Journal Volume # 1

Riveting, Forming, Welding, Projection Conveyors, Systems
ISO
MADE IN
THE USA
9001 : 2008
CERTIFIED
IT ALL STARTS WITH THE CUSTOMER’S PART
THE ORBITFORM JOURNAL
Assembly
Solutions for Manufacturing
Since 1984
1
ASSEMBLY EQUIPMENT
SOLUTIONS
FOR MANUFACTURING
SINCE 1984
Orbitform designs and builds assembly equipment
solutions
for
manufacturing,
including
Riveting,
Forming, Welding, Conveyors, and Custom-Engineered
Assembly Systems. Orbitform also manufactures its
own line of standard assembly products for machine
integrators, all made in the USA since 1984. Services
include Assembly Analysis, Tooling Development, and
low-volume production runs. What sets us apart from our
competitors is our unbiased approach. With Orbitform,
you’re not restricted to a single product line or assembly
process. We can offer a wide range of solutions, to
provide you the product, process or service that’s best
meets your needs. Orbitform…solution delivered.
Riveting, Forming, Welding, Projection Conveyors, Systems
PERMANENT
SEMI TUBULAR RIVET
IMPACT FORMED
SOLID RIVET
IMPACT FORMED
SOLID RIVET
ORBITAL FORMED
SOLID RIVET
HOT UPSET FORMED
TENON
ORBITAL FORMED
BOLT & NUT
ORBITAL FORMED HEAD
PERMANENT JOINT APPLICATIONS
This article examines basic applications and considerations for common
fastening and joining techniques used in permanent part assembly.
There are many reasons products should not be taken apart:
• Personal Safety ‑ the product is inherently unsafe to
repair.
• Operational Safety – high product liability if the product
fails during operation.
• Extreme operating forces – high shock, vibration,
Push‑Pull, and Shear.
• Regulatory requirements ‑ part must be new, not
repaired, required by law.
• Warranty / Product integrity ‑ part must be new and
not repaired.
• Modular assemblies – permanently assembled
components.
• Security/Tamper‑proof/Vandalism – you don’t want
anybody messin’ with it.
Industries familiar with these concerns include:
Automotive, Medical, Aerospace, Aviation, Electrical,
Power Distribution, Safety, Military, and basically any
products where lives are on the line and product liability
is high, for example: Airbag Canisters, Mountain Climbing
Gear, and Fire Extinguishers.
If your product doesn’t need to be taken apart, and you’re
using a non‑permanent fastening method such as retaining
rings, threaded fasteners, posts and cotter pins, etc., you
may want to consider permanent assembly for some of the
following reasons:
• Reduce the cost of fastening hardware: retaining rings,
threaded fasteners, nuts, washers, and cotter pins
• Reducing the costs of machining operations:
machining grooves and threads, drilling and tapping
holes
• Reducing the costs of assembly operations and
cycle time: forming a rivet or post vs. installing a
retaining ring, cotter pin, or driving a screw / nut
• Superior retention ‑ compared to cotter pins, retaining
rings, and Loctite®
• Improved aesthetics ‑ Formed head versus bolt head,
nut, screw head, cotter pin, or retaining ring.
We recognize every application is different, and there is
no “one size fits all” solution for permanent part assembly.
On the next page is a matrix of fasteners & fastening
processes, along with a few common joint requirements
and costing considerations.
