4. Upsetting machines

back to overview
Informations

Profile

Upsetting is based on the principle that two tool segments enclose the partially heated tube and the material is then upset in the axial direction by 1 or 2 punches. Both tube and solid materials can be partially upset. Contours are possible via the tool geometry.

Models

Get to know our models

Upsetting press
HP-40

Part dimensions
Øa: 20 - 35 mm
Length: 200 - 500 mm
Wall thickness: 3.0 - 7.0 mm

Technical data
Forming force: 400 KN
Output: 150 - 200 pcs./h
Forming: hydraulic

Upsetting press
HP-50

Part dimensions
Øa: 20 - 40 mm
Length: 200 - 1000 mm
Wall thickness: 3.0 - 7.0 mm

Technical data
Forming force: 500 KN
Output: 120 - 200 pcs./h
Forming: hydraulic

Bulging line
FFU 50e-line

Flange forming cold shockabsorber

Part dimensions
Øa: 40 - 50 mm
Length: 180 - 550 mm
Wall thickness: 2.0 - 2.5 mm

Technical data
Forming force: 500 KN
Press stroke: 600 mm
Output: 220 - 280 pcs./h
Forming: CNC electrical

Upsetting press
HP 150

Part dimensions
Øa: 60 - 120 mm
Length: 2000 - 3500 mm
Wall thickness: 5.0 - 10.0 mm

Technical data
Forming force: 1500 KN
Output: 20 - 30 pcs./h
Both sides formed
Forming: hydraulic

Upsetting press
TFM-150 e-line

Part dimensions
Øa: 40 - 65 mm
Length: 180 - 450 mm
Wall thickness: 5.0 - 11.0 mm

Technical data
Forming force: 1500 KN
Output: 125 - 160 pcs./h
one sides formed
Forming: CNC electrical

Upsetting press
HP 200

Part dimensions
Øa: 40 - 85 mm
Length: 500 - 1200 mm
Wall thickness: 5.0 - 11.0 mm

Technical data
Forming force: 2000 KN
Output: 100 - 150 pcs./h
one sides formed
Forming: hydraulic

Upsetting press
HP-300

Part dimensions
Øa: 60 - 120 mm
Length: 1500 - 13000 mm
Wall thickness: 5.0 - 11.0 mm

Technical data
Forming force: 3000 KN
Output: 120 - 150 pcs./h
one sides formed
Forming: hydraulic

Upsetting press
HP-400

Part dimensions
Øa: 60 - 140 mm
Length: 3000 - 13000 mm
Wall thickness: 5.0 - 14.0 mm

Technical data
Forming force: 4000 KN
Output: 100 - 150 pcs./h
one sides formed
Forming: hydraulic

Upsetting press
HP-400-2

Part dimensions
Øa: 60 - 140 mm
Length: 3000 - 13000 mm
Wall thickness: 5.0 - 14.0 mm

Technical data
Forming force: 4000 KN
Output: 200 - 300 op./h
Forming: hydraulic

Upsetting press
HP-1500

Part dimensions
Øa: 160 - 475 mm
Length: 8000 - 14000 mm
Wall thickness: 17 - 25 mm

Technical data
Forming force: 1500 KN
Output: 24 - 40 op./h
Forming: hydraulic

Components

Here you can find a list of all the components you can produce with our machines.

Active stabilizer

- Pipe dimensions between Ø37 x 10.5 mm
- Wall thickness upset on both sides up to Ø52.5 mm outside diameter on the flange
- Near-net-shape production, therefore less material used and shorter processing times

Active stabilizer

- Pipe dimensions between Ø37 x 10.5 mm
- Wall thickness upset on both sides up to Ø52.5 mm outside diameter on the flange
- Near-net-shape production, therefore less material used and shorter processing times

Camshaft tube

- Ø24.5 x 3.3 mm
- one-sided wall thickness upset to 12.5 mm with up to Ø36 mm outer diameter
- near-net-shape production, therefore less material used and shorter machining times

Camshaft tube

- Ø32.5 x 4.9 mm
- one-sided wall thickness partially upset to 10.5 mm
- near-net-shape production, therefore less material used and shorter processing times

Camshaft tube

- Ø26.6 x 4.3 mm
- one-sided wall thickness partially upset to outer diameter of Ø46 mm
- near-net-shape production, therefore less material used and shorter machining times

Camshaft tube

- Various tube diameters and wall thicknesses
- Wall thickness partially upset on one side
- Near-net-shape production, therefore less material used and shorter machining times
- Weight-saving solution as a hollow shaft

Drill pipes

- Various pipe diameters from 2.3/8'' - 6.5/8''
- Wall thickness partially upset on one or both sides
- No burr on the outside in the cylindrical upsetting area, due to closed external tool
- Upsetting according to API

