Progressive Header
A progressive header is a multi-station cold forming press that transforms a wire blank into a finished part across 5 or 6 successive forming stations in a single machine cycle.
A progressive header is a horizontal cold forming press that feeds wire from a coil, cuts it to a precise length, and transfers the blank through a series of forming stations — each performing a different cold forming operation — until a finished part exits at the last station. Every machine stroke produces one completed part.
Machine Architecture
Wire Feed System
The wire is drawn from a coil through a straightening system and fed into the machine by either a linear gripper system or rotating feed rolls. The feed length determines the cutoff length — the length of the wire blank.
Cutoff Station
A knife and bushing system shears the wire to the programmed length. Cutoff precision directly affects head weight and dimensional consistency of the finished part. On Manzoni machines, the High-Speed Bushing Knife system guides the knife throughout its full length to eliminate deflection and ensure consistent, burr-free cuts.
Transfer System
After cutoff, mechanical transfer fingers grip the blank and move it from one station to the next, synchronized with the ram motion. The transfer must open, advance, close on the blank, retract, and release — all within one machine stroke.
Forming Stations (5 or 6)
Each station has a die (stationary side) and a punch (moving side, carried by the ram). Stations are independently configurable: a station can perform upset, forward extrusion, backward extrusion, trimming, or piercing — or a combination. The sequence is designed by tooling engineers to progressively shape the blank toward the finished geometry.
Ejection (K.O. System)
At each station, a kickout pin (K.O. pin) ejects the formed blank from the die cavity after the ram retracts. On Manzoni machines, each station has positive kickout, independently adjustable, with a digital display showing the K.O. pin position — enabling precise setup without trial and error.
Speed and Output
Progressive headers are among the fastest forming machines in manufacturing. Output rate depends on wire diameter, part geometry, material, and machine series:
| Manzoni Series | Wire Ø | Max Speed |
|---|---|---|
| MA | up to 8 mm | 370 pcs/min |
| MB | up to 11 mm | 280 pcs/min |
| MC | up to 20 mm | 160 pcs/min |
| ME | up to 33 mm | 110 pcs/min |
| MF | up to 42 mm | 90 pcs/min |
Progressive vs Single-Die Headers
A single-die header (1 or 2 stations) is simpler and cheaper, but limited to parts with small L/D ratios and simple geometry. A progressive header handles complex shapes, deep holes, multiple upsets, and extrusions in a single pass — making it the machine of choice for precision automotive and aerospace fasteners.
Frame Construction: Steel vs Cast Iron
Traditional progressive headers use cast iron frames. Manzoni machines are built with the Manzoni Modular Steel Frame® concept — a welded steel structure that is three times tougher than cast iron at equivalent size. The steel frame allows higher heading tonnage with smaller machine dimensions, saving significant floor space.
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