NON-PERMANENT
BOLT & NUT
SCREW
COTTER PIN
RETAINING RING
STUD & NUT
NON-PERMANENT JOINT APPLICATIONS
Assembly Solutions for Manufacturing Since 1984
3
The Orbitform Journal
www.orbitform.com
800-957-4838
JOINT CHARACTERISTIC
PERMANANT
OVERALL COST
ASSEMBLY
LABOR COST
EQUIPMENT COST
MACHINING COST
FASTENER COST
AESTHETICS
HOLE FILL
SHOCK VIBRATION
RESISTANT
LOW
PROFILE
COMPRESSION
(CLAMP LOAD)
ARTICULATING
FASTENER /
PROCESS
COSTING
TENON
ORBITAL/SPIRAL
TENON HOT UPSET
SOLID RIVET IMPACT
SEMI-TUBULAR
RIVET IMPACT
RIVET
ORBITAL/SPIRAL
RIVET HOT UPSET
BOLT/NUT
FORMED
NON-PERMANANT
BOLT/NUT
STUD/NUT
SCREW
RETAINING RING
COTTER PIN
KEY:
POOR
The matrix rates generic process effectiveness
for each joint requirement. All fastening processes
were compared based on non‑manual, using
minimally‑automated methods and typical
application requirements. For the rating, we
examined the lowest cost and least number of
machining steps to achieve the requirement in
the simplest way possible. For example, a low
profile joint may be achieved with a counter sink or
counter bore, at the cost of extra machining, just
as aesthetics is greatly determined by the type
of fastener, coating and/or finish, which greatly
impacts the fastener’s cost. A retaining ring or
cotter pin is a more expensive fastener, compared
4
FAIR
GOOD
BEST
to a rivet, especially if that cost includes a mating
pin with groove or through‑hole, resulting in lower
machining costs because only a through‑hole for
the pin is needed. Overall cost considerations
include: fastener, machining, equipment/utilities, and
assembly costs, based on the best overall value.
All cost estimates are relative to each other across
processes. For example, a tenon has no fastener,
and therefore, no fastener cost relative to a rivet or
bolt, but a machined tenon has a greater machining
cost than a thru‑hole for a rivet or bolt. A tenon
formed as part of a casting would result in a different
costing analysis.
Assembly Solutions for Manufacturing Since 1984
Riveting, Forming, Welding, Projection Conveyors, Systems
ORBITAL‑RIVETING & FORMING
Orbital riveting and forming is a
cold forming process using a peen
tool held at a fixed angle to create
a sweeping line of pressure around
the part, progressively forming the
material with each rotation. This
process (fig. 1.1) reduces the
amount of forming force required by
approximately 80% of a standard
press. The orbital process can form
mild steel solid rivets from less than
1/16” up to 1‑1/2” in diameter. The
orbital forming process creates a low
profile, aesthetically appealing finish,
and allows for joint articulation as
seen in multi‑tool pliers, automotive
door hinges, casters, etc.
Spiral riveting and forming, also
known as Radial, is similar to the
Orbital process, but the material is
displaced from the center outward
in a rosette or rose curve pattern;
this creates less side force than the
orbital process, which can cause
parts to wobble during forming. This
is especially true when forming small
diameter rivets, and/or long rivets
that are not held rigid by the part or
part fixture during assembly. The
Spiral process is not recommended
for semi‑tubular and/or hollow rivets
because the peen loses contact with
the part being formed.
the final joint will allow the rivet to float
and will not provide any compressive
loading. If the manufactured rivet head
is supported (fig. 1.2), eliminating the
gap between the part and the rivet, the
joint will exhibit compressive loading.
To improve clamp loading options
include: a pressure pad to pre‑clamp
the part, increasing the advance rate
of the Powerhead, and/or using an
orbital head with a reduced attack
angle to increase downward force.
FIGURE 1.1: ORBITAL FORMING DIAGRAM
for long, thin, and unsupported rivets,
Spiral/Radial may be the better option.
In general, Orbital has a longer
reach than spiral, which can be
further extended using a special 3 or
4 degree long‑reach orbital head, or
an orbital head extension. To form
around obstructions, options include: a
c‑frame orbital head with an anti‑rotate
device, an offset orbital head, and/
or a modified peen with anti‑rotate
device. In addition, orbital heads can
be configured to form multiple rivets
simultaneously, using multi‑spindle or
multi‑point tooling heads.
Clamp loading will vary based on
forming a tenon or rivet, the type of
material, tooling, and fixturing used.
For example, If the part is supported
(fig. 1.3), allowing a gap between the
manufactured rivet head and the part,
Both Orbital and Spiral processes
are recommended for low profile joints
requiring articulation, because they
form the rivet head without completely
collapsing the shank. Clamp load
can be adjusted to maintain some
rotational torque/friction, as required in
applications such as surgical scissors.
Retaining rings and cotter pins
allow articulation, but do not provide
compressive loading characteristics,
and therefore allow vibration between
the fastener and the parts.
