Axial Forming.. 1
From Expanding... Axial Forming Hydraulic forming is an axial forming method for tubes and bars. The forming process is executed by means of a die. When forming a tube, a mandrel can be used additionally. With this method it is also possible to expand tubular workpieces. Principle: The workpiece is clamped in a hydraulically actuated multi segment chuck. The main working cylinder pushes a tungsten carbide die, carried in a reinforcement retainer over or onto the workpiece. In case of a tubular workpiece a separate cylinder moves a mandrel inside the tube. This can be done before, during or after the movement of the forming die. With this method, both the outer and the inner diameter can be processed. The stroke of the forming cylinders determines the forming length, whereas the die and mandrel determine the formed shape. Also non-symmetric or excentric shapes can be formed. 5 3 1 Forming cylinder (movement of cylinder) 2 Mandrel 3 Chuck cylinder (movement of the chuck) 4 Die 5 Workpiece 4 2 1 Tolerances: The lubrication between the die and the workpiece is done with a forming oil. It is usually sprayed onto the workpiece by a minimum quantity lubrication system. There is no need for a special surface coating of the workpiece for carrying the lubrication. The stroke and the speed of the cylinders are controlled by a progammable controller and can be adjusted. Achievable tolerances are in the range of ISO-class IT6 to IT8. Precise splines and serrations can be manufactured with a tolerance of below +-0,02 for the over pin diameter. 2
... To splining Example of shapes that can be manufactured: Expanding Reducing Profile forming Splining Flanging Upsetting 3
Impulses... Pulsation Forming = Extended Limits Axial forming machines from HMP are well proven and in use for many years for the forming of tubes and bars, particularly also for the manufacturing of High precision splines and serrations. Reinforced dies made out of tungsten carbide are pushed axially onto prefabricated blanks and then pulled back. The complimentary profile of the tool is thereby produced on the workpiece. This relatively well known process was developped by HMP to the present level of technology by means of carefully designed and assembled precise machines, continuously improved manufacturing engineering and tribology, and especially through modern tooling know how and manufacturing methods. Pulsation forming does the forming sequentially in small steps instead of working with a continuous forming speed. This innovation permits: Reduced forming force Possibility to form also thin wall tubes Conventional Forming: Pulsation Forming: F o r c e F o r c e Time Time 4
... For better Splines Impulses for better splines Increasing demands for the precision of male and female splines demonstrate the limitations of traditional processes like rolling, rackrolling, broaching and hobbing. Economy, reliability and simple operation are also good reasons for hydraulic forming. Field of application and advantages: - Male splines and other outer profiles - Female splines and other inner profiles - Serrations or splines according to DIN or SAE - Inner splines can be formed also in blind holes - Tolerances according to class 5 (DIN 3962), or better - Die can be adjusted in over pin diameter (+-0,02mm) - Block teeth or missing teeth possible - Low tooling costs - Cold formed workpiece - Uniform residual stress - Very small pitch errors - Splines with helix-angles are possible - Short cycle times (typically about 12 sec.) - Excellent surface quality - Low distortion in case of heat treatment process - Good straightness and concentricity - High tool lifetime 5
Workpieces Further application examples: 6
Machine examples: Machines Modular machine concept: Hydraulic forming machines from HMP are characterized by the well proven modular design. Single station cells as well as multi station linear transfer lines are offered. The machines have high uptime, high output and are very flexible. Changeover and operation is very easy. Our machinery program: Axial force: up to 4000 kn Workpiece diameter: up to 200 mm Forming stroke: up to 1000 mm Forming speed: up to 50 mm/s Installed power: up to 180 kw HMP offers a die changing system as an option. Several forming steps can be performed in one workpiece clamping. Fully automatic forming machine with a cycle time of 5 seconds 7
Your way to us By car: Take highway A8, exit Pforzheim West/Zentrum, exit No. 43, turn right at the first traffic light, turn next left (not into the parking lot) after 200 meters, and then again next left. Visitor parking (Besucher) is located directly in front of the building. By plane: The nearest airport is Stuttgart, from there take highway A8 to Pforzheim. From Frankfurt (Main) Airport take highway A5 (direction Basel), at junction Karlsruhe change to highway A8 to Pforzheim. By train: Pforzheim main station, from there approximately 10 minutes by taxi. 8