Offer
GABEC specializes in manufacturing special fasteners made of steel and non-ferrous metals using cold forging, rolling, and machining technology. Depending on the customer’s requirements, the fabricated elements can be delivered in various surface finishes, such as zinc, phosphate, copper, and zinc-nickel alloy coatings. With a modern machine park equipped with high-performance devices such as horizontal presses: 2, 4, 5, 6, and 7-die presses with pressing forces up to 300 tons, rolling mills, and CNC machining centers, we offer fasteners in a range of diameters from 3mm to 32mm and lengths up to 130mm.
Cold forming.
In simple terms, cold forging is a technological process in which metal is deformed under the application of force and with the use of tools. As a result, we obtain the desired shape, structure, and mechanical properties of the formed product.
The name of the technology refers to the fact that the process takes place at room temperature.
The material in the form of a wire coiled into circles is fed into the machine and goes through the individual steps of the process in an automatic cycle:
• Straightening
• Cutting
• Progressive molding in dies
• Rolling
Various plastic processing techniques are used to achieve the desired geometry, including swelling and tapering, often in combination with other operations such as trimming, piercing, thread rolling, and knurling. To carry out these processes at Gabec, we use modern progressive presses. Our equipment includes energy-efficient SERVO PRESSES equipped with 6 and 7 dies, as well as SERVO ROLLING MILLS. These machines are among the most advanced solutions in the world.
Cold forging technology is a highly efficient production process with very high dimensional repeatability. The products manufactured through this process maintain a favorable fiber arrangement, ensuring strength and excellent quality. An equally important advantage is the saving of material. To take the example of Gabec: waste in the production of thin-walled sleeve bushings using cold forging technology is around 6-8%, which, when compared to nearly 85% waste in mechanical machining technologies (CNC Machining), is an impressive result.
An example from our company: One piece of thin-walled sleeve, made by machining process, used to be produced in 35 seconds. Using cold forging technology, the same component is now produced in less than 0.5 seconds (140 pieces/min)! An additional benefit is the increase in durability, which in this case has improved by 40%.
Thread rolling.
Thread rolling is a cold forming method of forming the outlines of external and internal threads or other shapes on external surfaces and in holes of cylindrical cross-section. The thread obtained in this way has higher precision, strength, and durability than those produced by traditional methods. Thread rolling is used in many industrial sectors, including the production of automobiles, machinery, tools, hydraulic and pneumatic elements, as well as in the construction industry.
CNC machining.
CNC Machining is a cavity process that involves removing a layer of material from a workpiece to achieve a designed shape. If customers’ needs in terms of expectations for ordered fasteners exceed the possibilities of using cold forging technology, then machining, including CNC, is used.
Some cases justifying the use of machining technology include:
• as a finishing treatment after cold forging, also known as a second operation
• When the quantity demand does not justify the use of metal forming technology
• when the product geometry is unattainable with plastic forming process
• when the properties of the material grade requested by the customer do not allow its plastic deformation.
Machined materials include alloy steels, stainless steels, copper alloys, aluminum, and others.
Assembly of metal components and complementary technologies.
Sometimes customers require products in the form of a subassembly or component that consists of two different materials. Gabec provides special metal components that are permanently bonded to materials such as rubber, silicone, plastics, or are mounted together.
We carry out these processes in cooperation with our trusted partners, fully responsible for the quality of the final products.
When implementing these technologies, Gabec work closely with subcontractors to design and manufacture the molds. The molds are always created on-site in our tool room. This approach provides us with full control over the process and expands our expertise.
Range.
With an extensive machine park consisting of world-class horizontal presses: 2-, 4-, 5-, 6- and 7-station heading machines offering a forging force exceeding 300 tons, rolling mills and CNC machining centers, we offer fasteners in the range of diameters from 3 mm to 32 mm with lengths reaching 130 mm.