If the joint requires superior clamp
loading and torque control, one
fastening option is to use a bolt and
nut, and then orbitally form the bolt
against the face of the nut, locking
the nut in place. Another option is
to orbitally ring‑stake the nut into
the bolt’s threads to permanently
lock them together. This additional
operation adds to the production
cost and reduces throughput. As
a permanent solution, this is only
recommended when extreme clamp
loading and precise torque control is
needed.
SPIRAL FORMING DIAGRAM
As a rule of thumb, 90% of all
Radial/Spiral riveting can be done
with the Orbital process, with lower
maintenance costs as compared
to the Spiral/Radial process. The
complexity of the Spiral tooling head’s
planetary gear, thrust plate, and
pressure cup significantly increases
overall cost of ownership. However,
GAP
GAP
FIXTURE
HEAD SUPPORTED
FIXTURE
PART SUPPORTED
FIG 1.2
Assembly Solutions for Manufacturing Since 1984
FIG 1.3
5
The Orbitform Journal
www.orbitform.com
displaced into a pocket in the anvil,
creating a button shape similar to
clinching. This process eliminates the
cost of machining a hole, but with the
absence of a hole, some applications
may require external fixturing to align
the parts.
HOT UPSET FORMING & RIVETING
The Hot Upset forming and riveting
process uses heat and pressure
to form the fastener. Similar to
electro‑forging, the heated material
becomes malleable and collapses
under pressure applied by the
Powerhead. With this process it is
possible to form a round fastener into
a square hole, creating a high‑torque
joint. Unlike welding, in most cases
the base material does not bond with
the fastener, but depending upon
the material bonding may occur. In
addition, this process may change the
microstructure of the material being
formed, altering its metallic properties.
Testing the rivet or formed material is
recommended.
As a rule of thumb, Hot Upset is
best suited for hardened materials
that cannot be formed by other
methods. This unique process
provides greater hole‑fill, over 98%
percent, increases push‑out force, and
creates an overall tighter joint due to
HOT UPSET JOINT DIAGRAM
molecular contraction during cooling.
This process is not recommended for
joints that require articulation; it may
also affect surface coating aesthetics.
Example applications include
automotive striker‑wires, ball studs,
and joints with high torque and high
shock or vibration requirements, such
as military weaponry.
Hot Upset typically has a 3‑4 second
cycle time, which is generally slower
than orbital or impact riveting. In
addition, hot parts require special
handling considerations. Direct current
(DC) powered systems are more
6
800-957-4838
efficient and precise than their AC
counterparts, but come at a higher
initial cost. Cost of ownership includes
power consumption and tooling
electrodes. Hot Upset systems also
require a chiller to maintain optimal
tooling temperature.
IMPACT RIVETING ‑ SOLID & SEMI
TUBULAR RIVETS
Impact Riveting is a cold forming
assembly process using pneumatic,
electro‑mechanical, hydra‑pneumatic,
or hydraulic force to install a rivet.
Joint characteristics can vary greatly
depending on the rivet type, material
and geometry. Some common rivet
types include solid, semi‑tubular, and
self‑piercing. The forming sequence
is unique to each type of rivet. The
shank on a solid rivet must swell to fill
the hole before the head collapses. On
a semi‑tubular rivet, the hollow tenon
curls over on impact, drawing the parts
together with minimal shank swell.
Self‑piercing rivets (fig. 1.4), used
to join sheet metal and other thin
materials, pierce the upper layers
of material until the bottom layer is
Standard Impact Riveting machines
have a much quicker cycle time than
standard Orbital, Spiral and Hot
Upset machines, and provide higher
production throughput, commonly
used for high volume commodity
products such as HVAC duct work,
brake pads, and circuit breakers. In
addition, impact machines include
automatic rivet feeding systems,
eliminating manual rivet handling,
making the process ideal for installing
multiple rivets in a single part
assembly. In most cases the operator
handles the part, so there is no
cost for part fixturing. High capacity
FIGURE 1.4: SELF PIERCING RIVET
impact machines can install solid
rivets up to 5/8” inches in diameter,
providing a robust, low‑profile, solution
for permanent assembly. Typical
perishable tooling includes: Jaws,
Drivers, and Rollsets.
For high volume assembly of brittle
materials like clutch assemblies, circuit
boards and plastics, riveting machines
can be configured with load‑deflecting
components.
