Processes

Here you will find useful information about the different processes we implement with our machines. Whether you are interested in straightening, joining and pressing or measuring. Here you can find out what the processes are all about and what tasks they are used for best.

On this page:

Straightening

The deformation of metal workpieces is an undesired, yet material inherent consequence of various metal working and refining processes. It requires a sophisticated straightening process to bring the parts back into their ideally designed shape, so that these high-quality components can perfectly and durably fulfil their intended tasks.

MAE offers a wide range of machines for the precise and highly sensitive straightening of diverse workpieces, which meet the highest standards.

We look forward to putting our experience at your disposal for designing a concept that fulfils all your requirements.

Our machine concepts use conventional bend straightening and pressure straightening for through-hardened parts.

Torsion straightening for twisted profile bars, racks and guide rails is a special process for untwisting long workpieces in one or more sections.

We offer torsion straightening integrated in automatic and manual straightening systems or as a separate solution.

The MAE straightening stroke control of our manual S RH and P-H RH series guarantees sensitive, repeatable work and does not require specially trained operators. Measuring and straightening in one clamping ensure favorable cycle times.

Our M-AH and ASV series automatically straighten shafts and profiles in various lengths, while the M-ASRU series automates the straightening of spatially shaped components.

The software of the RICOS straightening computer is the result of decades of experience with a wide variety of tasks.

Innovative ideas make the straightening process ever more efficient and faster. Different interlinking concepts allow rational, low-personnel, and, if desired, fully automated continuous operation.

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Joining & Pressing

Joining & Pressing

Not only the straightening of workpieces is in our DNA. We are also your competent and reliable partner when it comes to joining and pressing components. Whether you are looking for machines individually designed to meet your requirements or want to make use of our modular system, we have the right press for every task.

Whether you are joining gear parts, rotor shafts or wheel sets: We have the right solution for you. The MAE machine series S with hydraulic servo drive offers customized and robust systems for your task.

The OPUS control system controls and documents the joining process. The software is customer-specific expandable.

Our horizontally acting double-cylinder wheelset presses of the RADS series with forces up to 6,300 kN are the specialists when it comes to assembling and disassembling wheelsets for rail vehicles.

They are particularly characterized by the innovative basic concept, the rational interlinking systems and the extensive control functions.

A modular system is the basis for the wide range of our standard hydraulic presses of the S and DS series with C and O frames.

For your specific task, we combine individual assemblies, adapt them and thus find a cost-optimized, individually optimized solution with pressing forces of up to 25,000 kN.

Hydraulic presses are subjected to considerable loads in daily operation. With over 60 years of experience, we therefore dimension particularly solidly – all components.

Extensive calculation software including a high-end finite element program is a further guarantee for exceptionally durable designs.

Please contact us for this purpose:

Measure

Measure

In everything we do, measuring the machined components plays an essential role. For both our straightening machines and our wheelset presses, we rely on precise and reliable measuring technology in addition to decades of experience.

In addition to measuring straight or profiled components with demanding geometries, we also reliably measure running and mating gears.

Our straightening machines are equipped with a tactile measuring system individually designed for the special features of the different workpieces. With a freely selectable reference base, you measure relative to the peaks or to two selected base measuring points – depending on the requirement or workpiece. Our RICOS directional measurement control system processes up to 1,000 measured values per revolution at all probe positions in real time. In this way, shape defects such as ovality or surface roughness are reliably detected. They are calculated, checked for compliance with the tolerance and mathematically separated from run-out errors.

But also the precise measuring of running or mating gears is no problem with our straightening machines:

  • Our patented ball probe is particularly suitable for hypoid gears and small production lots.
  • Master gears are the standard for quickly measuring running and mating gears. Our RICOS evaluates single and cumulative rolling jumps separately. Patented compensation software mitigates the influence of the master gear runout.
  • The TRILOS laser measuring system offers wear-free measurement of the vast majority of gear types. The robust design, automatic retooling and largely automatic set-up for new gear teeth are the special features of this system.

Our universal measuring device allows all geometric data of the wheelset relevant for the pressing process to be recorded in the automatic sequence. The axial positions of wheel and brake disks, gear components and shaft reference surfaces as well as the seat diameters on the wheelset shaft are taken into account. In addition, axial and radial runout of shafts, wheels and brake disks can be measured while the wheelset is rotating.

Depending on the task, tactile or laser measuring heads are used.

The collected data is recorded by our RACOS wheelset press control system and evaluated in real time.

At the same time, this makes our wheelset presses fully-fledged measuring machines, eliminating the need to measure the wheelset in another, external machine.

Please contact us for this purpose:

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Process: Straightening | Joining | Pressing | Measuring