Upsetting
Upsetting is based on the principal that two tool segments enclose a partially heated tube, which will then be upsetted axially by one or two mandrels. Upsetting is not limited to tubes, also bars can be partially formed. By using the tool geometry, specific contours can be realized in the part.
Advantages of Upsetting
- Weight reduction: The upsetting technology offers the possibility to define a specific wall thickness distribution, especially when it comes to weight-critical parts e.g. in cars. The upsetting technology allows for a change from solid material to tubes.
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Material savings: By using the upsetting technology and the corresponding shift of material, parts can be formed to defined geometeries without any loss of material. The real material usage can be reduced significantly.
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Quantity reduction of single components: Products, which were so far welded together out of several single components, can now be formed out of one single semifinished part. This results in a tremendous cost reduction for stock-keeping and provisioning of single components. A standalone solution has no welding seams and consequently no critical microstructures.
- Safety: Parts, which are produced by upsetting, do generally present a more homogenous fiber flow. Based on the uninterrupted fiber flow, parts can be exposed to higher forces in comparison to parts, which are produced by machining.
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In addition, the upsetting technology potentially allows for a replacement of the friction welding processes. This also results in material savings as the upsetted geometry is a "near shape" geometry, so very close to the contour of the final product.
