Possible applications

APPLICATION

Our technologies

PORTFOLIO

The following images show examples of components that can be formed with our systems for all technologies available at GFU.

01_DMC Marking

02_Pushpointing

03_High Speed End Forming

Part labeling by laser

- DMC and/or plain writing possible
- alterable size and style
- printing within the machine cycle
- camera check of printed DMC
- combinable with process data tracking

Tool marking by laser

- DMC and/or plain writing possible
- alternable size and style
- combinable with tracking of tool lifetime and machine setup data

Airbag inflator

- Ø30 x 1.8 mm
- 2-fold reduction (cold)
- precise geometries
- final machining possible

Cardan shaft

- Ø89 x 2.4 mm
- reduction (cold) to Ø71 mm
- high repeat accuracy

Premium Casing API (Integral joint)

- Ø406 x 17 mm
- Retraction angle 2°
- Retraction length 200 mm
- Conical reduction (cold) to Ø392 mm
- High repeat accuracy

Premium Casing API (Integral joint)

- Ø340 x 12.7 mm
- expansion angle 2°
- draw-in length 200 mm
- conical expansion (cold) to Ø326 mm
- high repeat accuracy

Premium Casing API (Integral joint)

- Ø340 x 12.7 mm
- expansion angle 2°
- expansion length 200 mm
- conical expansion (cold) to Ø354 mm
- high repeat accuracy

Tube pointing (cross section)

- Ø177.8 x 4 mm
- draw-in length approx. 300 mm
- reduction (cold) to Ø113.8 mm
- high repeat accuracy

Tube pointing

- Ø177 x 12.7 mm
- Retraction angle 15°
- Retraction length 200 mm
- Conical reduction (cold) to Ø100 mm
- High repeat accuracy

Scaffolding tube

- Ø57 x 2.9 mm
- draw-in length on both sides 330 mm
- reduction (cold) to Ø48.3 mm
- high repeat accuracy
- precise concentricity of the reduced tube ends

Shock absorber (piston side)

- Ø57 x 2.7 mm
- draw-in length 50 mm
- reduction (cold) to Ø52.6 m
- high repeat accuracy
- precise concentricity of the reduced tube end

Shock absorber (bottom side)

- Ø57 x 2.7 mm
- draw-in length 70 mm
- reduction (cold) to Ø47.2 mm
- high repeatability
- precise radial runout of the reduced pipe end
- combined with GFU high-speed endforming to close the necked bottom side

Airbag Inflator

- Ø30 x 1,9 mm
- draw-in length 35 mm
- reduction (cold) to Ø25,0 mm
- high repeatability
- precise radial runout of the reduced pipe end
- combined with GFU roll-forming operation to create the captured area

EV Rotor shaft

- 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
- 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

- Ø85 x 7 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 (ATV)

- Ø75 x 9 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 (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 (ATV)

- Ø68 x 10 mm
- left flange and right neck formed 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

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

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

- Ø115 x 8 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

- Ø78 x 9,5 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
- 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

- 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

- 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

- 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

Airbag inflator (Curtain)

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

Airbag inflator (Curtain)

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

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 (Curtain)

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

Airbag inflator (Curtain)

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

Airbag inflator (Curtain)

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

Airbag inflator (Curtain)

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

Airbag inflator (Curtain)

- 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 (Front airbag)

- Ø60 x 2,5 mm
- by GFU high-speed end-forming spherical shaped tube end
- reliable forming process with high repeatability

Airbag inflator (Curtain)

- 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

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

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

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.

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

- Ø50 x 2 mm
- cold forming of the segments for the spring plate support using the GFU beading process
- reliable process with high reproducibility
- defined segment contour
- stand-alone or in conjunction with a GFU flow-rolling machine
- short cycle times depending on pipe dimension, segment contour and number of segments

Shock absorber outer tube

- Ø38.8 x 1.4 mm - Ø50 x 2 mm
- cold forming of the spring plate seat using GFU ring beads Process
- reliable process with high reproducibility
- defined bead contour
- stand-alone or in conjunction with a GFU flow-rolling machine
- cycle times approx. 10 - 12 sec. depending on pipe dimension.

