100 YEARS OF EXPERIENCE AND TRADITION

The history of OEKA goes along with the technical and industrial progress,
the development of the metal forming technology and the change of metal materials in the 20th and 21st century.
In almost every decade, markets and products and with them machines,
procedures and materials are changing.

oeka-tech-tiefziehhuelsen oeka-tech-auslieferung-bamberg blauerstrich-180 Series Manufacturing oeka-tech-entwicklung-bamberg oeka-tech-konstruktion-bamberg oeka-tech-prototyping-bamberg oeka-tech-qualitaetssicherung-bamberg oeka-tech-serienfertigung-bamberg blauerstrich blauerstrich Development Delivery blauerstrich blauerstrich-180 Prototyping Design blauerstrich-180 Quality oeka-tech-werkzeugbau-bamberg blauerstrich Tool Manufacturing

PARTS CONCEPT DEVELOPMENT AND ECONOMIC CONSIDERATIONS

Development

  • Defining a component in compliance with specific requirements (material, geometry, surface)

  • Designing a part “suitable for deep drawing” in cooperation with the customer

  • Defining the measurement and packaging technology

  • Ensuring process reliability and economic efficiency

  • Optimizing a part’s function, quality and economic efficiency

  • Substituting components requiring metal-cutting machining

PARTS CONCEPT DEVELOPMENT AND ECONOMIC CONSIDERATIONS

Development

  • Defining a component in compliance with specific requirements (material, geometry, surface)

  • Designing a part “suitable for deep drawing” in cooperation with the customer

  • Defining the measurement and packaging technology

  • Ensuring process reliability and economic efficiency

  • Optimizing a part’s function, quality and economic efficiency

  • Substituting components requiring metal-cutting machining

We define a deep-drawn part based on our customer’s requirements concerning the part’s function and installation position within the overall assembly. These requirements flow into the component specification (e.g. materials, physical-technical characteristics, geometry and surface properties).

However, it is advisable to consider the specific conditions of the deep drawing process and discuss them with the customer even before preparing the final drawing and defining the final specification. These conditions include the wall thickness distribution, cold hardening, the surface structure, as well as radii and edges. Designing a part “suitable for deep drawing” not only helps to ensure its technical function; it is also beneficial for the overall manufacturing process and helps to ensure the process reliability – and thus also the economic efficiency – of the whole product.

Furthermore, it is essential to clarify contiguous topics at the very beginning of the “creation process” – such as measurement and testing procedures, parts cleaning and post-processing, as well as transport and packing instructions.

High cycle rates, relatively low material usage and a favorable strength/wall thickness ratio thanks to process-inherent cold hardening: All of these are compelling reasons why deep drawing is a manufacturing method which provides substantial benefits in terms of a component’s function, quality and economic efficiency.
With regard to economic efficiency, components manufactured with this method are far superior to others requiring metal-cutting machining.

3D-CAD-DESIGN OF PROTOTYPE AND SERIAL TOOLING

Design

  • Our customers benefit from our more than 100 years of experience and our knowledge database

  • Decisions are made by a team of specialists from Project Management, Design, Tool Making, Production and Quality Management

  • The Project Manager takes over the “patronage” for a product

  • CAD design of series and prototype tools in SOLIDWORKS

  • Tooling device design

3D-CAD-DESIGN OF PROTOTYPE AND SERIAL TOOLING

Design

  • Our customers benefit from our more than 100 years of experience and our knowledge database

  • Decisions are made by a team of specialists from Project Management, Design, Tool Making, Production and Quality Management

  • The Project Manager takes over the “patronage” for a product

  • CAD design of series and prototype tools in SOLIDWORKS

  • Tooling device design

All the tools and devices are designed and manufactured by our in-house teams. Our colleagues from Project Management, Design, Tool Making, Production and Quality Management create the tool concept as a design basis developed in close cooperation with each other.