Drill pipes

- Various pipe diameters from 2.3/8'' - 6.5/8''
- Wall thickness partially upset on one or both sides
- No burr on the outside in the cylindrical upsetting area, due to closed external tool
- Upsetting according to API

Drill pipes

- Various pipe diameters from 2.3/8'' - 6.5/8''
- Wall thickness partially upset on one or both sides
- No burr on the outside in the cylindrical upsetting area, due to closed external tool
- Upsetting according to API

Drill pipes

- Various pipe diameters from 2.3/8'' - 6.5/8''
- Wall thickness partially upset on one or both sides
- No burr on the outside in the cylindrical upsetting area, due to closed external tool
- Upsetting according to API

Premium Casing

- various pipe diameters up to 18''
- wall thickness partially upset on one or both sides up to 50 mm wall thickness
- no burr on the outside in the cylindrical upsetting area, due to closed external tool
- GFU supplied the only machine in the world for this application

Premium Casing

- various pipe diameters up to 18''
- wall thickness partially upset on one or both sides up to 50 mm wall thickness
- no burr on the outside in the cylindrical upsetting area, due to closed external tool
- GFU supplied the only machine in the world for this application

Pressure vessel

- Pipe dimension Ø32 x 1.8 mm
- wall thickness partially upset on both sides to 3.5 mm wall thickness for producing threads

Reinforcing steel (solid material)

- Diameter from 12 - 28 mm
- single-sided upsetting to be able to attach threads

Rotor shaft EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Rotor shaft EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Rotor shaft EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Rotor shaft EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Rotor shaft EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Various rotor shafts EV

- realized dimensions Ø45 - Ø60 mm
- one side or both sides partially upset wall thickness by GFU upsetting technology
- upsetting of a flange shape as a stopper is possible
- homogeneous grain structure in the upset area and therewith high capacity to withstand stresses
- within the same part various GFU forming technologies can be combined
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Stabilizer for trucks

- Starting tube Ø70 x 13 mm
- partial increase in wall thickness on both sides to 22 mm with simultaneous increase in outer diameter to Ø102 mm using GFU upsetting technology
- homogeneous fiber flow in the upsetting area; therefore high load-bearing capacity
- high reproducibility thanks to reliable process sequence
- lightweight construction thanks to production as a hollow body
- good raw material availability (tube)
- near-net-shape forming
- short cycle time with high output

Stabilizer

- Initial tube Ø36 x 5.5 mm
- partial increase of the wall thickness on one side to 11.5 mm with simultaneous increase of the outer diameter to Ø46 mm using GFU upsetting technology
- final offset of the axiality of the upsetting area in relation to the tube axis
- homogeneous fiber flow in the upsetting area; resulting in high resilience
- high reproducibility thanks to reliable process sequence
- lightweight construction thanks to production as a hollow body
- good raw material availability (tube)
- near-net-shape forming
- short cycle time with high output

Stabilizer

- Starting tube Ø29.5 x 5 mm
- partial increase in wall thickness on one side to 6 mm with simultaneous increase in outer diameter to Ø43 mm using GFU upsetting technology
- homogeneous fiber flow in the upsetting area; therefore high load-bearing capacity
- high reproducibility thanks to reliable process sequence
- lightweight construction thanks to production as hollow body
- good raw material availability (tube)
- near-net-shape forming
- short cycle time with high output

Performance data

The performance data of the upsetting press is individually adapted to the respective work piece. Assisted by using simulation software the capacity of the machine is customized to the parts and the volume. The machine is driven by servo/hydraulical, hydraulical and CNC-drives. This grants you the very best results related to quality and repeatability. Handling components are optimized to the respective parts. This enables high flexibility with costs as low as possible.

Fields of application

  • Rotor shaft EV / BEV
  • hollow camshafts
  • Drive shafts
  • Teering shafts
  • Steering gear shafts
  • Transmission shafts
  • Axles
  • Stabilizers
  • Drill pipes
  • Pressure tanks
  • Furniture tubes

Advantages

of upsetting

  • Weight optimization: Upsetting enables the directed allocation of wall thickness distribution on weight optimized parts, e.g. for automobile components. Upsetting technology allows the cutover from solid to tubes.
  • Material savings: Parts can be formed to the wanted geometrie with an upsetting operation and the linked material displacement and without material losses. The material input can be reduced destinctively.
  • Reduction of parts diversity: Parts which got welded of single components now can be produced from wrought material (tube). Because of this a high cost saving is generated by reducing the parts diversity.
  • Safety: Upset components are distinguished with a homogeneous fibre flow. Differing to machined shapes the forged / hammered components are characterized by higher strength.

As an additional advantage, upset parts in some cases can replace frictioni welding process. This generates significant cost savings on material, because upset parts are produced near net shape.

Get in touch