Special profiles – hot-rolled, cold-rolled or cold-drawn

Finished parts - customer-specific or ready to install

ZOLLERN’s special profiles move, guide, transfer, crush and drive.

Their exceptional component strength and durability, the high accuracy and quality are directly incorporated into the end products.

Using precisely pre-formed profiles greatly reduces the amount of work for subsequent machining processes. Material costs can be reduced by up to 60 per cent.

 

Specials
Applications

Steel profiles for linear technology

  • Ball and roller guides
  • Miniature rails
  • Heavy duty rails
  • Telescopic rail guides
  • Shaft supports
  • Linear axes

Modified steel grades with the highest degree of purity are used for profiles in linear technology. This results in linear guides with excellent properties, such as

  • very good hardenability
  • high wear resistance
  • realisation of high load capacities
  • minimum distortion during further processing

ZOLLERN uses inductive hardening to achieve partially high surface hardnesses up to 64 HRC in the edge area. The unhardened areas retain their positive properties from the cold forming and can be machined very economically.

Application: Profile for linear carrier
Material: Roller bearing steels

Description: Special shaped steel profiles
Application: U guides, ball guides and roller guides
Material: Rolling bearing steels

Special profiles for vehicle construction

ZOLLERN steel profiles are used in almost all areas of vehicle construction - as profiles for

  • Injection systems
  • Connection components
  • Adjustment systems
  • Steering systems
  • Safety systems
  • in the gearbox technology and pump technology, for example for vane pumps
  • Components for e-mobility

ZOLLERN steel profiles are individually designed and produced for the most diverse applications. The profiles an also be reliably reproduced in series with narrow tolerances. The targeted materials selection and special heat treatments simplify further machining, even for complex geometric profile shapes. The pressure tightness of the resulting produced components is guaranteed via eddy current and ultrasonic testing, even for machining steels.

Application: Profiles for steering column
Material: Head-treatable steel

Application: Profiles for seat adjustment
Material: construction steel

Application: Profiles for pumps e.g. vane pump, pendulum-slider pump, gear pump
Material: Roller bearing steels

Application: Profiles for ring fittings
Material: Free cutting steel

Application: Profiles for fuel injection system
Material: Free cutting steel / stainless steel

Application: Profiles for freewheels e.g. cage freewheels
Material: Roller bearing steel

Steel profiles in railway technology

From components in passenger transport to profiles for securing platforms and tracks using screen doors, our steel profiles offer very high dimensional accuracies, an optimal strength ratio and a high surface quality. They are therefore ideal for diverse applications in rail transport.

Steel profiles for mechanical engineering

ZOLLERN steel profiles are used in machine tools, printing machines and pumps, among other things, as

  • Clamping jaws
  • Pneumatic clamping elements
  • Clamping body for freewheels
  • Gear profiles
  • Scraper and chip deflectors for machine covers
  • Flat guide rails, terminal strips
  • Gripper profiles in robotics
  • Sliding blocks
  • Splined shafts, polygon shafts

Narrow radii, undercuts and the smallest dimensional tolerances are realised. Gears can be manufactured in a wide variety of gearing variants. Particular advantages result from components that have non-symmetrical special gearing, e.g. half pinions, special pinions. Thanks to the near-net-shape production, complex machining processes can often be done away with.

Description: round profile with notch in fixed length and galvanized
Application: Sectional door
Material: Construction steel

Description: wiper profile
Application: wipers (telescopic steel cover) for machine protection
Material: construction steel

Description: Special steel profiles for various slot nuts
Conditions: Available in coil or adiabatically separated short parts
Material: Heat-treatable steels

Steel profiles for fittings and locks

Large series can be economically implemented by using steel profiles. The amount of machining effort is minimised by using the profiles.

Steel profiles for fittings and locks, as

  • Pinion profiles for door closers, door openers, door stoppers
  • Housing for padlocks
  • Profiles for door and window locks
  • Special profiles for sliding blocks

Description, application: Connection pins for door lever unit
Material: structural and stainless steels for fittings
Method of manufacture: cold drawing and/or cold rolling

Description: round profile with notch in fixed length and galvanized
Application: Sectional door
Material: Construction steel

Description, application: Connection pins for door lever unit
Material: structural and stainless steels for fittings
Method of manufacture: cold drawing and/or cold rolling

Description, application: Pinion profiles for door closers
Material: Case hardening steel

Description, application: padlocks

Description, application: padlocks

Steel profiles for energy technology, generator construction and electric motors

Flawless surfaces and excellent mechanical properties characterise the profiles. They ensure the functional safety and durability in application as

  • keybars
  • spring-fingers
  • dovetail bars and
  • I-bars
  • pole shoe profiles

Description: Dovetail Bars, I- and T-bridges, keybars
Application: Profiles for generator construction
Material: Structural and stainless steels

