2. High speed end former

Profile

The High-Speed End-Forming Process is based on the spinning/flow-forming process principle. The main difference is that the tool is not a roller which runs off a specific shape, but a pot-shaped tool in which the entire course of the shape is incorporated. The components that can be produced by this process must be rotationally symmetrical.

Models

Get to know our models

High Speed end forming machine
RM 30-2

Gas springs

Part dimensions
Øa: 18- 30 mm
Length: 100 - 500 mm
Wall thickness: 1.0 - 2.5 mm

Technical data
Forming force: 25 KN
Rotation Speed: 1450 rpm.
Forming: CNC electrical

High Speed end forming maschine
RM 30-2-2

Radiator tubes (towel heater)

Part dimensions
Øa: 18- 30 mm
Length: 400 - 3000 mm
Wall thickness: 1.2 - 2.5 mm

Technical data
Forming force: 25 KN
Rotation speed: 1450 rpm.
Forming: CNC electrical

High speed end forming
RM 50-2

Airbag

Part dimensions
Øa: 20- 350 mm
Length: 120 - 550 mm
Wall thickness: 1.5 - 3.5 mm

Technical data
Forming force: 50 KN
Rotation speed: 1450 rpm.
Forming: CNC electrical

High speed end forming machine
RM 50-2

Shockabsorber

Part dimensions
Øa: 30- 54 mm
Length: 150 600 mm
Wall thickness: 1.5 - 3.5 mm

Technical data
Forming force: 60 KN
Rotation speed: 1450 rpm.
Forming: CNC electrical

High speed end machine
RM 65-2

Shockabsorber

Part dimensions
Øa: 30- 65 mm
Length: 150 - 550 mm
Wall thickness: 1.5 - 3.5 mm

Technical data
Forming force: 50 KN
Rotation speed: 1450 rpm.
Forming: CNC electrical

High speed end forming machine
RM 75-1

Shockabsorber

Part dimensions
Øa: 40 - 75 mm
Length: 150 - 600 mm
Wall thickness: 1.5 - 3.5 mm

Technical data
Forming force: 60 KN
Rotation speed: 1450 rpm.
Output: 300 - 400 parts/h
Forming: CNC electrical

High speed end forming machine
RM 75-2

Shockabsorber

Part dimensions
Øa: 40 - 75 mm
Length: 150 - 600 mm
Wall thickness: 1.5 - 3.5 mm

Technical data
Forming force: 60 KN
Speed: 1450 rpm.
Output: 300 - 400 parts/h
Forming: CNC electrical

High speed end forming machine
RM 100-1

Rotor shafts

Part dimensions
Øa: 40 - 100mm
Length: 150 - 550 mm
Wall thickness: 3.5 - 11.0 mm

Technical data
Rotation speed: 800 rpm.
Output: 100 - 150 parts/h
Single sided formed
Forming: CNC electrical

High speed end forming
RM 100-4

Rotor shafts

Part dimensions
Øa: 40 - 100 mm
Length: 150 - 500 mm
Wall thickness: 3.5 - 7.0 mm

Technical data
Forming force: 100 KN
Rotation speed: 800 rpm.
Output: 100 - 170 parts/h
Single sided formed
Forming: CNC electrical

High speed end forming machine
RM 220-2

Roller conveyer

Part dimensions
Øa: 60- 219 mm
Length: 400 - 2200 mm
Wall thickness: 3.5 - 7.0 mm

Technical data
Forming force: 100 KN
Rotation speed: 600 rpm.
Forming: 120 - 150 parts/h
Forming: CNC electrical

High speed end forming machine
RM 400-1

Accumulator

Part dimensions
Øa: 160 - 406 mm
Length: 600 - 2800 mm
Wall thickness: 5.0 - 40.0 mm

Technical data
Forming force: 500 KN
Rotation speed: 400 rpm.
Forming: Servo - Hydraulic

Components

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

Accumulator

- Ø120 x 6 mm
- both ends neck shaped by GFU high-speed end-forming
- homogenous grain structure in the transition area to the neck shape and therewith high capacity to withstand stresses

Airbag inflator

- Ø30 x 2.5 mm
- stepped neck shape to Ø17 mm
- constricted combustion chamber side Ø17.6 mm
- mechanical treatment in line

Airbag inflator

Combustion chamber side
- Ø30 x 2.5 mm
- constricted combustion chamber side Ø17.6 mm
- final mechanical treatment in line

Airbag inflator

combustion chatcher side
- Ø30 x 2.5 mm
- stepped neck shape to Ø17 mm
- final mechanical treatment in line

Airbag inflator

- Ø30 x 2.2 mm
- stepped neck shape to Ø17 mm
- constricted combustion chamber side Ø27 mm
- mechanical treatment in line

Airbag inflator

Combustion chamber side
- Ø30 x 2.2 mm
- constricted combustion chamber side Ø27 mm
- final mechanical treatment in line

Airbag inflator

Combustion chatcher side
- Ø30 x 2.2 mm
- stepped neck shape to Ø17 mm
- final mechanical treatment in line

