Felss Group GmbH

The cold forming process rotary swaging enables efficient and economical production of lightweight components. In this process, several tool segments act simultaneously on a workpiece in rapid succession. The material to be machined begins to flow and is formed with high precision. The process is suitable for forming a wide variety of external and internal geometries. It offers a much wider range of possibilities than most other cold forming processes. For example, a hose connection is just as possible with it as the high-precision and fast production of steering spindles, drive shafts, airbag cylinders or actuators.

Axial forming offers advantages in many different areas of application, especially for high-quality gear components that require economical production processes. With axial forming, all gear dimensions are achieved with the highest precision. Since the gearing is an exact copy of the tool, there are basically no pitch errors. The profiles are highly precise and the root radius is completely symmetrical, which significantly increases fatigue strength. Each component is produced in short process times and, unlike machining processes, the strength of the components is increased.

The Tube+ process developed and patented by Felss enables partial tube thickening in the cold forming process for the first time. The process is used in the production of precursors that contribute to simplifying the process chain in subsequent steps. It represents a supplement or alternative to rotary swaging.

Since the acquisition of the HMP companies in 2019, the Felss product portfolio also includes rolling technologies and equipment of various kinds. Whether wire reducing rolls, flat and profile wire rolls, ultra precision rolls, strip rolls or cross profile rolls.

Generation e - a new dimension of flexibility

Be it through batch size adaptability at short notice, long-term expandability of production lines or consistently simple process control: generation e expands the playing field for the numerous utilization advantages of cold forming, thus enabling not only more efficient production processes but also economical component designs in completely new application areas.

E for energy efficient:

Produce sustainably - reduce your energy and raw material consumption. With Generation e, your production is 25% more energy-efficient: the new design not only saves you electricity costs during production, but also operating materials such as lubricating oil - without compromising on production quality. And that's good news not only for your wallet, but also for the environment.

Electric axes: Lower power consumption thanks to intelligent energy management and elimination of hydraulic reactive power.

Stand By: Elimination of energy consumption during downtimes thanks to energy-saving mode.

Lubrication on demand: Targeted lubricant application for lower oil consumption and more cleanliness.

The rotor shaft is produced by a newly developed production process that intelligently links rotary swaging, axial forming and heat treatment. This process allows the hybrid shaft to be realized hollow and with a much simpler plug-in spline.

Component weight reduced

Producing the rotor shaft from tube using the rotary swaging process is not only highly accurate and fast. It also significantly reduces the weight of the component. Weight is an important factor, particularly for electric cars, because every kilogram less increases the range of the vehicles with their relatively heavy batteries. The newly developed production process, in which rotary swaging, axial forming and machining processes are intelligently combined, offers great opportunities for Felss Rotaform in the future .