Forming machines for rotary swaging and axial spline forming at room temperature.
Applicable for forming of high-strength / lightweight parts with high precision.
STRECON is the official agent for the Felss Systems in Scandinavia.
Axial Forming Axial Forming of high-strength, high-precision splines
Axial Forming of high-strength, high-precision splines
Felss has developed a patented axial forming machine that is capable of net-shape forming of high-strength, high-precision splines by a special low-force, recursive cold forming process. The process is applicable for both external and internal splines, and for hollow and solid parts. It is especially beneficial for high-quality spline components requiring economical production processes.
The process is simple: A spline tool presses the external splines against a hollow or solid material in an axial direction. The teeth are formed directly at the same time using a one-piece tool which makes the forming process highly precise. The net-shape spline forming is achievable at a close and consistent tolerance class of IT 5 to 6, and spline quality is improved typically by 40%. This is possible because of the special frequency cold forming process and a special high-stiffness tool system, which allows for a fine adjustment of the inner diameter of the spline forming die.
The axial forming machine can be used to produce a wide range of different forms, profiles, internal and external splines, and blind holes etc. It is especially used by the automotive industry for low and high-volume production of a broad variety of parts with spline characteristics. Examples of such parts are transmission main shafts, transmission input/output shafts, camshafts, rear axle shafts or steering shafts. Other examples in additional industries are different spline profiles such as involute toothing, ball track profiles, cylindrical serrations, and diametric pitch splines.
The machine is available with a horizontal process layout for longer parts (up to 1,800 mm), and with a vertical layout for shorter parts (up to 300 mm). Both machines have 600 kN in press force. It is also available in other customized equipment layouts for example as integrated units in transfer lines.
Rotary Swaging Rotary Swaging for production of lightweight and economical components
Rotary Swaging for production of lightweight and economical components
Rotary swaging is a special kind of cold metal forming, which can be described as a high-speed multi-hammer process. The hammering process is especially applicable for the forming of hollow, thin-walled, and light-weight external and internal geometric parts with high strength arising from the work hardening of the part material. The inner geometry is obtained by inserting and positioning internal mandrills during the swaging process. When several tool segments strike the workpiece simultaneously with a speed of more than 1000 strokes per minute, the material starts to flow and is formed with high level of precision. Rotary swaging is designed as a cost-efficient alternative to traditional metal forging and machining operations.
Two types of rotary swaging exist, namely in-feed swaging and recess swaging. High-precision swaging is achievable with the method of recess swaging with a mean value up to Ra 0,1 µm in surface roughness. For in-feed swaging the surface roughness would be in the range of Ra 1,0 µm. Felss is offering rotary swaging machines with standard sizes covering a part range of Ø0,4 – Ø120 mm for hollow components, and Ø0,4 – Ø65 mm for solid (bar/wire) components.
The technology of rotary swaging offers a broader range of possibilities than most other cold forming processes because of the wide range of forms and different degrees of deformation. Rotary swaging is in particular used in the automotive industry for mass production of a broad variety of parts. Examples of such parts are steering upper and lower shafts, steering input shafts, drivetrain side- and intermediate shafts, transmission main-, input- and output shafts. The technology is also widely used in other industry applications.
The swaging units are offered as stand-alone machines or as units for integration into a production line / cell, or the complete transfer line itself.
Transfer Systems Transfer Systems for time-saving production of ready-to-install components
Transfer Systems for time-saving production of ready-to-install components
Felss Transfer Systems allow time-saving production of ready-to-install components in just one machine run. The transfer system is designed and built as modular systems interlinking different technologies. This is possible because of the core competencies within the Felss Systems combined with other technologies such as turning and milling, stamping, rolling, and marking. Semi-finished products can thus be processed to the ready-to-install stage in one pass. The Felss Transfer Systems also allow systems to be integrated for feature testing such as cameras or measurement and test stations.
The advantages of Felss Transfer Systems are the ready-to-install light-weight parts in just one machine run, which minimizes the work in process as well as handling and personnel costs. The forming processes also run in quick succession and it is therefore a time-saving component production.