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Quality Control Troubleshooting Guide
Cold Headers
It often takes years for a new machinist to learn all of the likely causes for the various quality problems that will arise. These troubleshooting algorithms can help your personnel by giving them the benefit of years of experience at the click of a mouse. Select the Quality Defect in the list below, then follow the links (if applicable) to learn the most likely causes.
Select Quality Defect:
- Flash All Around the Finish Blow Head and on Cone Blow Blank:
- Shorten Cutoff Blank.
- If Head is then under filled, shorten Cone Blow Pin or remachine cavity on Cone Blow Punch to upset more material.
- Flash on Finish Blow Head but NOT on Cone Blow Blank:
- Check Head Height of the finish blow.
- If height is oversize or correct, reduce Cutoff length and install longer Cone Blow Pin.
- If problem continues, machine a smaller Cone Blow cavity.
- If flash occurs but Head Height is undersize, back up the Cone Blow punch.
- Flash Also on Cone Blow Blank:
- Align Cone Blow Punch to Die.
- Check squareness of the Cutoff Blank.
- Check the squareness of the Cone Blow Pin.
- No Flash on the Cone Blow Blank with Finish Head Concentric to Body:
- Realign Finish Punch to Die.
- Check for damage in the Finish Blow Punch cavity.
- No Flash on the Cone Blow Blank with Finish Head NOT Concentric to Body:
- Realign Cone Blow punch to Die.
- Be sure Cone Blow cavity is not too long causing buckling of blank during the Finish blow.
- Remachine the Cone Blow punch as required and recut Cone Blow Pin.
- Finish Blow is Not Concentric but Cone Blow is Concentric:
- Check the alignment of the Finish Punch to the Die.
- Check to see if Cone Blow is too long and narrow causing the Finish Blow to fold over.
- Be sure that enough material is upset in the Cone Blow blank to fill the Cone Blow cavity. If not increase cutoff length.
- Both Finish Blow and Cone Blow are NOT Concentric:
- If Cone Blow is NOT filling Cone Blow cavity, increase length of Cone Blow Pin or increase Cutoff Length.
- If Cone Blow is filling cavity, realign cone blow to Die.
- Cone Blow bore may be too large for wire size.
- Cold Shut Only Part Way Around the Head:
- Check to be sure the Cone Blow is not too narrow.
- Check Cone Blow to be sure it is not too long.
- Check to see if the Cone Blow cavity was not fully filled during upset. If not, install a longer Blow Pin in the Cone Blow, or increase the Cutoff Length. Replace the Cone Punch if cavity is too large.
- Consider replacing the Cone Punch with a Sliding or Spring-Blow Punch.
- Cold Shut All the Way Around the Head:
- If there is NO flash on the Cone Blow Blank, check to see if the Cone Blow is fully filling the cavity. If not, install a longer Blow Pin in the Cone Blow, or increase the Cutoff Length. Replace the Cone Punch if cavity is too large.
- If there IS a flash on the Cone Blow Blank, shorten the Cut Off Blank length. If the Cone Blow Blank then under fills the cavity, shorten the Blow Pin or machine a new Cone Blow cavity to a smaller size.