THE IMPACT RIVETING PROCESS
Assembly Solutions for Manufacturing Since 1984
Riveting, Forming, Welding, Projection Conveyors, Systems
To consolidate equipment and
reduce the work area footprint, a single
machine can be configured to install
up to four rivets simultaneously; other
options for multi‑riveting include dual
head and multi‑head machines. Using
an offset driver accessory, riveting
heads can be positioned as close as
1/16” of an inch between rivet heads.
ROLLER FORMING ‑ ASSEMBLING
CYLINDRICAL PARTS
Another permanent fastening
method, specifically designed for
assembling large diameter parts, is
Roller Forming. Roller Forming is a
non‑impact process using a spinning
Roller‑head with two or more rollers
to apply a symmetrical force to the
part. Roller forming is used for flaring,
forming a lip, crimping, or forming
a groove in cylindrical parts too
large for other processes. Assembly
applications include: water pumps,
bearings, ball joints, air bag canisters,
electrical sensors, fuses, solenoids,
and parts where a groove or lip is
needed, such as sealing the end of a
tube.
As a general rule, 90% of all Roller
Forming applications are between
3/8” and 6” inches in diameter. Wall
thickness can vary from 1/32” to
over 1/4” of an inch depending on
the type of material. The Roller‑head
RPM and advance rate are controlled
by a Powerhead configured with
an integrated Load Cell and LVDT
for process monitoring and control.
For part clamping, a Thru‑Spindle
Pressure Pad option is available. For
static Roller‑heads, typical cycle times
range from 3‑5 seconds depending on
ROLLERFORMING DIAGRAM
the application.
Articulating Roller‑heads are used
for navigating around part obstructions
and applying horizontal pressure
needed for crimping or grooving
applications. Pneumatically actuated
Articulating Roller‑heads can deliver
a horizontal force up to 5,000 lbs.
@ 100 psi. Typical cycle times for
an Articulating Roller‑head range
from 4‑10 seconds depending on the
application.
Roller Forming’s non‑impact
symmetrical loading and precision
control allows this process to form a
retaining lip over glass or other brittle
materials. Roller Forming can also
If your product doesn’t need to be
taken apart for shipping, maintenance
or repair, permanent part assembly
can be a cost effective solution to
other fastening methods, in addition
to increasing production throughput,
and reducing fastener, machining,
and overall assembly costs; you
also get the many inherent benefits
of permanently assembling your
product. S. Cumming & J. Price
RIVETING
FORMING
SEND
US YOUR
CONVEYORS
SAMPLE PARTS
FOR ASSEMBLY
ANALYSIS
SYSTEMS
ROLLERFORMING A LIP
replace multi‑point crimping with a full
360 degrees of contact retention. If a
torque resistant interface is required,
rough or knurled mating component
surfaces are needed to grip against
the formed lip or groove. This process
can, in some cases, replace welding
to provide a strong joint with an
aesthetically appealing finish, reducing
production time and assembly cost.
Sealing characteristics depend
on the part’s design and usually
requires the addition of a gasket or
O‑ring; customer testing is highly
recommended.
Modular Assembly Components
Custom Engineered Systems
Service Parts & Tooling
Assembly Solutions Lab
Orbitform designs and builds assembly
equipment solutions for manufacturing,
including Riveting, Forming,
Welding, Conveyors, and CustomEngineered Assembly Systems.
Orbitform manufactures its own line
of standard assembly products,
all made in the USA since 1984.
Services include Assembly Analysis,
Tooling Development, and low-volume
production runs
PROJECTION WELDING
TOOLING
1600 Executive Dr, Jackson, MI 49283
www.orbitform.com
(517) 787-9447
Assembly Solutions for Manufacturing Since 1984
7
The Orbitform Journal
www.orbitform.com
800-957-4838
Here at Orbitform, we recently developed a unique
riveting process called Hot Upset. This rivet/forming
solution uses force and heat to form rivets or part
tenons, providing greater strength, increased hole‑fill,
improved resistance to push‑pull forces, and an overall
tighter joint, due to material contraction during cooling.
Similar to electro‑forging, the heated
material becomes malleable and
collapses under pressure applied by
the Powerhead. With this process it is
possible to form a round fastener into
a square hole, creating a high‑torque
joint.