Description: Dovetail Bars, I- and T-bridges, keybars
Application: Profiles for generator construction
Material: Structural and stainless steels

Description: Dovetail Bars, I- and T-bridges, keybars
Application: Profiles for generator construction
Material: Structural and stainless steels

Steel profiles for construction and construction machines

There are many possible applications of special profiles in the construction and construction machinery industries:

  • Kelly profiles for kelly bars in drilling technology
  • Splined shafts
  • Special profiles for scaffolding and façade construction (construction elements consisting of several profiles are also possible)
  • Formwork profiles
  • As hydraulic housing
  • For forklift truck attachments
  • For machines in concrete block manufacture

The profiles impress with their strength, wear resistance, sub-zero toughness, durability and high quality. Adapted profile shapes and special surface treatments create very good prerequisites for the following welding work

Description, Application: Kelly profile for Kelly drill pipes
Material: Heat-treatable steels such as 25CrMo4. Also pre-quenched and tempered steels can be used.
Manufacturing process: Cold drawing

Steel profiles for weapons technology

  • Breechblocks
  • Triggers
  • Percussion pieces
  • Gas pressure loader
  • Sight rails and other products

made from ZOLLERN steel profiles are proven in use for hunting and sporting guns.

The uninterrupted fibre flow and the excellent homogeneity of the hot and cold formed steel profiles allow for a high fatigue strength. The selected combination of material and tempering processes used on ZOLLERN profiles convinces with strengths of up to 1,200 MPa. These profiles can therefore even withstand extreme dynamic stresses. ZOLLERN steel profiles are an economic alternative to traditional production technologies in the hunting and sporting guns industry.

Description: Steel profiles for firearms
Application: Locking, hook piece for chamber
Material: Heat-treatable steels, also in quenched condition available

Description: Steel profiles for firearms
Application: Slides
Material: Heat-treatable steels, also in quenched condition available.

Special profiles in medical technology

Our special profiles are aimed at the high standards in medical technology. They have an excellent surface quality and are made of high-quality materials, as well as in implant quality.

The profiles made of stainless steels are ideal for technical medical parts and devices. Other materials, such as titanium, are possible.

Description: Flat and rounded flat special steel profiles
Application: Bone nails and fixations
Material: Stainless steels also in implant grades

Steel profiles for textile machines

ZOLLERN steel profiles work reliably in flat knitting machines, circular knitting machines, spinning machines, weaving machines, knitters and carding machines.

As

  • Take-off rolls
  • Thread guide
  • Deflecting aids
  • Needle rails
  • Slide rails and
  • Under-apron bridge elements

they provide quick and precise movements.

The surface quality of the profiles meets very high demands in terms of function and appearance.

Special profiles for recycling and crushing

Steel profiles are used for recycling, keeping clean and crushing in various forms, such as:

  • Knife holder
  • Chopping blades
  • Terminal strips
  • Cutting bars
  • Chip deflector
  • Rake profiles for sewage treatment plants

In sectors such as

  • agriculture and forestry
  • the paper industry or also
  • the waste and recycling industry.

The partially inductively-hardened, inductively through-hardened or tempered profiles are particularly wear-resistant. ZOLLERN steel profiles are safe, high-strength and weight-saving.

Description: Special steel profiles for the recycling industry and agriculture
Application: Shredder blades, knife holder, knife bars
Material: Case hardening steel, chipper steel, quenched and tempered steels

Splined shafts, other applications

ZOLLERN supplies splined shafts from tempered steel for universal joints and special profiles according to the relevant standards, such as DIN ISO 14.

There are many applications for special profiles – there are always new possible applications – get in touch with us directly and ask!

Description: Splined shafts to customer drawing or according to DIN 5471, DIN 5472, ISO 14 etc.
Application: For various applications
Material: Steel grade depending on customer requirements

Description: Splined shafts to customer drawing or according to DIN 5471, DIN 5472, ISO 14 etc.
Application: For various applications
Material: Steel grade depending on customer requirements

Processes

Hot rolling

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences

Heat treatment

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences.

Cold drawing

With cold drawing, the pre-formed hot rolled profile is drawn one or multiple times by a carbide die and brought into the desired shape. Stress introduced is neutralised between the forming steps via heat treatment.

Cold rolling

With cold rolling, a wire rod is brought into the specified final contour at room temperature by rolling. Several rolling units in a production line automatically perform this process and give the profiles a high surface quality. The process is particularly well-suited for manufacturing small profile geometries, which are needed in larger quantities.

Inductive hardening

ZOLLERN uses inductive hardening to increase the wear resistance of the profile surfaces. Hardening depths of 0.5 to 5 millimetres and hardness values of up to 64 HRC are achieved.

Products made from special profiles

The steel profiles are processed further in a precise way, from the mechanical machining to the surface finishing. ZOLLERN supplies custom products in different stages of production up to ready-to-install components. Hollow profiles with internal geometry or welded profiles are also available.