What Are the Main Failure Modes of Header Punches in High-Volume Cold Heading, and How to Prevent Them?

This technical guide analyzes the primary causes of header punch failure in high-speed fastener manufacturing. It identifies abrasive wear, plastic deformation, and misalignment as the core risks to production efficiency. By optimizing tool hardness (Rockwell C50-65), selecting high-grade materials like tungsten carbide, and maintaining precision concentricity, manufacturers can significantly reduce downtime and scrap rates. The article provides data-driven strategies for B2B procurement managers to improve “cost per hit” and tool longevity.