

• Flanged nuts and locknuts

• Automotive chassis bolts with underhead serrations

• Non‑standard custom parts: stepped shafts, pins, inserts, and special cold‑formed blanks for subsequent machining

3. Working Principle & Machine Structure

The machine operates on a horizontal transfer principle. A continuous coil of wire is fed into a straightener and then cut to precise length by a cut-off mechanism. The cut blank is transferred through six forming stations via a high‑precision transfer finger system.

Each station performs a dedicated operation:

All stations operate simultaneously in a cycle, allowing the machine to produce 60–150 finished parts per minute, depending on part size and complexity.

Key structural components:

• Heavy-duty cast iron frame – absorbs high impact loads with minimal vibration.

• High-precision main slide (ram) – guided by extra-long slideways for stable heading force.

• Eccentric or crank drive system – converts rotary motion to linear heading force.

• Transfer system – cam‑driven, servo‑controlled, or mechanical fingers with positional accuracy within ±0.1 mm.

• Wire straightener & feed mechanism – handles wire diameters from 3 mm to 24 mm (depending on model).

• Automatic lubrication system – ensures continuous oil supply to bearings, cams, and slideways.

• Safety clutch & overload protection – prevents tool and machine damage in case of jamming.

4. Key Technical Advantages

4.1 Material Savings (No Waste)
Unlike CNC machining (which generates chips), cold heading uses 95–100% of the incoming wire. For high‑volume production, material savings alone can pay back the machine cost within months.

4.2 Superior Mechanical Properties
Cold working work‑hardens the material. Fasteners produced by cold heading exhibit:

• Higher tensile and yield strength (20–30% higher than machined parts from same material)

• Denser grain flow following the part contour

• Excellent fatigue resistance and impact toughness

4.3 High Production Efficiency
A 6‑station cold header produces 30,000 to 80,000 parts per 8‑hour shift, significantly outperforming CNC lathes or hot forging presses per unit floor space.

4.4 Close Dimensional Tolerances
Typical tolerances:

• Diameter: ±0.05 mm

• Length: ±0.10 mm

• Concentricity: 0.1 mm TIR
  This often eliminates secondary machining operations.

4.5 Low Operating Costs

• No heating energy (cold process)

• Long tool life (carbide dies typically last 100,000–500,000 parts)

• Low skill requirement for operators (automatic cycle)

5. Product Types Produced on a 6-Station Cold Header

Standard parts:

• Hexagon head bolts (ISO 4014, DIN 931)

• Socket head cap screws (ISO 4762, DIN 912)

• Hexagon nuts (ISO 4032, DIN 934) – with piercing station

• Semi‑tubular rivets and solid rivets

• Machine screws and self‑tapping screws

Non‑standard & custom parts:

• Stepped pins and shafts for automotive transmissions

• Special inserts for plastic injection molding

• Flanged components with underhead serrations

• Hollow parts (via backward extrusion)

• Battery terminals and electrical contacts

• Bearing rollers and needle blanks

• Blind rivet bodies

• Pre‑formed blanks for cold thread rolling

6. Wide Industry Applications

Because of its versatility and efficiency, the 6‑station cold heading machine serves virtually every sector of modern industry:

7. Automation & Smart Features (Modern Configurations)

Today’s 6‑station cold heading machines can be equipped with:

• Servo-controlled transfer for faster changeover and higher positional accuracy

• In-process monitoring (force, part length, ejection detection)

• Chip-free operation (no coolant needed, dry forming possible)

• Quick-change tooling system – changeover in under 30 minutes

• Integration with thread rolling machines and parts counters for fully automated lines

8. Conclusion

The 6-station automatic cold heading machine is not merely a fastener maker—it is a versatile, high-speed metal forming platform capable of producing both standard fasteners and complex custom parts with zero material waste, superior strength, and low cost per part. From aerospace-grade titanium bolts to automotive chassis components and industrial rivets, this machine delivers consistent quality at mass-production volumes.

For manufacturers seeking to expand into custom cold-formed parts or upgrade from older 2‑die/3‑die machines, the 6‑station configuration offers the ideal balance between complexity, tooling cost, and output rate. With proper tooling design, it can replace multiple secondary operations (turning, drilling, milling) in a single, efficient cold heading cycle.