Walform Tube

WALFORM TUBE

Walform tubes or reshaped tubes are available in customizing for DIN fitting assembly installation. The tube consists of four components which are a nut made according to the DIN standard, a 24-degree cone seat with a DIN body, a cap seal, and a mechanically reshaped tube end.

The body and nut are made following the DIN EN ISO 8434-1 standard. The tube provides an elastomeric and metal-to-metal seal. Further, the tube has a high resistance against pressure and corrosion, easy installation, strength, and personnel safety during operation. The tube fitting is divided into three – Walpro Metallic Seal Cutting Ring, Walring Soft Seal Cutting Ring, and Walform Reshaping System.

Tube Outer Diameter Size	6mm to 42mm
Tube Wall Thickness Size	1mm to 6mm
Assembly Set	Walform Tube DIN union nut Walform Seal DIN fitting body
Working Pressure	250 bar to 800 bar

1. What are Walform Tubes?

Tubes are connected to systems during installation. Tubes are considered as lifelines of the hydraulic systems. Hydraulic tubes are available in various sizes and types to fit into the systems. Walform tubes are made following the DIN EN ISO 8434-1 standard. The maximum working pressure for the walform tubes is up to 800 bars.

Walform Tube Assembly Set

The walform tubes are produced in sizes ranging from 6 - 42 mm in diameter. More so, to enhance the quality and durability of the walform tubes, the materials are made of carbon steel and stainless steel (1.4571). Walform tubes provide a metal-to-metal sealing made of an elastomeric material. The tubes' components are classified into four: body made in DIN standards with a 24-degree cone seat, cap seal, mechanically reshaped tube end, and a nut made in DIN standards.

2. How to form a Walform Tube?

The walform tube is produced by inserting a cylindrically-shaped deburr tube inside walform machine and running the machine. Below is the procedure that explains how to run the Walform machine to form the walform tube.

STEP 1
Turn on the walform machine by pressing the master switch button.

STEP 2
Press on the change tool button which would enable you to open the tool holder.

STEP 3
Once the tool holder is opened, select an appropriate clamping jaw and insert it inside tool holder

STEP 4
Screw in the reshaper screw inside the machine by hand until it feels tight.

STEP 5
Close the tool holder of the machine.

STEP 6
Hold the start key and function key together for roughly 2 seconds until the white indicator lamp is turned on. This shows that the walform machine is ready to form the tube.

STEP 7
Now insert the nut into the tube and slide the tube in an horizontal direction into the reshaper. Be sure to allow the tube touch the reshaper.

STEP 8
Once it reaches a stop, hold the tube firmly and confirm that the tube axis and tool axis are aligned.

STEP 9
Put the pressure at 99% and press the start button. The machine begins to form the tube. Note that once the machine begins operation, the process cannot be interrupted by an external force.

STEP 10
After the forming process is complete, the walform machine stops.

STEP 11
Pull the tube with some force and check for any default such as cracks or surface damage in the formed shape.

STEP 12
Take note of the control diameter.

To change the tool, the machine must be switched off first. The steps listed above must be followed, perhaps with a different clamping jaw or reshaping depending on your specification.

To remove the reshaper, use the removing tool to unscrew the reshaping in a counter-clockwise direction, out of the tool holder.

To remove the clamping jaw, slightly press and pull out the clamping jaw out of the tool holder.

BAHASA INDONESIA

3. What are the benefits of the Walform Tube?

The process to form of walform tube is by inserting the tube into the configured walform machine. Overall, system performance can be improved, which in turn improves the equipment's effectiveness. The tube's life cycle and fitting installation or equipment can be extended significantly and reduces high repair or maintenance cost in long-term application.

The advantages of each walform tubes are discussed below:

Simple and practical installation process in forming.
Time efficiency in assembling tube and fitting installation.
Create reliable tube retention with high dynamic loads.
Reduce system leakage issues.
Cost saving as lesser cost spending in labor or parts repairing.
High consistent system performance.

Walform Tube with Nut

4. What are the types of Walform Tubes?

Walform tube fittings are made in three different forms. They are Walpro Metallic Seal Cutting Ring, Walring Soft Seal Cutting Ring, and the walform reshaping system. These tubes are suitable for use in a variety of materials especially for steel and stainless steel.

Walpro Metallic Seal Cutting Ring: the Walpro Metallic Seal Cutting Ring comes with a two-edged cutting ring, also called the profile ring and a controlled final assembly. It provides a metal-to-metal sealing and the tightening torque is reduced at a 25% rate compared to the standard assembly. The assembly fittings have a reduced rate of failure due to the design of the complete assembly machine. The tightening travel for the final in-service assembly is rated between 30 degrees to 60 degrees. The system performs three basic functions which are force closure, retaining functions and combined seal. More so, the tube can be used for short bending lengths and certified for use with the Benteler Zista Seal and Zistaplex tubes.
Walring Soft Seal Cutting Ring: the Walring Soft Seal Cutting Ring has a two-edged cutting ring with a captive seal and machine assembly. The sealing comes in an elastomeric material and it provides a metal-to-metal seal. It is prefabricated as an assembly machine and has a 25% torque reduction when likened to the manual assembly of a cutting ring. The tightening travel for final in-service assembly is between 30 to 60 degrees after machine assembly. The Walring is also suitable for short bending lengths and certified for operation by the Benteler Zista Seal and Zistaplex tubes. Also, the Walring has a controlled final assembly with the M-R7 machine.
Walform Reshaping System: the Walform Reshaping system allows a cold reshaping of the tube end with a captive seal. The system is designed as a reshaping machine that uses an elastomeric with metal-to-metal sealing. The tightening travel for final in-service assembly stops at the point of resistance and the risk of assembly failures is minimal. The torque reduction value is 25% greater than the manual assembly of a cutting ring.