Our customer, an automotive part
manufacturer, needed to assemble
a product with hardened rivets,
each with a long tenon stick‑out. To
meet their production requirements,
we needed to form two rivets per
machine cycle. We examined both
orbital and spiral forming options
in our applications lab, but due to
the extreme hardness of the rivets,
final form characteristics did not
meet our customer’s specification.
Also some samples showed signs of
cracking, which in this application was
unacceptable. We then tested our Hot
Upset forming solution, which resolved
the forming challenges. We offer both
AC and DC Hot Upset systems. In
this case, the customer chose a DC
system for its power consumption
savings versus the lower initial cost of
an AC system.
Orbitform designed and built a
custom Hot Upset system. The design
included two standard Orbitform
modular Powerheads, the same
Powerheads used in our Orbital,
Spiral, and Roller Forming products.
Using standard Powerheads instead
of traditional weld cylinders eliminated
the need for an external air/oil tank
and intensification valve. To stabilize
the customer’s part during the forming
process, the system was outfitted
with a part clamping pressure pad.
To verify a quality form, process
monitoring included: LVDT’s and load
cells to monitor head stroke position
and force, and sensors for Powerhead
advance and retract. The customer’s
HOT UPSET PROCESS
safety specification included: light
curtain, guarding and palm button
activation.
Hot Upset typically has a 3‑4 second
cycle time, which is generally slower
than orbital or impact riveting. In
addition, hot parts require special
handling considerations. Direct
current (DC) powered systems are
more efficient and precise than their
AC counterpart, but come at a higher
initial cost. Cost of ownership includes
power consumption and tooling
electrodes. Hot Upset systems also
require a chiller to maintain optimal
tooling temperature.
Check out our matrix on page 5 for an
overview of joint characteristics and
their costs. Hot Upset is included in
the research.
HOT UPSET DUAL POWERHEADS
8
Assembly Solutions for Manufacturing Since 1984
Riveting, Forming, Welding, Projection Conveyors, Systems
Permanently assembling parts using an orbital
process offers many advantages including: 80%
less force required than a conventional press,
a low profile aesthetically appealing head‑form,
low cost fasteners, a high strength joint, and the
option to allow a joint to rotate.
Proper machine setup and
maintenance is critical in achieving a
desirable head form and consistent
results. With over 25‑years of
experience, Orbitform’s application
engineers and service technicians
have seen what can happen on the
factory floor. Here are a few tune‑up
tips to keep your orbital assembly
equipment running smoothly, and
producing quality parts.
ALIGNMENT
To assure a quality head form it is
critical that the center of the orbital
head be aligned with the center of the
rivet being formed. A misalignment
can produce undesired results,
rejected parts and possible damage
to bearings and the orbital head.
Alignment issues can come from: the
fixture, the part, and/or the machine
setup. The easiest method to check
the alignment is with Orbitform’s
Orbital Alignment Kit. Typically on a
1/4” diameter rivet, the center of the
orbital head should be within 0.004”
Total Indicator Runout from the center
of the rivet.
THE PEEN
The peen is the perishable tooling
that touches the rivet or part being
formed. Make sure the peen‑holder
turns freely inside the orbital head.
The peen is held in place with a
magnet or set screw and should be
easy to remove. Apply an anti‑seize
lubricant to its shank at least once a
week.
Check the peen for excessive wear.
Never sharpen or machine a worn
peen. Changing the length of the peen
changes its point of contact, which
can affect the resulting head form,
and possibly lead to bearing failure.
Always replace worn tooling. Make
sure new tooling meets the standards
for hardness, polish, and coating set
by the manufacture.
Check if the peen is too hot to touch
after forming. Excessive heat can lead
to or indicate bearing failure. A hot
peen may mean it’s hitting the part too
hard or dwelling on the part too long
and/or not rotating properly. The flow
control on the Powerhead’s exhaust
may need to be adjusted to increase
or decrease the Powerhead’s advance
rate.
LUBRICATION
Orbitform’s Powerheads are lubed
for life and require little preventative
maintenance. However, the orbital
head should be inspected and
greased after approximately 100 hours
of forming time. Do not confuse this
with 100 hours of machine operation.
