COLD FORMING TROUBLE SHOOTING GUIDE |
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| Problem Area | Problem / Possible Cause or Solution |
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Wire Slippage / Short Feed • Feed Roll Pressure (Not Enough / Too Much) • Quill / Cutter ID Too Small • Quill / Cutter Misaligned • Quill Land Too Long • Wrong Or Worn Wire Grooves • Too Much Oil On Wire • Kinks Or Gouges In Wire • Coil Too Large Or Tangled Wraps • Wire Coating Packed In Quill Area • Power Feed Rolls Still Clamped Wire Distortion / Scratching • Too Much Feed Roll Pressure • Wire Coil Not Centered To Machine • Wire Straightener Improperly Adjusted |
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Wire Slippage / Short Feed • Feed Grip Pressure (Not Enough / Too Much) • Quill / Cutter ID Too Small • Quill / Cutter Misaligned • Quill Land Too Long • Worn Feed Grips • Too Much Oil On Wire • Kinks Or Gouges In Wire • Coil Too Large Or Tangled Wraps • Wire Coating Packed In Quill Area • Cutter Lever Not Returned To Down Position Wire Distortion / Scratching • Too Much Feed Grip Pressure • Wire Coil Not Centered To Machine • Wire Straightener Improperly Adjusted |
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Short Cutoff / Short Feed / Inconsistent Length • Wire Slipping - See Feed Problems • Inconsistent Wire Diameter Distorted Cutoff • L/D (Length To Diameter) Ratio Too Small • Too Much Cutter To Quill Clearance • Quill / Cutter ID Too Large • Wrong Stock Gage Tip (When Applicable) • Hitting Stock Gage Too Hard (When Applicable) • Wire Straightener Improperly Adjusted Bad Shear / Cutoff Slivers / Scrapping / Rubbing • Incorrect Quill / Cutter Clearance / Diameters • Quill / Cutter Misaligned • Dull Or Incorrect Cutting Edges • Distorted Wire |
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Die Splits (Longitudinal) • Insufficient Interference Fit • Insert Outside Diameter Too Small Die Breaks (Transverse) • Too Much Interference Fit • Insert Outside Diameter Too Large Die Breaks Prematurely • Corners In One Piece Die • Trapped Lube In Unvented Die • Incorrect Interference Fit • Mis-Transfer • Improper Die Segmenting • Overfill Of Enclosed Upset • Improper Support Behind Die Insert • Poor Die Ratio • Die Material Too Soft / Hard |
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Head Breaking Off • Mismatch Between Punch / Case Radii • Back Of Head Or Filler Out Of Square • Punch Head Clamped Tight In Case • Head Too Large / Missing Relief On Rear End Forming End Breaks Off • Punch Body Bound Tight • Punch Is Off Center • Mis-Transfer • Improper Heat Treat Or Material • Poor Concentricity • Punch Going Solid When Cycling Machine Empty Corner Chipping / Galling • Corner Too Sharp • Trapped Die Lube • Area Reduction Is Too High / Low |
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Die Insert Bore Galls • Insufficient Die Lubrication • Incorrect Die Lubrication • Die Material Too Soft • Clearance Of Blank To Die Is Too Close Die Insert Outside Diameter Galls • Too Much Interference Fit • No Assembly Lubrication • May Require Tapered Insert Design Formed Blank Galls • Poor Wire Coating • Incorrect Die Lubrication • Too Many Extrusion Passes • Clearance Of Blank To Die Is Too Close • Transfer Not On Center |
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Concentricity Control / Punch Nib Breakage • Preliminary Cone Off Center • Final Upset Tool Off Center • Too Much Stock To Upset With Bowed Grain Flow (Use Sliding Tool) • Upset From Larger Stock Size • Additional Upset Blows • Transfer Fully Loaded • Circular Rings On ace Of Upset Insert • Punches Fit Too Loose To Holder • Trapped Oil • Poor Transfer Finger Control Inconsistent Fill / Or Height • Sliding Tool Sticking • Trapped Oil |
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Corner Won’t Fill • Trapped Corners In A One Piece Die • Vents Too Large And Plugging Up • Vents Are Too Small • Vents Do Not Have An Exit • Poor Die / Tool Polish • Fit Of Blank To Die Is Too Tight • Blank Coming In Has Improper Shape • Too Much Die Lube • Die Lube Too Thick • Wire Is Too Hard From Over Drawing Corner Overfills • Blank Coming In Has Improper Shape • Too Much Stock • Wedge Set Too High |
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Dropped Blanks / Finger Bent / Broken / Worn / Gouged • Blank Not Kicked Clear Of Die • Incorrect Kick Out Stagger (Clipping Kickout Pin) • Incorrect Gripping Notch • Incorrect IFO Cam Setting • Bent Or Broken Finger • Loose Friction Drag / Broken TKO Spring • Blank Kicked Into Back Side Of Fingers • Fingers Interfere With Punch Or Tool Case • Finger Break Away Hole Too Large • Finger Material Too Soft / Hard Scratch Marks On Part • Finger Notch Edges Too Sharp • IFO Cam Closing Too Early / Opening Too Late • Incorrect Finger Grip Notch |
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Will Not Extrude • Extrusion Land Too Long • Insufficient Venting • Tight Kickout Pin Or Intermediate Kickout Pin • Too Slow - Parts Only Jogged • Poor Wire Coating / Die Lube / Die Polish • Area Reduction Too High Bowed (Bent) Extrusion • Tool Is Off Center (Open) • Uneven Extrusion Land / Relief Off Center • Too Much Clearance Of Blank To Die • Memory Of Wire - Must Use Wire Straightener Chevron Formation (Internal Bursting) • Extrusion Die Design (Angle / % Reduction Area) • Material Structure / Work Hardening Effects • Number Of Extrusion Passes |
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Concentricity Control / Depth Variation • Preform Indent Not On Center • Punch Is Off Center / Punch Nose Off Center • Preform Blank Fit To Die Too Loose • Hole Is Too Deep • Uneven Land Or Extrusion Relief Off Center • Punch Is Bent (Even Tungsten Carbide) • Face Angle Too Large (Punch Wandering) • Improper Lube Placement (“Picks Up” One Side) • Poor Punch Polish / Coating Poor Punch Life • Trapped Die Lube • Incorrect Die Lubrication • Extrusion Corner Too Sharp • Improper Material • Bottom Web Too Thin |
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Burr / Poor Trim • Dull / Bellmouthed Trim Insert • Incorrect Trim Timing Trim Die Life • Trim Chip Too Thin • Trim Land Too Large / Corners Too Sharp • Incorrect Insert Material / Coating • No Relief In Trim Insert |
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Burr / Poor Pierce Out • Dull / Worn Piercer Or Marking Pin • Mark Diameter Too Small • Slug Too Thick Piercer Life • Piercer Corner Too Sharp • Incorrect Piercer Material / Coating / Geometry • Slug Too Thick |
