Efficient forming geometries for tube end machining
Forming versatility in axial and roll transfluid procedures
Now more than ever, selecting the suitable procedure for attaching connection elements to tube ends is essential for economical machining processes. This is because geometries are becoming more and more complex and the pressure of remaining cost efficient is increasing significantly. There are various options such as being able to solder or weld objects such as a rotary part that was manufactured in advance onto a tube. The tube normally has to be calibrated for this. Soldering in a furnace sometimes changes the bent geometry, the join or the surface. And induction soldering is very cost-intensive. Leak-tightness must also be checked if necessary. Overall, this process is very time-consuming and always comprises a process chain in which additional soldering paste, a soldering ring or gas is required, as well as forming gas for welding. Large, complicated equipment is required for this.
Forming provides an efficient solution. The material is always peen hardened here. The degree of forming is the parameter that can be used to determine the remaining change to a workpiece during the forming process. The degree of forming depends on the geometry, the material and the cold forming procedure used. transfluid Maschinenbau GmbH has developed various cold forming solutions for axial, roll and combined forming. Here, machines form the basis while the tools safeguard the process. We have particular expertise in the tool technology area. The transfluid experts reduce follow-up costs and guarantee quality at the same time thanks to their intelligent tool solutions.
Axially precise upsetting
The company has designed its "t form" REB systems for axial upsetting. Depending on the requirements, the machine configuration is determined by three significant factors: the tube size, the material and the forming geometry. For example, sharp-angled contours require significantly more upsetting output than smooth ones. The REB forming machines can provide fast tool changing, extreme degrees of forming and complex geometries. The tool sequence is positioned vertically or horizontally via a servo motor. Up to six forming stages and one intermediate clamping unit enable virtually all forming requirements to be met. Integrated rolling stations are used for specific tube forming processes. The system is operated via a touch screen with an integrated database. Specific machining sequences, process and machine parameters can be managed here. With regard to drives, transfluid optionally equips the REB systems with hydraulic, numeric or electrical drives. Furthermore, for very short cycle times, there is also the option of carrying out this forming procedure step-by-step in transfer systems to make it quicker.
Roll to a complex form
The tube size and forming geometry play an important role in designing the transfluid SRM roll forming machines exactly. The tube diameter determines the machine's basic construction with regard to the opening stroke and the output torque. The procedure is particularly suitable for creating sharp-angled contours for sealing elements and optimised surfaces. All drives are electrical servo drives and can be CNC controlled if required. This allows tool-independent forming and stores all setting parameters. Time-consuming adjustments are not necessary. Tubes can either be formed from inside to outside or from outside to inside.
Why axial and roll can be connected so well.
Combination machines are used according to the geometry. transfluid combines the benefits of both machining procedures here. Often, axial pre-upsetting is carried out and the final geometry is achieved using the roll process. For example, to ensure that trimming before the axial tube forming process is also possible or to ensure that a pre-upset geometry can be rolled subsequently, the combined procedures are available in one machine or as a transfer system, in which the machining processes are carried out one after the other. With fast tool changes included, the advanced, high-tech combination can be used for extreme forming - for sharp-angled contours/radii, high demands on the surface and forming closely behind the arcs.
Complex geometries and safe flaring
The transfluid UMR forming machines are used for flaring connections. The machine size depends on the tube size of up to 325 mm in diameter and the tool is adjusted to the appropriate forming geometry. Fast tool changes ensure that time is saved and the system also enables tube ends to be closed. The UMR systems run virtually regardless of the tool with a freely-programmable, controlled forming taper. Flares of between 20° and 90°, as well as clamping lengths of around 1 x D can therefore be produced, which have excellent sealing surfaces. Flares of up to 90° can therefore be manufactured in one work step. Flange connections can also be produced using this transfluid solution. The company's advanced forming technology will be one of the main topics of expert discussion at Tube 2016 on the transfluid stand, G34 in hall 05.
Trade fair: Tube, Düsseldorf, 04-08/04/2016, Hall 05 / Stand G34