END-FORMING MACHINES

The Walform machine offers several benefits for the connection system, including:

• Portability: The machine is designed in a portable form factor, making it easy to transport to different job sites.
• High Quality: The machine ensures consistent high-quality standard with efficient reshaping of tube production.
• Reliability: It provides lasting functional reliability even under dynamic pressure impulse and high vibration loads.
• Avoids Faults: The machine reliably avoids both insufficient and excessive tightening, which are common causes of faults.
• Assembly Assistance: It serves as a final assembly stop, guaranteeing standard re-assembly and assembly of the system.
  These benefits make the Walform machine a valuable tool in various industries that require high-quality and reliable connections. 

Features of walform assembly: 

• Meets fitting DIN 2353 standard requirement
• Viton Walform seal with secondary metallic seal
• One piece of reshaped tube is required
• Fewer of components are required
• Low torque and equal standard

Benefits of walform assembly: 

• Connection meeting market industry specifications
• Eliminates leak path and does not allow tube pull-out easily
• Redundant sealing for overall system performance improvement
• Fewer components reduce material and labour cost
• Large volume of high quality installation assemblies can be produced efficiently and consistently
• Provide an easy, simple, practical and safe assembly process that can be carried out by anyone
• Unmistakable pressure point clearly indicates the end of the assembly travel; it makes excessive or insufficient tightening virtually impossible as the standard is consistently controlled by the machine assembly
• Manpower cost saving; the machine requires only one man to operate one machine and lesser time is required to configure a tube and larger volume can be produced
• Material cost saving; the minimizing mistake can help to reduce wastage as well as cost of replacing the tube and fittings that are damaged in the assembly process

4. What is a walform machine installation tool?

   Before operation of walform machine, the right tool installation is required such as reshaper, clamping jaw and removing tool. Both clamping jaw and reshaper come in two types of material, 316 Stainless Steel and ST37.4/52.4 Carbon Steel

   The application jaw size measurement is according to the tube outer diameter size. The reshaper has three types of design, with or without internal support and adapter ring. The selection of the correct reshaper design is based on the tube material and wall thickness, refer to table below for further information:
   
   

5. How does the machine improve business productivity compared to conventional method?
   
   The process to create reshaping tube is made simpler with shifting from conventional manual method to partial machine method. The need is to prepare a worker to insert the tube into the configured walform machine. The primary cause issue in system installation is internal or external fluid leakages. With applying the walform machine in system installation, the overall system performance efficiency is improving whilst the risk of leakages is being reduced.

   The time required to produce a reshaped tube with walform machine is 5 to 8 seconds compared to conventional manual method is at approximately 60 seconds. Overall, the Walform machine saves at least 50 seconds for each tube reshaping process and this transform to 6 to 10 more tube reshaping can be made. Therefore, the overall productivity and output increases.

6. Start-up & preparation of Walform machine
   
   Step 1: Tube preparation

   Saw off the tube at the right angle according to the length required. Deburr the tube ends from external and internal with a maximum 0.2mm size allowed. Remove the paint in the clamping and reshaping area if any is found. Clean the bare metal of the tube end and make sure the tube is in perfect condition with no spalling and no damage.

Close the tool holder and swing the toll holder back into position. Slip the tool holder back into its mount and pull out the unlocking pin and turn both tool holder handles in clockwise direction until the unlocking pin engages again. Plug in the main cable and set the master switch to “I”, which means ON and the machine ready indicator lights up.

7. How to use a walform machine?

1. Insert the tools and close the tool holder and the red indicator lamp expires. 
2. Press the start button key and the machine is in basic position. This procedure is repeated after every tool change procedure. 
3. Press the start key button key and function key simultaneously. Hold them down for approximately 2 seconds. The ready indicator is the white indicator lamp that lights up. The insertion position will be moved by the clamping jaws.
4. Slide the nut into the tube and insert the tube horizontally up to the stop and hold it tight with your hand. Tube axis and tool axis must be coincided. 
5. Set the walform pressure on 99% and press the start key. The procedure runs automatically and cannot be interrupted by external factors. 
6. Remove the reshaped tube by pulling it from the machine. 
7. Examine and check the reshaped tube for detectable quality defects such as surface damage, spalling or cracks. 
8. Check the control diameter and kindly take note that the excessively small reshaping diameters impair the function of the fitting. 
9. When changing the tools, switch off the machine and start with the beginning step above.

Reshaper: Screw the reshaper anticlockwise out of the holder using the removing tool.

Clamping Jaw: Force out the clamping jaws by applying slight pressure and tilting at the same time. The reshaper and clamping jaw for each size always form a single unit.

8. Where is the Walform machine used at?

   Typical markets are as per below:

• Stationary/Industrial Equipment
• Marine / Maritime
• Oil & Gas
• Construction
• Agriculture
• General Hydraulics
• Metals & Mining
• Pulp & Paper
• Testing
• Steel
• Recycling
• Infrastructure

Typical applications are as per below:

• Machine Tool
• Hydraulic Presses
• Excavators
• Loaders
• Harvester/Balers
• Mining Equipment
• Concrete Pumpers
• Offshore Equipment