If a part takes 5 seconds to form, that
would be one minute of forming‑time
for every 12 parts, one hour for 720
parts, or 72,000 parts for every 100
forming‑hours. Be careful not to over
grease the orbital head. Typically, a
single shot from a hand pump is all
that’s needed. Over greasing can
create extra drag on the bearings and
restrict the peen‑holder from rotating
freely.
Assembly Solutions for Manufacturing Since 1984
9
The Orbitform Journal
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AIR
Orbitform’s Powerheads are rated to
100 psi of air pressure. We generally
size our Powerheads based on air
pressure available in the plant. If
the pressure on the factory floor
drops, the Powerhead’s force will be
diminished; this can effect cycle‑time,
and the overall head‑form. Verify the
recommended air pressure is within
the machine’s specification.
Just as important as air pressure
is air volume. The more air‑driven
equipment added to a production line
the greater the overall volume of air
needed to run them. Air pressure may
be within limits, but the machines may
be starved for air, which can affect
cycle‑time and forming results.
This is especially true when forming
multiple rivets with quick forming
cycles. Make sure the lines can deliver
the required volume of air; if not an
accumulation tank may be needed.
An orbital riveting or forming process
can solve many challenging assembly
requirements; a well‑tuned machine is
the key to consistent forming results
and quality parts.
10
J. Price
Assembly Solutions for Manufacturing Since 1984
800-957-4838
Riveting, Forming, Welding, Projection Conveyors, Systems
If you need to install multiple rivets, you could
benefit from our multi‑head and multi‑point
impact riveters. Multi‑head riveters consist of
two or more riveting heads, designed to work
on the same part simultaneously. Note: Additional options and features
are available. Each machine is
configured and tooled to suit your
specific riveting application. Please
submit part and rivet samples for
evaluation.
We offer fixed and adjustable tool
configurations to suit a wide range of
applications. Consolidate equipment
and reduce work area footprint
with one of our adjustable center
distance dual‑head riveters (Fig. 1), or
increase production throughput with a
multi‑head fixed‑tool riveter (Fig. 2).
It’s also possible to install multiple
rivets simultaneously with a single
fixed‑tool or fixed‑center (FC) riveter,
configured with multiple rivet feeders,
drivers, jaws, and rollsets (Fig. 3).
FIG 1
OPTIONS:
• Dual fixed tool, dual adjustable, multi
head, and multi‑point configurations
• Pneumatic, electro‑mechanical,
hydra‑pneumatic, and hydraulic
• Offset Driver package provides
minimum distance (rivet head
diameter + 1/16”)
• Safety probe, light curtain, palm
buttons, and Lexan® and/or wire
mesh guarding
• Custom fixturing and part clamping
• Vibratory rivet feeding system
upgrade
• Integrated load cell for monitoring
riveting forces
FEATURES:
• Multi‑head systems allows heads to
be turned on/off separately, to use a
single head for rework
• Rotary Hopper rivet feeding system,
mechanical or pneumatic, with track
assembly
• Install solid rivets up to .63” diameter (tooling is designed to suit
your specific rivet size)
• Install semi‑tubular rivets from 1/16”
up (tooling is designed to suit your
specific rivet size)
• Multi‑point riveting from a minimum
distance (rivet head dia + 1/16”) up
to 4” apart
Assembly Solutions for Manufacturing Since 1984
FIG 2
FIG 3
11
The Orbitform Journal
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800-957-4838
An automotive parts supplier needed to permanently retain a sound
deadening baffle plate on the inside of an engine cover. Screws were
expensive, time consuming to install, and tended to fall out over time.
What they needed was a permanent
cost effective solution. Orbitform’s
application engineers suggested
Orbitally forming tenons molded into
the die cast A380 aluminum cover.
One issue was the tolerance in lining
up the cast tenons on the cover
with the holes on the baffle plate.
The holes had to be oversized, and
A380 aluminum can only form so far
without cracking. Orbitform engineers
suggested that a cone shape, similar
to a Belleville washer, be stamped
into the holes on the baffle plate
to snug up to the formed tenon if
tolerances were off.
BEFORE
Then extensive testing in Orbitform’s
application lab determined the
optimal tenon geometry. To form the
tenon’s head, Orbitform’s engineers
developed a captured conical peen,
to contain the A380 aluminum
during forming. In addition, die cast
aluminum is abrasive, containing
around 8% Silicon, causing excessive
tool wear and galling. To combat this,
the M2 steel peen was coated with
Titanium Nitride.