Based on our more than 100 years of experience and our rich tradition of deep drawing, we have developed a precious knowledge database over the course of several decades. Today, not only our in-house teams, but also all our customers can benefit from this wealth of knowledge. By mastering the challenges of new projects we continuously broaden our horizons in terms of materials, technology, procedures and measurement technology.
For us, innovation is not just an empty word – we practice what we preach!
The documented know-how flows into the design of all the tools required for new projects. Our designers have already worked with proven and up-to-date 3D CAD software from SOLIDWORKS for many years.
Every project is centrally coordinated by the Project Manager, who remains the “patron” of the project over its entire life cycle.

CLOSE-TO-PRODUCTION PROTOTYPES FOR PRODUCT OPTIMIZATION AND RISK REDUCTION

Prototyping

  • Prototyping reduces risks during product ramp-up and ensures series manufacturing in compliance with deadlines and cost budgets

  • Metal-cutting-machined prototypes and rapid prototyping as a short-term solution

  • Near-series prototypes are made with deep-drawing tooling systems (geometry, material properties, surface) within just a few weeks

  • Component and procedures optimization during the test sample process

CLOSE-TO-PRODUCTION PROTOTYPES FOR PRODUCT OPTIMIZATION AND RISK REDUCTION

Prototyping

  • Prototyping reduces risks during product ramp-up and ensures series manufacturing in compliance with deadlines and cost budgets

  • Metal-cutting-machined prototypes and rapid prototyping as a short-term solution

  • Near-series prototypes are made with deep-drawing tooling systems (geometry, material properties, surface) within just a few weeks

  • Component and procedures optimization during the test sample process

Complex, multi-stage, high-quality tools are required for the series production of precise deep-drawn parts made from sheet metal materials. The series tool must be set up “unerringly accurately” in order to minimize risk and avoid subsequent time- and cost-intensive tool changes or even the need for reconstruction from scratch. Since saving costs and time is crucial for our customers, development risks and restarts must be avoided to the greatest extent possible. The speedy availability of near-series parts is playing a major role in this context.

In many cases, metal-cutting-machined or rapid-prototyping-machined sample parts, which we can provide at cost-efficient rates on a short term basis, are sufficient to examine fitting conditions and geometrical aspects.

Since sheet metal deep drawing alters the material properties (cold hardening) and surface structure, turned, milled or sintered sample parts are often not conclusive. In many cases they differ significantly with regard to the material and surface properties of serial parts. This means that no evidence of the component’s suitability for subsequent “real-time operation” can therefore be provided.

We provide our customers with near-series sample parts made with deep drawing tooling systems in close cooperation with a local partner. The samples more or less correspond to the serial parts as far as their material, mechanical and geometrical properties and their surface finish quality are concerned. During the course of the sampling process we already identify possibilities for optimizing both the component itself and the forming process in close cooperation with our customer.
This allows for testing the shape and function of the deep-drawn parts in mounted state and making further modifications as required – at a comparably low cost and within a relatively short period of time.

IN-HOUSE TOOL MANUFACTURING ENSURES HIGH FLEXIBILITY AND PERFECT CONDITIONS FOR PRODUCT LAUNCH

Tool Manufacturing

  • Our in-house tool and fixture making guarantees high quality, flexibility and speed

  • The smart combination of experience and innovation enables optimal solutions

  • Our competence team manufactures tools for transfer presses and progressive die processes

  • Continuous tool optimization enhances process reliability and economic efficiency

  • In-house tool maintenance as a preventive measure and in “emergency cases”

  • Integrated training of future know-how carriers

IN-HOUSE TOOL MANUFACTURING ENSURES HIGH FLEXIBILITY AND PERFECT CONDITIONS FOR PRODUCT LAUNCH

Tool Manufacturing

  • Our in-house tool and fixture making guarantees high quality, flexibility and speed

  • The smart combination of experience and innovation enables optimal solutions

  • Our competence team manufactures tools for transfer presses and progressive die processes

  • Continuous tool optimization enhances process reliability and economic efficiency

  • In-house tool maintenance as a preventive measure and in “emergency cases”

  • Integrated training of future know-how carriers

Our in-house tool making team manufactures all the tools for production on transfer presses and in progressive die processes. The individual tool components – such as stamps, rings and blank holders – are pre-manufactured and adjusted by means of turning, milling, grinding, eroding, hardening and coating if required. The assembly of transfer sets and modules, consisting of a large number of individual elements, is followed by testing and fine adjustment on the testing press or the production machine.

