How Cold Forging Machines Revolutionize the Production of New Energy Vehicle (NEV) Battery Terminals

   Introduction As the global demand for New Energy Vehicles (NEV) surges, the efficiency and quality of battery components have become the focus of manufacturers. Among these, the battery terminal (pole pillar) plays a crucial role in electrical connectivity. Traditional machining is no longer

enough. Enter Cold Forging Technology—the game-changer for high-volume, high-precision battery part production.

1. Why Cold Forging for Battery Terminals?

Battery terminals are usually made of high-purity copper or aluminum. Cold forging offers distinct advantages over traditional CNC machining:

• Enhanced Strength: The material undergoes "work hardening," improving the mechanical properties of the pole pillar.

• Superior Conductivity: Unlike casting, cold forging preserves the continuous grain flow of the metal, ensuring optimal electrical performance.

• Material Savings: Cold forging is a near-net shape process, reducing scrap rates by up to 70% compared to cutting.

2. The Role of High-Precision Cold Forging Machines

To produce a perfect battery terminal, the Cold Forging Machine must provide stability and immense pressure. Modern multi-station cold headers allow for:

• Multi-Stage Forming: Shaping complex geometries in a single cycle.

• Tight Tolerances: Meeting the strict micron-level requirements of EV battery packs.

• High-Speed Output: Achieving production speeds of 60–120 pieces per minute.

3. Copper vs. Aluminum: Forging Challenges

In the NEV sector, both copper and aluminum terminals are used.

• Copper Terminals: Require high pressure due to material density but offer the best conductivity.

• Aluminum Terminals: Lightweight and cost-effective, requiring specialized lubrication during the cold forging process to prevent sticking.

4. Future Trends: Automation and Sustainability

The integration of IoT and automated feeding systems with cold forging machines is the next step for "Smart Factories." By reducing energy consumption and material waste, cold forging aligns perfectly with the green energy goals of the EV industry.

Conclusion If you are looking to scale up your battery component production, investing in a professional Cold Forging Machine is the most cost-effective path. It ensures high precision, durability, and a lower cost per part.