Manufacturing Technology

SACMA Group is expanding its capabilities with a new machine programme, solidifying its position as a leader in the production of headers – designed for special materials for key industries including aerospace. This expansion enables SACMA to provide tailored solutions for specific demands, ensuring the high standards required for working with specialised materials continue to be met.

Offering versatile and user-friendly solutions, the WF Headers from SACMA Group cover a wide range of wire diameters from 3mm to 25mm, with temperature capabilities ranging from 300°C (572°F) to 900°C (1,652°F). The machines are also versatile, with no single limitation to the product range, making them suitable for producing fasteners, nuts, brackets, fittings and customisable solutions.

Also designed to accommodate various production volumes, from small batches to large-scale manufacturing, WF Headers are equipped with a universal heating unit suitable for all types of materials, enabling quick changeovers and motorised adjustments. The multi-station warm forming machines use precise tooling design to form near-net-shape blanks, sometimes eliminating the need for grinding operations. This revolutionary process is made possible by the fully integrated heating unit, which includes two induction coils – one installed just after the wire feeder and the other inside the frame, next to the cut-off quill. This unique system ensures the wire heats uniformly, reaching the core and guaranteeing perfect homogeneity of the blank for the forming process.

For maximum stability, the bed frame and coolant system are continuously thermoregulated, optimising tolerance management for parts. The most popular models for the aerospace industry are the SP260WF900 and SP360WF900. These machines come equipped with the latest version of the HMI program, which features a simple and intuitive interface. All part recipes are also saved without any limitations, ensuring easy and quick changeovers.

In addition to the multi-die warm forming machines, the combined one die two blow header model KSP12 completes the full range, offering an integrated warm forming unit and threading station in an all-in-one solution for manufacturing simple fasteners.

To complete the range of SACMA headers, Ingramatic’s Warm Forming Threaders are designed to thread blanks both cold and warm, depending on the material and production speed requirements. These heavy-duty machines feature the revolutionary I-Thread concept, offering significant improvements in thread quality, productivity and efficiency.

The WF threaders are capable of rolling all shapes of bolts, screws, studs and parts made from materials that cannot be processed by standard rolling machines. Among the most popular models in the aerospace industry are the RP220WF, which includes a 12kW heating unit, and the RP420(L)WF, featuring a 24kW heating unit. These machines come equipped with a Quick Set-up system, where all adjustments are fully motorised. The one-piece iron casting bed frame, along with the reaction block designed to counter the stresses during thread rolling, ensures there is no flexion while threading special materials and profiles.

User-friendly and highly ergonomic, the machines feature an HMI program with all WF functions integrated into a dedicated page for the Warm Forming unit. This allows for constant control, displaying real-time temperature and the required kilowatts to heat the parts. The Single Starter unit, driven by a torque motor, and the servomotor for die match adjustment, contribute to a simple and effective set-up. Additionally, the electronic handwheel enables all machine adjustments such as die match, feeding rail position and starter unit, without the need for hand tools.

For secondary operations, HS ASPE offers the DT12 and DT20 models – combined machines capable of performing drilling, tapping, broaching, boring, facing and chamfering. These operations can be carried out sequentially or in overlapping modes, utilising up to four spindles. This functionality not only increases product consistency, and output rates, but also reduces the need for multiple machines, ensuring higher productivity and reliability.