Airbag inflator

- Ø30 x 1.8 mm
- closed bottom side by GFU high-speed end-forming
- reliable forming process with high repeatability
- final mechanical treatment possible

Airbag inflator

- Ø40 x 2 mm
- by GFU high-speed end-forming spherical shaped tube end
- reliable forming process with high repeatability

Airbag inflator

- Ø30 x 2 mm
- bottom side closed gas-tight and contoured terminal side necked by GFU
- reliable forming process with high repeatability

Axle shaft

- Pipe Ø88.9 x 6.1 mm
- Flange Ø145 x 11 mm
- Creation of a flange from a pipe with simultaneous thickening of the wall thickness at the flange using the GFU flow-rolling process
- Homogeneous grain structure in the transition area to the flange and therewith
- Quick cycle time with high production rate

C02 pressure vessel

- Ø40 x 2 mm
- by GFU high-speed end-forming
--bottom side close gas tight
-open end neck formed to Ø14 mm
- reliable forming process with high repeatability

Conveyor roller

- Ø89 x 3.7 - Ø219 x 6.0 mm
- double-end forming of bearing seats by GFU high-speed end-forming technology
- significant increase of lifetime cycle of the rollers compared with traditionally welded parts
- reliable forming process with high repeatability

Flange shaft

- Tube Ø64 x 11 mm
- Flange Ø106 x 15 mm
- Creation of a flange from a pipe with simultaneous thickening of the wall thickness on the flange using the GFU high-speed end forming process
- Homogenous grain structure in the transition area to the flange and therewith high capacity to withstand stresses
- quick cycle time with high production rate

Pressure tank

- Ø34 x 2 mm
- bottom side closed gas tight and terminal side necked by GFU high-speed end-forming technology
- reliable process with high reproducibility - short cycle time with high output
--bottom side approx. 8 sec./pc.
--neck side approx. 12 sec./pc.

EV Rotor shaft

- Ø74 x 6 mm
- double end necked by GFU high-speed end-forming technology
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

EV Rotor shaft

- Ø50 x 6 mm
- double end necked by GFU high-speed end-forming technology
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

EV Rotor shaft (ATV)

- Ø80 x 5 mm
- double end necked by GFU high-speed end-forming technology
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- rectangular shape in the transition to the neck shape
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

EV Rotor shaft

Various EV rotor shafts

- Ø50 - Ø110 mm
- double end necked by GFU high-speed end-forming technology
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- from smooth transition to rectangular
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- quick cycle time with high production rate

Seat shaft

- Ø32 x 2 mm
- one-side neck forming
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses (crash-relevant part)
- defined notch forming at the opposite side
- lightweight build as hollow shaft
- good availability of raw material (tube)
- near-net-shape forming
- turn-key production line with approx. 9 sec. cycle time and high production rate incl. forming units, mechanical treatment, optical measurement and marking

Shock absorber outer tube

- Ø30 x 1.4 mm - Ø72 x 3.5 mm
- one-side gastight closing of the tube by GFU high-speed end-forming technology (single-piece solution)
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- defined bottom shape for precise valve seat
- turn-key production line with various additional treatments
- cycle time in accordance with the tube dimension and required bottom shape between 8 - 11 sec.

Shock absorber outer tube

- Ø 50 x 2 mm
- one-side gastight closing of the tube by GFU high-speed end-forming technology (single-piece solution)
- reliable process with high repeatability
- homogeneous grain structure in the transition area and therewith high capacity to withstand stresses
- defined bottom shape for precise valve seat
- turn-key production line with various additional treatments
- cycle time approx. 8 - 9 sec.
- optionally forming of the spring seat rest

Shock absorber outer tube

Performance data

Depending on capacity requirements, there are various options for workpiece transport; simultaneous double-sided machining is also possible.

Fields of application

GFU flow rolling lines are used in the production of:

Rotor shafts
Pressure vessel for fire extinguishers
Airbag container
Accumulators
Railing tubes
Tubular heater
Designer furniture
Shockabsorber
Gas pressure absorber
Valve push rods
CO2 cartridges
Gearbox flanged shafts (sunshafts)
Idlers (conveyor belts in mining)

Advantages

of flow rolling:

Reduction of individual components: A decisive advantage of the roller burnishing process is that the geometry of the tube end can be deformed almost at will without additional material. This also includes the fact that the gas-tight sealing of tubes takes place without any filler material or additional component, thus significantly reducing the costs of stocking and storing individual components.

Machining times: Component machining times can be reduced by up to 50% compared to conventional processes, depending on the component, thanks to the new roller burnishing process. Enormous productivity increases can be achieved by combining roller burnishing technology with an individually designed handling system, suitable for your product.

Tolerances: Despite hot processing, tolerances in the length range of +/- 0.1 mm can be achieved using roller burnishing technology. Depending on the type of component, diameter tolerances of less than +/- 0.1 mm can be achieved.

When designing the component with regard to the production process, it should already be possible to exploit all advantages ideally in the design phase. Our development and testing department will be happy to assist you in this regard.

Various GFU technologies can be combined with the flow-rolling process to design efficient manufacturing.