We take great pride in our Toolmaking team of experienced and committed, long-standing colleagues and motivated young talents. Based on our in-depth tool design know-how, young tool makers receive qualified vocational training in our Toolmaking department.

Depending on wear and tear and the service life of the individual active tools we specifically manufacture spare parts in order to reduce any subsequent manufacturing downtimes to a minimum. In the case of breakage or fatigue we replace the defective component with a spare part. This enables us to continue manufacturing immediately after release. Wherever possible, we replace tool components as a preventive measure if required. After every manufacturing order we clean, inspect and, if necessary, repair our tools before putting them back into storage.

Our in-house teams take care of the continuous inspection, maintenance and optimization of all our tools, with a clear focus on precision, flexibility and speed.

CONTINUOUS VALUE CHAIN FROM DEEP FRAWING UP TO 100 PERCENT INSPECTION – EVERYTHING UNDER ONE ROOF

Series Manufacturing

CONTINUOUS VALUE CHAIN FROM DEEP FRAWING UP TO 100 PERCENT INSPECTION – EVERYTHING UNDER ONE ROOF

Series Manufacturing

Deep Drawing:

  • Manufacture of small, medium and large series parts
  • Deep drawing on transfer presses 
(pressing force: 125 to 3000 kN, up to 22 work stages)
  • Deep drawing in progressive die processes 
(pressing force: 750 to 1250 kN)
  • Forming on single presses (pressing force: 650 – 1000 kN)

Thanks to its high flexibility OEKA TECH covers a large spectrum of different quantities – from small-series to large-series production. We manufacture large and medium series on transfer presses and in progressive die processes on automatic punching presses and automatic forming machines. In addition, various single presses are available for prototyping and small-series production.

Our machinery pool includes thirteen transfer presses with a pressing force in the 125 kN to 3000 kN range (from 12.5 to 300 t) and up to 22 work stages. We use automatic punching presses and automatic forming machines with pressing forces from 750 to 1250 kN (75 to 125 t) for progressive die tools.

Cleaning / Lubricating

  • Cleaning / Aqueous (water-based) degreasing
  • Cleaning / Solvent-based degreasing

To remove the drawing agent required for the drawing process from the parts manufactured, our plant is equipped with both solvent-based and aqueous degreasing facilities. We use the aqueous system wherever possible. However, solvents must be used in many cases in order to comply with increasing requirements for the cleanliness of parts.

Surface Machining / Deburring:

  • Deburring:Vibratory finishing in the rotary vibrator, with or without grinding beads
  • Smoothing and compacting by means of ball polishing
  • Drying in circular kilns

Depending on the process applied, sharp ridges and more or less distinctive burr formation can be observed on the edges of deep-drawn parts. In many cases these can hamper further machining steps and parts transport. After deep drawing and cleaning, the products run through an individually adjusted vibratory finishing process for deburring and rounding off cutting edges and cutouts. The rotary vibrators used for this purpose are filled with compound liquid, as well as grinding and polishing beads of various geometries made from stainless steel or ceramics. In many cases processing without the use of any additional grinding beads is sufficient, i.e. the deburring is ensured by the frictional forces caused by the parts moving against each other in the rotary vibrator.

We deploy the ball polishing procedure in order to reduce the surface roughness of parts and compact the structure on its surface. While the parts slipped onto racks are rotating in the facility, the vibration of the polishing beads pulsating at high frequencies provides for the necessary smoothing and compacting.

After vibratory finishing and ball polishing – both in wet procedures – the products are surrounded by a hygroscopic medium and gently dried in the circular kiln while being exposed to the correct temperature.

