Processes & Machines
The Felss Group employs a variety of production processes – rotary swaging, axial forming, bending, autofrettage and tube end machining. Felss unites innovative technology with smart ideas to create tangible benefits for users.
What is rotary swaging?Rotary swaging is a traditional metalworking process involving almost no cutting in which blank tubes are formed by dies that open and close up to 1,000 times a minute.
What is axial forming?The geometry of components often incorporates toothing or splines. Axial forming allows outer and inner toothing to be created on rods and tubes in a single operation.
What is bending?Fuel, electrical and hydraulic lines and components used in heat and refrigeration systems need to be engineered and manufactured for an exact fit. This often requires complex and precise bending operations.
What is autofrettage?The tubes in automobile engines and hydraulic systems often need to withstand extreme pressures. To optimize the strength and stability of these components, autofrettage machines use pumps to briefly raise the pressure inside the tubes to as much as 9,500 bar. This alters the microscopic structure of the tubes' inside walls.
Machining tube ends
What is tube end machining?The finish of a tube end is crucial to a precise fit with other components. To ensure that a system is properly sealed, tube ends need to be machined with care for exact sizing and a perfect finish.
Rotary-swaged components are lightweight and manufactured precisely and efficiently. Rotary swaging also offers a lot of flexibility in terms of design. Developed more than a century ago, the process still has many advantages.
Injection pressures in excess of 2,000 bar enable engines to use fuel even more efficiently. Autofrettage ensures that lines and tubes are robust enough to withstand high alternating pressures.
The four “E’s“ are the defining capabilities of an innovative machine solution: ease-of-use, expandability, elasticity and energy efficiency. The benefits for users include variable lot sizes and systematic quality control.
Splined parts are often manufactured in a mass-production environment where the goals are always high precision, speed and resource efficiency. That’s something axial forming can deliver.
When bending fuel lines and E-drive wires or components for refrigeration and thermal engineering, it’s the whole process that counts. Our tube specialists produce turnkey, perfectly interlinked system solutions.
The Aximus generation of systems uses Felss's patented frequency-modulated axial forming to produce splines. The benefits for users lie in the systems’ modular design, efficiency and precision.