Various machines and accessories
Cemsa introduces new electro-upsetting machine for tubular bars
Innovation in electrothermal forming processes continues to evolve to meet the demands of the automotive industry, where precision, reliability, and energy efficiency are becoming increasingly important. In this context, Cemsa International has expanded its product portfolio with a new single-station electro-upsetting machine designed for the production of special tubular bars used in automotive suspension systems.
Advanced technology for more efficient production
The new solution builds on Cemsa International's extensive expertise in resistance welding and electrothermal forming technologies. The system is equipped with a power unit combining a three-phase inverter with a high-power single-phase transformer, capable of operating at a 100% duty cycle.
Compared with conventional AC systems equipped with SCR control, this configuration reduces energy consumption by up to 40% while ensuring precise heating control, consistent part quality, and greater operational reliability. These features contribute to lower operating costs and improved overall process efficiency.
Precision, safety, and automation-ready design
In the single-station configuration, the electro-upsetting process takes place inside a closed die positioned between the current-carrying electrodes and the anvil. The two ends of the tubular bar are processed sequentially to accurately form the required internal and external enlargements. A subsequent mechanical operation completes the final geometry of the component, helping to simplify the overall production cycle.
Particular attention has also been paid to safety and ergonomics. The machine is designed to be operated by a single operator and incorporates a protection system with photoelectric safety barriers. In addition, it is already prepared for future integration with robotic automation systems, providing manufacturers with a platform ready to support the transition toward smart manufacturing.
A development focused on the future
The machine's main technical features include a rated power of 160 kVA at a 100% duty cycle, a maximum upsetting force of 10,000 daN, a clamping force of 20,000 daN, and the ability to process tubular bars up to 2,000 mm in length.
Development is underway on a two-station version designed to process both ends of the bar simultaneously. This evolution is expected to further increase productivity, reduce cycle times, and enhance overall process efficiency, reinforcing Cemsa International's commitment to innovation in the metalworking industry.
For more information or to request a customized quotation, please contact the company using the details provided on this page.
