TPT March 2011

A utomotive T ube & P ipe M anufacturing

High volume component cutting for automotives systems are available. As an example, the capacity for tubes of 100mm OD, wall thickness 8mm and cut length 20mm is 4,000 cuts per 8-hour shift, equalling 2.5 million cuts per year.

FOR some applications, cutting to length is not enough – cutting to the precise dimension is required. Plantool’s state-of- the-art cold circular saws are designed for precise mass production. The cutting process is optimised by using intelligent, rigid machines, effective chip removal and the right lubrication of tungsten carbide tipped (TA) blades. For tube and pipe cutting Plantool provides its patented multifunction technology. The principal idea of the company’s patent is to combine turning of the pipe with two or more simultaneously cutting blades. As a result of this innovation the cut off process is faster, produces fewer chips, consumes less energy and extends the life of the saw blades. Plantool’s saw type 2/15 HF uses the patented multifunction cutting technology. The machine has been designed for tube cutting up to 140mm diameter, and is equipped with two blades attached to spindles with one 15kW motor each. Semi- automatic and fully automatic feeding EMS, France, is the manufacturer of a complete range of tube end-forming machines with standard working power from 30kN to 800kN. These machines – electrically or hydraulically driven – are utilized in the fabrication of automotive products. The single or double machines enable the forming of one or two ends, with a maximum of 10 successive working stations. The machines require no setting down of the tube and include end-forming, chamfering, machining and rolling operations. The company recently supplied its machinery to a German automotive subcontractor to simultaneously end-form

scopes of delivery: stand alone saws; saws included in an integrated production line; saws dovetailed with the customer’s existing production system; or saws as integrated parts of special purpose machines. Plantool Oy – Finland

Plantool has served customers in the metal industry since 1976, and since the 1990s has delivered over 80 circular saw units. The company offers four different

Email: plantool@plantool.fi Website: www.plantool.fi

Plantool’s 2/15 HF saw

Complex tube end-forming in the automotive industry

both ends of stainless steel bent tubes. This task is difficult as both ends of the tube are not located on the same axes. In carrying out this work, an important ID expansion of 50 per cent was achieved. The machine developed by EMS was able, under one clamping movement, to perform extreme end-forming with a working power of 400kN. EMS is still currently developing the cutting machine systems for this process. In addition to the classic CT system using knives – that allows cutting of over-length without scraps – EMS has also developed the CTR model. The CTR machine is based on a wheel that approaches and cuts the tube from

inside to outside. The result is a clean cut, without burrs and deformation. The new fully electric model of cutting machine (type CTR AK), allows a combination of cutting, rolling and calibration of tubes up to Ø 400mm, with all type of material and wall thickness. The new model also cuts tubes with several angles, without any burrs or deformation. The new model is highly appreciated by the aerospace and exhaust industries because it is silent and electrically driven, and allows manufacturing of tube ends without scraps or burrs. EMS also undertakes the manufacture of full automatic production lines for manufacturing press-fittings. The operations for this area include cutting, chamfering and end forming of stainless steel, steel, brass or copper tubes for the heating and sanitary industries. EMS is a leader in production lines or machines for mounting of catalytic exhaust systems, including forming, mounting, spinning and measuring technologies. Other EMS services include maintenance, supply of cutting and end-forming tools, and production of pre-serial prototypes. EMS – France Website: www.ems-sa.com

The tube from the German automotive subcontractor, end-formed using EMS technology

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M arch 2011

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