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.

Grafik

Drill Pipe according API Standard

Ø 2.3/8“ – 6-5/8“

  • Lengths 1.5m – 14m
  • Drill pipe for the oil and gas industry and for steered ground drillings
  • Possibility to upset on both sides: External Upset "EU", Internal Upset "IU", Internal External Upsaet "IEU"
  • Upsetting operation in order to realize an external thread as connecting element
OCTG Drill Pipe

Camshaft for Cars

Ø 24.5 x 3.25 mm

  • Upsetting on one side
  • Machining afterwards
  • The product is used in a six-cylinder sports car
  • Upsetting in three steps in order to thicken up the wall at the end of the tube
Camshaft for Cars

Camshaft for Cars

Ø 24.5 x 3.0 mm

  • Upsetting on one side
  • Machining afterwards
Camshaft for Cars

Camshaft for Cars

Ø 26.5 x 4.25 mm

  • Upsetting on one side
  • Machining afterwards
Camshaft for Cars

Camshaft for Cars

Ø 24.0 x 4.25 mm

  • Upsetting on one side
  • Machining afterwards
Camshaft for Cars

Active Stabilizer Bar 
for SUVs

Ø 93 x 6 mm

  • Upsetting on both sides (3 steps)
Active Stabilizer Bar

Passive Truck Stabilizer

Ø 80 x 10 mm

     

  • Used as truck stabilizer bar in the rear axle
  • Upsetting in two steps
  • Upsetting and expanding on both sides
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Truck Stabilizer Bar

Pressure vessels, used for sporting weapons

Ø 33 x 2.2 mm

  • In order to be able to realize the inner thread, the wall thickness on both sides of the tube has to be partially upsetted.
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Pressure Vessels

Construction Steel / Reinforcing Bars

Ø 12 - 28 mm

  • Upsetting on one side
  • Upsetting operation in order to realize an external thread as connecting element
  • Lengths up to 6.000 mm
  • Reinforcing bars for reinforcement continuity system
Construction Steel / Reinforcing Bars

Construction Steel / Reinforcing Bars

Ø 12 - 28 mm

  • Upsetting on one side
  • Upsetting operation in order to realize an external thread as connecting element
  • Lengths up to 6.000 mm
  • Reinforcing bars for reinforcement continuity System
Construction Steel / Reinforcing Bars

Drive Shaft (Solid Material)

Ø 26.5

  • Lengths 930 - 600 mm
  • Possibility to upset on both sides
  • Upsetting operation in order to realize a spline as connecting element
Drive Shaft (Solid Material)

Fields of Application

  • Camshafts / tubes
  • Drive shafts
  • Steering columns / steering shafts
  • Steering racks
  • Gear shafts
  • Axles
  • Stabilizer bars
  • Drill pipes
  • Pressure vessels / cartridges
  • Furniture tubes
  • and many more…

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.

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  • 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.

  • 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.