Thermal Treatment:

  • Various hardening procedures
  • Various annealing processes

To ensure the suitability of the deep-drawn parts for various applications and functions, their material properties and physical-technical characteristics (strength, hardness, etc.) must be modified after the forming process. This is performed by means of specific thermal treatment, such as hardening and annealing processes after the deep drawing.
Thermal treatment in general – and the hardening of thin-walled deep-drawn parts in particular – are generally considered a challenge. Parts are exposed to process-inherent tensile and compressive stress during forming. Thermal treatment relaxes these types of stress and the part geometry changes, i.e. the parts tend to become deformed (e.g. warping or ovalization). To ensure the dimensional accuracy of the parts after thermal treatment, the unmachined part (“blank)”) must be dimensioned accordingly.

We have acquired comprehensive know-how in the design and manufacture of hardened and annealed deep-drawn parts over the course of many years.

Surface Finishing / Compacting :

  • Blasting with various blasting agents (glass beads, plastic granulate, etc.)
  • Brushing and grinding

We also offer surface machining procedures such as blasting, brushing and grinding.

Surface machining with various blasting agents – such as glass beads or granulate made from stainless steel, ceramics and plastics – can modify a part’s surface roughness and compact, and thus strengthen, the material structure.

Brushing and grinding procedures are mainly used for decorative purposes. Here, the focus is on high-quality design and the appealing look of visible parts.
These two processes also serve to specifically modify the surface roughness.

Coating:

  • Galvanic coating
  • Anodization / hard anodization

After forming, an electroplated coating is applied in order to protect components against corrosion or for functional reasons. We offer all kinds of commonly accepted metallic coatings.

Gloss or hard anodization of deep-drawn parts made from aluminum materials: All these procedures are also part of our surface machining portfolio. Gloss anodization rather serves for decorative purposes, whereas hard anodization is ideal for achieving wear-resistant and mechanical stress-resistant surfaces.

Heat treatment, as well as the machining and coating of surfaces, are sub-contracted to experienced partners, with whom we have cooperated on a regular basis for many years.

Component Assembly:

  • Manual assembly
  • Semi- and fully automatic assembly

The OEKA TECH service portfolio also includes component assembly. Depending on the number of parts, the work steps involved are performed fully-automatically, semi-automatically or manually. Assembled components can consist of various deep-drawn parts manufactured in-house and purchased components such as pressure die cast parts, fine blanking parts or bent parts.

Laser Machining:

  • Laser technology

We use laser technology in order to provide the surface of deep-drawn parts with inscriptions, logos or symbols. These procedures enhance a component’s visual appearance. When combined with high-quality surface finishing they are ideal for creating a sophisticated design.

100% inspection:

  • Visual inspection
  • Dimensional and functional inspections
  • Manual and automatic inspection

If necessary, the components run through automatic or manual 100% inspection at the end of our manufacturing chain in order to ensure their suitability for a component’s subsequent processing steps or application at the customer. The focus of this inspection is on visual, geometrical or functional aspects.

  • Manufacture of small, medium and large series parts
  • Deep drawing on transfer presses 
(pressing force: 125 to 3000 kN, up to 22 work stages)
  • Deep drawing in progressive die processes 
(pressing force: 750 to 1250 kN)
  • Forming on single presses (pressing force: 650 – 1000 kN)

Thanks to its high flexibility OEKA TECH covers a large spectrum of different quantities – from small-series to large-series production. We manufacture large and medium series on transfer presses and in progressive die processes on automatic punching presses and automatic forming machines. In addition, various single presses are available for prototyping and small-series production.

Our machinery pool includes thirteen transfer presses with a pressing force in the 125 kN to 3000 kN range (from 12.5 to 300 t) and up to 22 work stages. We use automatic punching presses and automatic forming machines with pressing forces from 750 to 1250 kN (75 to 125 t) for progressive die tools.

  • Cleaning / Aqueous (water-based) degreasing
  • Cleaning / Solvent-based degreasing

To remove the drawing agent required for the drawing process from the parts manufactured, our plant is equipped with both solvent-based and aqueous degreasing facilities. We use the aqueous system wherever possible. However, solvents must be used in many cases in order to comply with increasing requirements for the cleanliness of parts.

