Advanced flanging with smart tool solutions

Smart design and optimal timing are central to press tool implementations. The dies, each with its own task and function, are designed to run in a high-precision sequence. All steps must be carefully timed to prevent costly jam and to keep the production line running smoothly at all times.

Detailed planning is essential for every vehicle manufacturer designing a production line and its sequence. Each die in production must operate optimally, as the speed and reliability of simultaneous or sequential steps are crucial for production efficiency. When selecting the solution for each die, the manufacturer must meticulously balance force, reliability, and consumption of space of the components.
Flanging sheet metal at a small angle is a challenge, since it leaves only a very narrow space for the support cam behind the filler slide. Furthermore, the operation demands accuracy in timing and force. It must also be reversible to allow removal of the vehicle part from the die after the flanging.

Using advanced, cost-effective cutting tools

KALLER Flex Cam simplifies cutting tools by increasing the number of operations in a die on a production line. The KALLER Flex Cam can perform high-precision, controlled piercing and stamping by using highly accurate guiding elements without side deflections.

Adding KALLER Flex Cam to your vehicle production line has several benefits:

  • Simplifies process engineering, die design and tool manufacturing
  • Enables positioning of KALLER Flex Cam at any angle, with 360° application area
  • Punches even upwards at negative angles
  • Adds operations and flexible solutions to new dies
  • Uses space efficiently
  • Reduces total number of dies and tools with multi-functionality and durability
  • Protects against tool damage and over-pressure with controlled force and safety features

Using KALLER Flex Cam enables vehicle manufacturers to:

  • Reduce production cost per part
  • Increase production rate and efficiency
  • Reduce tooling costs with less tool and die investments
  • Be more environmentally sustainable with less tools

Efficient, space-saving and powerful tool parts

When forming a roof, front fender or side of a vehicle, it is common practice to use compressed air cylinders to apply force to moving tool parts. This solution works when less power will suffice and when bulky compressed air cylinder parts will fit into the configuration of the production line.

But when the list of requirements calls for a stronger and more space economic performance than can be provided by compressed air cylinders, a hydraulic driven, multi-functional, and compact solution like the KALLER Flex Cam will solve the case.

With the KALLER Flex Cam, flanging an edge at a 110-degree angle is no problem. Sheet metal is pressed around a filler slide, while the filler slide is locked into position with a support cam.

The support cam is pushed into position from below. Thanks to the hydraulics, the filler slide is supported with full autonomy, sufficient force, and perfect timing. Moreover, the operation can be done at different angles.

Retraction of the cam is done with the same precision and timing, ensuring efficiency and preventing jam.

The hydraulic powered cam is slender and moves freely between other tools in the press, even in a very narrow space.

A COMPACT AND POWERFUL SUPPORT CAM

KALLER Flex Cam is a compact hydraulic powered cam. It has the capacity to push a support cam from any angle and with ample force to support a filler slide that in turn supports the flanging of the sheet metal.

KALLER Flex Cam is powered by gas springs that execute with excellent timing. Its reliability, durability, and long life span requires minimal service, and it performs with high force, autonomy, accuracy, and timing. Small but strong, the KALLER Flex Cam can apply 25 times the force of a compressed air cylinder.

 

KALLER Components for this solution:

  • Control block available to monitor nitrogen pressures, Cam, Force Cylinder and Accumulator.
  • Sensor kits for Compact Cams allow for both forward and retract control.
  • Quick couplings simplify die servicing.
  • Manifold block simplify hose system layout.
  • Security block limits the oil pressure level in case of wrong usage.

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Front Fender - Bottom part of tool

 

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Undercutted side filler cam

About KALLER Flex Cam

The KALLER Flex Cam has become a standard component for many vehicle manufacturers, and is often included in different vehicle manufacturing tool standards globally. 

The KALLER Flex Cam system has, with a proper set-up, performed more than two million cycles without any servicing required.

 

For more information on the KALLER Flex Cam, please contact your distributor >>.

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