Complex forms with minimal tooling costs
Rolling tube forming also masters demanding challenges efficiently
The demands for tube processing are increasing. Geometry is becoming increasingly complex and materials are becoming ever stronger in connection with progressively light design. At the same time there are louder and louder calls for efficiency across all sectors. Rolling tube forming by Transfluid offers a solution – this is a process that opens up special opportunities for forming and reduces the use of tools to a minimum. Rolling technology always displays its particular strengths most clearly if forming is to be carried out on tubes that have already been axially preformed, if sharp edged contours need to be created for sealing elements or if perfect surfaces are required.
One rolling head, various processes
For the tool-independent tube forming and for the creation of almost freely formed geometries all t form bead rolling machines by these specialists for tube processing machines have a servo-electric drive and an easily operated CNC control system if required. This allows the functions of different axes to be moved in an overlapping fashion. As all the setting parameters are stored there are no complex adjustments and this saves valuable time. The forming process is possible both from outside to inside and from inside to outside. Further advantage of rolling tube forming: even completely different geometries can be formed with a single tool, a clamping jaw and the rolling head. Tool wear is almost totally ruled out in a rolling process. The lubricants that are necessary in the forming process can also be reduced to a minimum.
High-strength materials and forming with flanges
If very demanding forming is necessary on high-strength materials then a closed rolling head is used. The forming rollers are completely supported within this. The forming of highly complex geometries without space in the axial direction is carried out using three rollers that are included in an open structure. This means that the roller geometry can be carried out directly on a tube/flange connection. It is also possible to roll threads or add edge designs with the same roller head and the corresponding rollers, with or without forming, depending on requirements. Trimming of already bent components can also be realised by rolling tube forming without cutting and almost without burrs.
Forming and separating
If complex geometries need to be formed almost without clamping length then a roller head takes over this role, allowing the rolling or separating process across two rollers. One roller is positioned as support on the inside or outside of the tube while the counter roller delivers the form. This kind of inner support or forming roller can be used from an internal tube diameter of 12 mm, whereby very different tool pairings can be used. For example this makes it possible to form and separate simultaneously. Another advantage of this technology: the excellent surface quality that is created by the forming. It is usually possible to do without a cost-intensive form clamping piece on tubes that have already been bent. This is because of the extremely low loads that are transferred to the tube during the rolling process.
If the rolling tube forming reaches its limits for specific forming processes then it is of course also possible to use pre-compressed tubes in the rolling process – or the rolling machine can be combined directly with a compressing machine. Transfluid is also offering a solution to this challenge with its combination machines, making even extreme forming reliable and safe.