Development of a new forming process for gun-nail heads by simulation

This paper describes how a model material technique has been applied in the analysis and development of a roll forming process for heading shanks, gun nails in particular. A commercial modelling wax “Filia” is extruded to the dimension of the model shank before the head is roll-formed by means of equipment designed for this process. The dependence of the roll diameter, of the velocity between the roll and the tool, and of the interface friction are shown for the model technique and compared with a theoretical estimate and with experimental results. A compound wax is used to study the proportion of virgin surface from the cropping in contact with the roll and the tool. A machine for production of gun nails was developed based on the model analysis. Experiments carried out with this machine confirm the results and the advantage of the model material technique.