Ahlen, May 18, 2010 - New standards in flow-forming technology -
- New product development of the world’s largest flow-forming machine
- Precise flow forming of tubes over 13 metres long
- Giant machine dimensions: 30 m, 120 tons
Leifeld’s latest challenge was to design the world’s largest flow-forming machine for a Chinese customer. Leifeld was chosen over its competitors in recognition of its first-class service, excellent price/performance ratio, and four critical requirements: variable forming lengths, quality of manufacture, flexibility for different applications, and economy of production.
New dimensions in forming
Leifeld’s new ST 650 H 9100-4RS flow-forming machine makes new forming dimensions possible. Until now, simple parts worked with low precision technologies. With this pioneering technology, Leifeld has established new standards by allowing tube forming in forward flow-forming up to 9 m and in reverse flow-forming of 13 m and more. Compared to a standard 3-roll flow-forming machine, such as the Leifeld ST 650 H 3100 S, with a reduced wall thickness of 30% the new design will draw out a semi-finished product of higher quality to 13 m, instead of 4.3 m, in reverse flow-forming in one run-over.
Up to now, high-strength materials were formed with a wall-thickness of up to 28 mm. The flow-forming machine realizes its true capacity. With Leifeld’s new design and high-precision forming, wall thicknesses of more than 30 mm are now possible. In addition, this machine can achieve the reduction limit of 90% fully in only one run-over.
Perfectly designed: The world’s longest flow-forming machine
Leifeld’s engineers were challenged to develop a new concept for a large-scale flow-forming machine that could be built in only eight months, while maintaining an attractive price/performance ratio and low entrepreneurial risk.
To achieve this, the machine was designed to employ reinforced module assemblies from the smaller ST machines, so that all of the main components could also be used in the construction of smaller machines, with a reduced manufacturing time. Comprehensive use of modern and uniform CAD systems made it possible to involve external suppliers at an early stage of the design process, shortening design and production to a possibly record-breaking time.
In order to increase the forming capacity, Leifeld relied on a 4-roller flow-forming slide which sets new limits in flow-forming technology with regard to force, stiffness, and precision. Furthermore, the forces of the roll feed axes were considerably increased tremendously. Sliding guides were installed for the take-up of the high radial forces using the smallest construction space. The slide frame with the four radial flow-forming sleds was also optimized for stiffness and strength.