Not all materials can be formed in ambient temperature without the risk of cracks or abnormal tool wear causing the production to be unprofitable. Such materials are aeronautic titanium, aluminium alloys series 2000 and 6000, nickel superalloys like Inconel, Inconel®or Waspaloy®, stainless steels or 100Cr6 steel. Thanks to the use of induction heaters, capable of warming up the screws (or only a part of it) to the temperatures reaching 900°C it is possible to form such materials with normal tool wear and to obtain the right geometrical quality of the part. Still the use of heating unit is not enough – the key is to design the machine in such a way that the heat from inductor, from the feeding rails to the tool holder do not propagate into the machine, because otherwise we could not talk about any dimensional precision nor permanent process temperature control. That is why the stationary tool holder and the inductor heater are chilled in a close circuit cooling system. For temperature control there is optical pyrometer checking the temperature of each parts before the threading operation.


To compliment the Sacma warm former line, Ingramatic introduces their Warm Forming machines.  Combining the heavy duty design and features of the revolutionary I-Thread, the WF provides a significant increase in thread quality, productivity and efficiency by rolling all shapes of bolts, screws, studs and parts made of materials difficult to roll.  The machine features include new feeding rails for the installation of an induction coil with an exclusive design, a 30KW generator, a chiller, a high frequency inverter box, an optical pyrometer, and a cooled stationary die holder.  A set of selectors manage the parts at the end of the heating area to ensure the parts are consistently oriented to the starter unit at the correct temperature. The repeatability of the heating is assured by using a longer induction coil compare what it is actually existing on the market with the home made solution or a rollers adapted with a heating unit. As per Sacma headers, this induction coil design allows the system to warm wide range of materials with only one induction coil. Consequently, this Warm Forming roller provides quick changeover making it ideal for the small lot sizes in the Aerospace fastener market.


As usual for the machines made by Sacma Group, the R&D developed a fully integrated machine. This philosophy is applied for both hardware equipment and management of the heating unit. The I-Panel provided by Ingramatic allows the machine to manage the heating unit in automatic mode during the startup of the production but also during the stoppage of the machine. This means that the critical operations normally made by the operators manually are now directly managed by the PLC of the machine. When the machine starts the production, the PLC manage the heating unit until the correct temperature is reached, then starts to feed the starter unit with a precise amount of warmed parts. It is possible to set up a tolerance for the temperature and reject the parts not at the right temperature. This is the only one guarantee to obtain the perfect integrity of the threads and also to avoid any damage of the material structure. During the startup operation, the machine reject automatically the parts not at the right temperature thanks to the optical pyrometer driving directly the rejection device. A special software allows the machine to reduce the number of rejected parts. During the production, to manage the quality and the repeatability of the part dimensions, the pyrometer and the load monitor check each part and reject the n.c. parts automatically without stopping the machine and the heating unit.


Ingramatic said that for a complete changeover, 30 minutes are necessary and for a changeover consisting only on the part length, 10 minutes are enough. This makes the RP420-WF30 very competitive for the Aerospace market where the production quantity are very low.

This is possible because the RP420-WF30 is part of the I-Thread machine design, the revolutionary line of thread rolling machines emphasized by the following points:

  • Quick Setup, all adjustments fully motorized.
  • Rigid, the exclusive new design frame has been optimized by using FEM software with a “C” shaped stiffener, specifically designed to counter the stresses caused by thread rolling of heat treated parts and special profiles.
  • User friendly / Ergonomic, I-Panel Touch Screen controls with all WF functions integrated in a page dedicated to the Warm Forming unit and a constant control thanks to the main page showing the real temperature and the KW necessary to warm the parts.
  • Flexibility, Single Starter unit driven by servomotor – Patented system, servomotor for the die match with load monitor control and hydraulic clamping of the drive unit.
  • Simple to use for the operators, the Electronic handwheel can be used for all machine adjustments - die match – rail position - starter unit; eliminating the use of hand tools.
  • High speed & Reliability thanks to the precision of the starter unit, the unique design of the feeding rails and the square design of the frame.


Regarding the spare parts and service, Ingramatic uses the same components than Sacma. This guarantees the immediate availability of spare parts ensuring the best service and consents Ingramatic to provide a tested and approved complete machine avoiding to make any improvisation.

With this new WF line, Sacma Group, already leading the market of headers made for exotic materials, completes perfectly its whole range of machines and now is able to provide any kind of machinery for the Aerospace market and other market using special materials for making screws and bolts.

The Ingramatic and Sacma Warm Forming machines can also be used in cold forming mode making them flexible and competitive to guarantee its payback.



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