  • Deburring:Vibratory finishing in the rotary vibrator, with or without grinding beads
  • Smoothing and compacting by means of ball polishing
  • Drying in circular kilns

Depending on the process applied, sharp ridges and more or less distinctive burr formation can be observed on the edges of deep-drawn parts. In many cases these can hamper further machining steps and parts transport. After deep drawing and cleaning, the products run through an individually adjusted vibratory finishing process for deburring and rounding off cutting edges and cutouts. The rotary vibrators used for this purpose are filled with compound liquid, as well as grinding and polishing beads of various geometries made from stainless steel or ceramics. In many cases processing without the use of any additional grinding beads is sufficient, i.e. the deburring is ensured by the frictional forces caused by the parts moving against each other in the rotary vibrator.

We deploy the ball polishing procedure in order to reduce the surface roughness of parts and compact the structure on its surface. While the parts slipped onto racks are rotating in the facility, the vibration of the polishing beads pulsating at high frequencies provides for the necessary smoothing and compacting.

After vibratory finishing and ball polishing – both in wet procedures – the products are surrounded by a hygroscopic medium and gently dried in the circular kiln while being exposed to the correct temperature.

  • Various hardening procedures
  • Various annealing processes

To ensure the suitability of the deep-drawn parts for various applications and functions, their material properties and physical-technical characteristics (strength, hardness, etc.) must be modified after the forming process. This is performed by means of specific thermal treatment, such as hardening and annealing processes after the deep drawing.
Thermal treatment in general – and the hardening of thin-walled deep-drawn parts in particular – are generally considered a challenge. Parts are exposed to process-inherent tensile and compressive stress during forming. Thermal treatment relaxes these types of stress and the part geometry changes, i.e. the parts tend to become deformed (e.g. warping or ovalization). To ensure the dimensional accuracy of the parts after thermal treatment, the unmachined part (“blank)”) must be dimensioned accordingly.

We have acquired comprehensive know-how in the design and manufacture of hardened and annealed deep-drawn parts over the course of many years.

  • Blasting with various blasting agents (glass beads, plastic granulate, etc.)
  • Brushing and grinding

We also offer surface machining procedures such as blasting, brushing and grinding.

Surface machining with various blasting agents – such as glass beads or granulate made from stainless steel, ceramics and plastics – can modify a part’s surface roughness and compact, and thus strengthen, the material structure.

Brushing and grinding procedures are mainly used for decorative purposes. Here, the focus is on high-quality design and the appealing look of visible parts.
These two processes also serve to specifically modify the surface roughness.

  • Galvanic coating
  • Anodization / hard anodization

After forming, an electroplated coating is applied in order to protect components against corrosion or for functional reasons. We offer all kinds of commonly accepted metallic coatings.

Gloss or hard anodization of deep-drawn parts made from aluminum materials: All these procedures are also part of our surface machining portfolio. Gloss anodization rather serves for decorative purposes, whereas hard anodization is ideal for achieving wear-resistant and mechanical stress-resistant surfaces.

Heat treatment, as well as the machining and coating of surfaces, are sub-contracted to experienced partners, with whom we have cooperated on a regular basis for many years.

  • Manual assembly
  • Semi- and fully automatic assembly

The OEKA TECH service portfolio also includes component assembly. Depending on the number of parts, the work steps involved are performed fully-automatically, semi-automatically or manually. Assembled components can consist of various deep-drawn parts manufactured in-house and purchased components such as pressure die cast parts, fine blanking parts or bent parts.

  • Laser technology

We use laser technology in order to provide the surface of deep-drawn parts with inscriptions, logos or symbols. These procedures enhance a component’s visual appearance. When combined with high-quality surface finishing they are ideal for creating a sophisticated design.

  • Visual inspection
  • Dimensional and functional inspections
  • Manual and automatic inspection

If necessary, the components run through automatic or manual 100% inspection at the end of our manufacturing chain in order to ensure their suitability for a component’s subsequent processing steps or application at the customer. The focus of this inspection is on visual, geometrical or functional aspects.

ON-TIME AND ACCURATELY

Delivery

ON-TIME AND ACCURATELY

Delivery

Deep-drawn parts and components “Made in Germany” go reliably and on-time from Bamberg to all corners of the world – wherever our customers need them.