Shock absorber outer tube

Roll-off piston for air suspension

- Cold forming of the piston contour using GFU radial forging process
- reliable process with high reproducibility
- defined contour with undercuts

Ball shaft

- Ø62 x 6 mm reduced to Ø34 mm on both sides
- cold forming of the ball contour using GFU radial forging process
- reliable process with high reproducibility
- defined near-net-shape production

Conical table leg

- Ø50.3 x 1.4 mm reduced to Ø28 mm on one side
- cold forming of the cone using GFU radial forging process
- long transition area (cone)
- reliable process with high reproducibility

Tube pointing

- Ø95 x 4 mm reduced to Ø36 mm on one side
- cold forming of the cone using GFU radial forging process
- short cycle time
- large bandwidth

drain pipe

- Ø46 x 2.5 mm constricted in the middle to Ø30.5 mm
- cold forming using GFU radial forging process
- high reproducibility

Stabilizer

- Ø52 x 7 mm reduced to Ø44 mm on one side
- cold forming using GFU radial forging process
- reliable process with high reproducibility

One-piece axle beam

- Ø127 x 12 mm with stub axles formed on both sides
- one-piece solution, without welding
- hot forming using GFU radial forging process
- defined outer and inner contour on the stub axle
- upsetting of the wall thickness possible
- exact positioning of the forming on both sides to take the axle length into account
- reliable process with high reproducibility

One-piece axle beam

- Ø88.9 x 8.3 mm with stub axles formed on both sides
- one-piece solution, without welding
- hot forming using GFU radial forging process
- defined outer and inner contour on the stub axle
- upsetting of the wall thickness possible
- exact positioning of the forming on both sides to take the axle length into account
- reliable process with high reproducibility

One-piece axle beam

- Ø127 x 18 mm with stub axles formed on both sides
- one-piece solution, without welding
- hot forming using GFU radial forging process
- defined outer and inner contour on the stub axle
- upsetting of the wall thickness possible
- exact positioning of the forming on both sides to take the axle length into account
- reliable process with high reproducibility

One-piece axle beam

- Ø132 x 19 mm with stub axles formed on both sides
- one-piece solution, without welding
- hot forming using GFU radial forging process
- defined outer and inner contour on the stub axle
- upsetting of the wall thickness possible
- exact positioning of the forming on both sides to take the axle length into account
- reliable process with high reproducibility

Front upper control arm (FUCA)

- Aluminum billet partially upset using GFU upsetting technology
- Bending for preforming (near net shape) for the subsequent closed-die forging process
- Burr reduction
- Reduction in part costs

front upper control arm (FUCA)

- Bending of stretch-rolled aluminum billets for preforming (near net shape) for the subsequent closed-die forging process
- reduction of flash
- reduction of part costs
- short cycle times

Mudguard bracket for trucks

- Ø52 x 3 mm, partially swaged on one side using GFU swaging technology
- swaged end turned inwards using GFU flow-rolling process to enable thread attachment
- one-piece solution, without welding
- high reproducibility
- subsequent processes such as machining, bending, measuring in line possible

Scaffolding support

- Ø48.3 x 2.7 mm, drawn in on one side
- right-angled setting of the shoulder with partial increase in wall thickness in the transition area
- one-piece solution, without welding
- high reproducibility
- connected turn-key production line with short cycle times (approx. 20 sec.)

External punching on shock absorber tube

- Pipe dimensions between Ø27 - Ø65mm
- Wall thicknesses between 1.5 - 3 mm
- Hole diameters between Ø10 - Ø40 mm
- Clean cut
- Precise axial and radial positioning
- Multiple punching possible on one pipe

External punching on shock absorber tube

Internal punching on shock absorber tube

- Pipe dimensions between Ø40 - Ø65mm
- Wall thicknesses between 1.5 - 2 mm
- Hole diameters between Ø8 - Ø10 mm
- Clean cutting pattern
- Precise axial and radial positioning
- Multiple punching possible on one pipe

Internal punching on shock absorber tube

Rotor shaft EV

- realized dimensions Ø45 - Ø117 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

Various rotor shafts EV

Rotor shaft EV

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

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

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 5" x 12 mm

- 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

Drill pipes API 5CT EUE

Premium Casing 14" x 20 mm

- 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 14" x 20 mm

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

Rebar (solid material)

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

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