5. What Walterscheid Machines are compatible with the Tube Fittings?

The Walterscheid company has further produced machines compatible with the tube fittings to enhance operational performance and reduce installation stress and time. There are two major machines which are M-R7 and M-WF385Xplus.

Walform Tube

M-R7 Machine: This machine is fit for use with Walpro and Walring systems. They are used with tube fittings measuring between 6 to 42 mm in diameter. The machine is designed with RFID technology which allows tool detection and setting of process values. The machine also provides an automatic assembly of the tube by simply pushing in. Overall, the M-R7 machine is operating on a fast time which improves efficiency and reduces cost.

M-WF385Xplus Machine: The machine is designed to be used with walform tube connectors measuring between 6 to 42mm. They are compact and lightweight which enables easy transportation from one place to the other. Also, the tools can be easily installed and they work with reduced noise. The machine consumes less energy with color-coded tools which makes identification of tools easier to avoid mistakes.

6. What are the differences between the three Tube Fittings?

The differences between the tube fittings are shown as per below:

1. WALPRO

Fitting complete with cutting ring or sleeve
Highly tightness assembly installation
Consistent quality of fitting assembly and lifetime period of the connection
Cutting ring without deformation
Withstand high nominal working pressures
Materials are available in steel and stainless steel 1.4571
All components made following DIN 2353 / DIN EN ISO 8434-1 standard

2. WALRING

Fitting complete of walform seal and cutting ring or sleeve concept
Reliability in the application of high or heavy load oscillating and impulses loads
Verified, secured, reliable and trustworthy system
To support the hydraulic tube behind the two cutting blades, the conical part formed a shape
Convenient, simple and clear installation check.

3. WALFORM plus

Piping connections consist of only three main components.
Absolute and reliable tightness
The pipe endings connection are machine pressed to form a WALFORM shape
The pipe is linked by a common neck, a nut, and a walform seal
Fewer parts is required and lower material costs
Only one individual sealing point in the connection
Easy and quick installation in the forming process
Significantly reduced tightening and installation time consuming as compared to the fittings with a cutting ring.

The table below shows the walform seal dimension for walform tube:

Bar	Tube OD	Type	Reference	Kg per piece	M	Type	Reference
500 (7252)	6	M 6L	WAL 039842	0,9	M 12 x 1,5	WF-WD 6L/S VI	WAL 610871
500 (7252)	8	M 8L	WAL 039843	1,4	M 14 x 1,5	WF-WD 8L/S VI	WAL 610872
500 (7252)	10	M 10L	WAL 039844	2,0	M 16 x 1,5	WF-WD 10L/S VI	WAL 610873
400 (5801)	12	M 12L	WAL 039845	2,5	M 18 x 1,5	WF-WD 12L/S VI	WAL 610874
400 (5801)	15	M 15L	WAL 039846	4,0	M 22 x 1,5	WF-WD 15L VI	WAL 610875
400 (5801)	18	M 18L	WAL 039847	6,0	M 26 x 1,5	WF-WD 18L VI	WAL 610877
250 (3626)	22	M 22L	WAL 039848	8,0	M 30 x 2	WF-WD 22L VI	WAL 610879
250 (3626)	28	M 28L	WAL 039849	8,5	M 36 x 2	WF-WD 28L VI	WAL 610881
250 (3626)	35	M 35L	WAL 039850	13,0	M 45 x 2	WF-WD 35L VI	WAL 610883
250 (3626)	42	M 42L	WAL 039851	21,5	M 52 x 2	WF-WD 42L VI	WAL 610885
800 (11603)	6	M 6S	WAL 039852	1,0	M 14 x 1,5	WF-WD 6L/S VI	WAL 610871
800 (11603)	8	M 8S	WAL 039853	1,7	M 16 x 1,5	WF-WD 8L/S VI	WAL 610872
800 (11603)	10	M 10S	WAL 039854	3,0	M 18 x 1,5	WF-WD 10L/S VI	WAL 610873
630 (9137)	12	M 12S	WAL 039855	3,5	M 20 x 1,5	WF-WD 12L/S VI	WAL 610874
630 (9137)	16	M 16S	WAL 039857	6,0	M 24 x 1,5	WF-WD 16S VI	WAL 610876
420 (6091)	20	M 20S	WAL 039858	9,5	M 30 x 1,5	WF-WD 20S VI	WAL 610878
420 (6091)	25	M 25S	WAL 039859	19,5	M 36 x 1,5	WF-WD 25S VI	WAL 610880
420 (6091)	30	M 30S	WAL 039860	21,5	M 42 x 1,5	WF-WD 30S VI	WAL 610882
420 (6091)	38	M 38S	WAL 039861	31,0	M 52 x 1,5	WF-WD 38S VI	WAL 610884