Axial forming

Frequency-modulated axial forming

Axial forming is a process of cold bulk metal forming, which can be used to integrate longitudinal internal and external profiles in net-shape quality into rotationally symmetric components. The recursive feed motion of the tools causes significant reduction of the forming force compared to continuous processes. Thus thin-walled lightweight structures can be realized with profiles generated by forming technology so that the profiles do not fail when subjected to the forming force.

The shaped elements obtained by axial forming are characterized by high accuracy, excellent surface qualities, continuous fiber orientation, integrated strain-hardening and residual compressive stresses. These characteristics generally lead to increased fatigue strength.

  • Manufacturing of gears in a light-weight shaft for a modular concept of electric powertrains

  • Utilization of new high strength materials
  • Gear manufacturing without reworking
  • Manufacturing of complex component geometries

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and technological dimensioning of processes, tools and machines

Development and evaluation of forming strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes

Quality assurance

  • Certification according to ISO 9001
  • Statistical process control (SPC)
  • FMEA

Machine technology

  • Axial forming machine AXIMUS V02


  • Simulation software: Simufact, Forge, Ansys
  • Design software: Pro Engineer Creo, Catia V5
  • Statistical design of experiments: Cornerstone