Introduction


During the hydroforming process, pipes and profiles are expanded using fluid media within an enclosed forming tool. This way, hollow bodies with complex external geometries and special strength properties can be produced.

 

 

Value Added Chain

Value Added Chain


Gräbener Maschinentechnik offers the entire value added chain of the hydroforming technology from one single source. Optimally harmonized and interconnected processes ensure effectiveness, economic efficiency and best results. From feasibility studies, prototyping and small series production up to the complex turnkey solution we will find the best possible concept.

 

 

 

 

Tool Engineering

Tool Engineering

 

Where as the mechanical and electric components generate the necessary forming forces and movements, the component is ultimately shaped by forming tools.Gräbener Maschinentechnik supports the customer with the tool design and if so desired supplies finished tools.

On the basis of the simluation results, we calculate the fundamental parameters, such as the optimized bending geometry, the necessary forming forces, the forming strokes and the forming pressure. As a result, the component contour and the integrated tool functions can be arranged perfectly when designing the tool.

By means of an FEM calculation, the tool concept is modeled and optimized under dynamic conditions. The next step is the authorization by the customer. The manufactured and assembled tools are tested in hydroforming presses available at the Gräbener workshop and are improved further. This procedure ensures a perfect tuning to the production system for which the tool is intended.

 

 

 

4-column presses

Customized Solutions

 

Hydraulic Presses respectively closing devices are the mechanical framework when it comes to hydroforming. Gräbener Maschinentechnik offers various press concepts which are cusomized for the respective application – with closing forces of up to 18,000 tons. As a special machine builder, we are able to create concepts which are tailored to the requirements and needs of our customers.

 

 

4-column presses

 

With a 4-column press, the upper and lower traverse are connected by means of pre-tensioned tie rods. On the one hand, this allows for an optimized deflection compensation of the construction. On the other hand, the design provides the greatest possible access to the tool area of the press. This allows the application of hydroforming tools which, including the cylinders, are larger than the actual table surface. 4-column presses are our universal presses which can be used for a wide range of applications. The accessibility from four sides ensures an optimum operating and handling comfort.

 

4-column presses are standardized for closing forces of 630, 800, 1,000, 1,200, 1,500, 1,700, 2,000, 2,500, 3,500 and 5,000 tons. These presses are especially suitable for the Opens internal link in current windowhot stamping process.

RoboClamp®



RoboClamp®

(acc. to patent EP1138410 licensed for Europe)

 
The RoboClamp® is a pre-tensioned C-frame press which is especially suitable for the economic production of long components, such as side rails or cross members, roof frames and other component groups. The RoboClamp® provides easy access from three sides; tool change and loading is carried out by robots.

 

This type of press is standardized for closing forces of 3.250, 6.500, 13.000 and 18,000 tons.

 

By the way: for the construction of the RoboClamp® as the world's most powerful hydroforming press we were honored by the ministry of economics with the award "Germany at its best".

 

Frame presses


Frame presses

 

Frame presses are designed as rigid welded constructions. These compact presses are especially suitable for the low pressure hydroformin and for smaller components, such as exhaust parts or fittings like tees and reducers.

 

 


 
 
 
 

 

 

PressPro® en

Control and Feedback Control Technology

 
PressPro®

  

An optimum forming process is also depending on a perfect interaction of operator and machine. For this purpose, the visualization system PressPro® has been developed.

 

With the aid of PressPro®, the operator can develop, optimize and execute the forming process independently. The open and flexible system allows freely definable process steps for protoyping as well as for series production. Pre-defined sequences can be assigned to aech tool, saved in the corresponding tool data base and accessed from there as well. The time between the tool set-up and the production of the first "good" part can be reduced significantly.

  

HNC-100 / MAC-8 / MLC-H en


HNC 100 / MAC-8 / MLC-H Best-in-Class-Controller for most sophisticated applications

  

So far, Gräbener Maschinentechnik, as a specialist for the hydroforming technology, has banked on the hydraulic control systems HNC-100 and MAC-8. Both controllers provide the general controlling functions for the hydroforming processes. In order to avoid developing two controller systems further, Gräbener Maschinentechnik, in cooperation with Bosch-Rexroth, combined the advantages of the two systems and developed the MLC-H.

 

 

MLC-H

 

Gräbener Maschinentechnik as renowned hydroforming specialist has developed a new generation of control and feedback control systems for all hydroforming presses on the basis of the motion logic system IndraMotion by Bosch-Rexroth.

 

The entire control system for hydraulic, electric and hybrid drives builds on a compact controller based hardware. Here the PLC merges with the motion controller to a new system MLC-H which allows an optimum control of the highly complex hydraulic process of hydroforming. Using condition monitoring, process and control parameters are optimized consistently.

 

The thus resulting reduction of cycle times, loading and tool wear are major advantages for our customers. 

 

  

 

Prototyping en

Prototyping & Small Series Production

 

With a total of now four presses available today, Gräbener Maschinentechnik GmbH & Co. KG is in possession of the world`s largest number of prototyping presses. With the former Schuler premises in Wilnsdorf-Wilden ("Schuler Hydroforming"), the Graebener Group also took over three further hydroforming presses. Thus, presses with closing forces of  2,500 and 10,000 t have been added to the already existing presses with closing forces of 1,500 and 6,500 t.

 

The 1,500 t press is used continuously by customers for prototyping and the production of parts in small and medium lot sizes. The 6,500 t press is used throughout the entire year in order to meet the ever increasing demand for metallic separator plates for the fuel cell production.

 

The completely overhauled 2,500 t hydroforming press is also used for further enhancing the open and this highly felxible control program Opens internal link in current windowPressPro® developed by Gräbener to the benefit of our customers.

 

The 10,000 t press, which by the way is the hydroforming press with the world's largest table surface (6,000 x 2,200 mm), is currently being overhauled in order to be ready for prototyping purposes or small series production. This press is especially suitable for multiple tools.

 

The experiences gained in our prototyping center are used to the best advantage for the engineering and manufacturing of new machines in order to provide our customers with a competitive technological edge.

 

 

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