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XtruForm

XtruForm (XF) is our forming machine that uses stretch-roll forming (SRF) technology. SRF is a patented, numerically controlled metal forming process for stretch forming extrusions to arbitrary geometries. Utilizing SRF technology produces parts with stress residuals and geometrical accuracy comparable to those achieved by stretch bending but yields significant cost savings as well as a number of other advantages and new capabilities compared to traditional stretch bending. 

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  • Eliminates tooling and reduces heat treatment​

  • One-step forming in –W or –T; Pre-forming in –O​

  • Improved material utilization by nesting parts​

  • 5 DOF articulation for compound contours along yaw, pitch, and roll axes + automated alignment​

  • 120 ipm forming speed​, 20-inch minimum radius

  • Forms all formable alloys and tempers

  • Springback compensation via CNC program

  • Full-featured GUI

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​​Options and Accessories:

  • Packages for different Z- and C- size ranges, bulbs, reverse flanges

  • Pinch roller packs and jaw inserts/belt packs

  • XCAM - on machine CAM from DXF/IGES/STEP

  • XtruClean (XC) accessory for cleaning and deburring parts

  • XtruInspect (XI) accessory for part inspection​

  • XtruTwin (XT) software for database management​

  • XtruNest (XN) option for XP to optimize material usage

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How XF works 

The Stretch Roll Forming (SRF) technology, embodied in our XtruForm (XF) machines, stretch bends components to the required contour. The process resembles CNC roll bending in the way the contour is produced but adds a longitudinal stretch force to prevent section buckling, reduce springback and reduce residual stresses. SRF works by using two sets of opposing stretch stations, exit and brake stations, that act like players in a tug-of-war game with the extrusion as the rope.

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To increase the stretch force at each station beyond what can typically be applied by rollers, belts are used to apply traction forces to the extrusion.  Each station has a pair of vise jaws that clamp across the legs of the cross-section and apply traction forces along the length of the part. The cumulative effect of the incremental stretch force applied by each station on the exit and brake sides results in the maximum stretch force in the extrusion occurring between the exit and brake stations. 

The bend contour is controlled by moving and orienting the traction stations with respect to the stretch bending plane, to bend the extrusion to the curvature required.  Dynamic CNC positioning of the exit stations as the extrusion flows through the stretch bending plane is required to bend it to the curvature required at each point along the length, and to follow the motion of the bent extrusion as it moves through the stations.  

XtruForm machines can create contours both in yaw plane and pitch plane, allowing production of complex parts with 3D spline contours.

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