Improvement Solutions & Case Studies

For small screw first punches, we apply specially selected ultra fine grain carbide materials.

Due to high-frequency impact and concentrated stress during cold forging, conventional carbide materials often suffer from:

• Punch cracking

• Edge chipping

• Abnormal wear

• Unstable tool life

By using optimized ultra fine grain carbide grades, impact resistance and wear resistance can be significantly improved, increasing punch life up to 2 times longer than conventional materials.

Different metal materials generate different levels of material flow, friction, and impact stress during cold forging.

For example：

• Stainless Steel

• Titanium

• High Carbon Steel

Using the same carbide grade for all materials may lead to：

• Galling

• Wire scratching

• Localized cracking

• Head collapse

• Short tool life

Therefore, we apply specialized carbide grades according to different forming zones and material characteristics.

Including：

• High impact zones

• High wear zones

• High friction zones

• High material flow zones

This approach improves tooling stability and overall service life.

For medium and large special fasteners, large wire materials must be reduced into specified dimensions while preserving sufficient upper material volume for special head forming operations.

This forming zone commonly experiences：

• Extreme impact stress

• Severe wear concentration

• Unstable material flow

• Localized heat accumulation

• Tool cracking

This area is also one of the most difficult challenges in fastener die design.

We improve performance through：

• Reduction transition zone design

• Material flow control

• Carbide grade allocation

• Balanced impact and wear resistance design

This significantly improves material flow stability while reducing abnormal wear and premature cracking.

We are familiar with international fastener and tooling standards.

Customers do not need to provide complete engineering drawings. Simply providing：

• International standard

• Product specifications

• Application requirements

allows us to quickly provide：

• Forming evaluation

• Tooling recommendations

• Manufacturing feasibility

• Improvement solutions

This significantly reduces development time and communication costs.

With extensive experience supporting various fastener manufacturers and special application products, we also provide technical support and manufacturing consultation for special fasteners.

Especially for：

• High-mix low-volume fasteners

• High-quality construction fasteners

• Automotive special fasteners

• Medical device fasteners

• AI equipment & automation assembly screws

We can assist with：

• Forming feasibility evaluation

• Tooling and material recommendations

• Forming process optimization

• Special head design support

• Machine compatibility solutions

Helping customers reduce development risks while improving production stability and product quality.

Aisin Brake Screw Forming Improvement Case

The customer needed to manufacture special brake screws.

The original forming process required :

• 5 Die 5 Blow machine

However, the customer only had :

• 2 Die 3 Blow machine

Resulting in：

• Unable to accept orders

• Unable to mass produce

• Insufficient equipment capacity

Based on the customer’s existing equipment conditions, we redesigned：

• Forming sequence

• Material flow direction

• Reduction structure

• Blow configuration

• Tooling structure

We also optimized specialized carbide grades for different stress zones.

The customer successfully produced the product using the existing 2 Die 3 Blow machine without purchasing additional equipment.

Successfully solving：

• Equipment limitation issues

• Special head forming challenges

• Tool life problems

• Order acceptance limitations

This solution helped the customer achieve stable mass production and increase business opportunities.