What is axial forming?

In axial forming, the shape-defining tool is moved axially over a firmly clamped workpiece via its entry cone The tool’s internal diameter or internal profile, for example a spline geometry, is formed directly to the workpiece. The tool is made from a hardened sleeve or, in reinforced form, preferably features a carbide core. For tubular components, the tool can also be designed as a mandrel to shape the internal geometry. The high precision of the tools can be transferred directly to the component, although suitable measures must be taken to compensate for elastic springback.

A special version of the process, known as recursive or frequency-modulated axial forming, builds up the forming force through small, repeatedly interrupted forward movements alternating with incrementally smaller reverse relief strokes. This process is patented by FELSS GmbH. The sequential movement – “two steps forward, one step back” – repeatedly relieves the forming zone, helps prevent the lubricant film from breaking down and can reduce the required press forces by up to 50%. As a result, even very thin-walled components can be formed without the risk of bulging or buckling.

Applications:

• Splining solid and hollow shafts, stub shafts, sliding elements and similar components
• Involute and serrated splines, up to module 2.5Evolventen- und Kerbverzahnungen (max. Modul 2,5)
• Forming of high-strength materials
• Forming of thin-walled lightweight components
• Production of internal splines

Neben der Entwicklung, Erprobung und Prototypenfertigung bieten wir auch Lohnfertigung an. For this purpose, we have, among other equipment, a horizontal, highly flexible hydraulic axial forming machine with up to 50 t press force (30 t with frequency modulation) for workpieces up to approx. 70 mm in diameter and 1,000 mm in length. The working stroke is up to 260 mm. The system is designed as a semi-automatic machine.