Net shape cold forging to close tolerances under QS 9000 aspects

The paper outlines the quality tools suggested by QS 9000 which have to be applied in the process design and development phase and also in the product and the process validation phase in the specific case of cold forging. Examples of complicated net shape cold forging parts are given. The benefit of application of the finite element method (FEM) in process design and optimization is described. Quality methods like statistical process control (SPC), process failure mode and effect analysis (FMEA) and their limits are discussed. The advantages of worker self inspection by use of a flexible coordinate measurement machine (CMM), quality control by neuronal network and of total tool management are pointed out.