Because the tenons were close to
walls and on different planes, it was
not possible to use a height‑sensing
pressure pad to monitor and control
the form. Instead, the orbital riveter
was set up to form to a force, creating
a permanently formed head within
the tolerance of the cast aluminum
tenons and baffle plate. Assembly
solution delivered.
12
Assembly Solutions for Manufacturing Since 1984
AFTER
PART: BEFORE AND AFTER
Riveting, Forming, Welding, Projection Conveyors, Systems
If you are struggling to permanently assemble
tubular or large diameter parts, Orbitform’s Roller
Forming process may be the solution. Roller Forming
is a non‑impact process using a spinning Roller‑head
with two or more rollers to apply a symmetrical force
to the part.
Roller forming is used for flaring,
forming a lip, crimping, or forming
a groove in cylindrical parts too
large for other processes. Assembly
applications include: water pumps,
bearings, ball joints, air bag canisters,
electrical sensors, fuses, solenoids,
and parts where a groove or lip is
needed, such as sealing the end of a
tube.
An automotive part supplier wanted
to reduce the cost and weight of
their water pump by converting its
cast iron housing to cast aluminum.
ROLLER FORMED AUTOMOTIVE PART
Originally the bearing was press‑fit
into the housing. The result was
lighter, but thermal expansion was
greater. Repeated heating and cooling
caused the bearing to walk‑out. The
customer tried adhesives to retain the
bearing, which added expense and an
additional process that was messy.
Orbitform’s Applications Engineers
worked with the customer to design a
retaining feature that could be formed
using Orbitform’s Roller Forming
process to permanently retain the
bearing. A custom static two‑roller
tooling head was developed and
tested using Orbitform’s standard
Powerhead. For this application our
engineers determined a rotational
speed of 400 rpm was optimal when
combined with the downward force of
the Powerhead. The customer verified
the result using a push‑out test, which
caused the cast aluminum housing to
fail without pushing the bearing past
the formed retaining lip.
A custom designed fixture held the
housing assembly, and a Thru‑Spindle
Pressure Pad held the bearing in
place. Process monitoring included
bearing presence confirmation, a
load cell to monitor force, and LVDT
to monitor the Powerhead’s stroke
position. Three interchangeable
Roller‑heads allowed the customer
to use the same machine for three
different water‑pump assemblies.
Safety equipment included a light
curtain, guarding and Opto‑Touch
activation buttons.
As a general rule, 90% of Roller
Forming applications are between
3/8” and 6” inches in diameter. Wall
thickness can vary from 1/32” to over
1/4” of an inch depending on the type
of material. The Roller‑head RPM
and advance rate are controlled by
Orbitform’s standard Powerhead
to precisely form the material. The
Powerhead can also be configured
with an integrated Load Cell and
LVDT for process monitoring and
control, along with a Thru‑Spindle
Pressure Pad for part clamping
during the forming process. For static
Roller‑heads, typical cycle times range
from 3‑5 seconds depending on the
application.
Assembly Solutions for Manufacturing Since 1984
13
The Orbitform Journal
www.orbitform.com
800-957-4838
IT ALL STARTS WITH THE CUSTOMER’S PART
RIVETING
FORMING
CONVEYORS
ROLLER FORMING DIAGRAM
Roller Forming’s non‑impact
symmetrical loading and precision
control allows this process to form
a retaining lip over glass and other
brittle materials. This process can,
in some cases, replace welding
to provide a strong joint with an
aesthetically appealing finish.
Sealing characteristics depend
on the part’s design and usually
requires the addition of a gasket or
O‑ring; customer testing is highly
recommended. Roller Forming can
replace multi‑point crimping with a full
360 degrees of contact retention. If a
torque resistant interface is required,
rough or knurled mating component
surfaces are needed to grip against
the formed lip or groove.
Orbitform is the only company
that offers pneumatically actuated
Articulating Roller‑heads for navigating
around part obstructions and applying
horizontal pressure needed for
crimping or grooving applications.
Orbitform’s Articulating Roller‑heads
can deliver a horizontal force up to
5,000 lbs. @ 100 psi. To fine tune
the forming process or accommodate
multiple parts with different diameters,
Articulating Roller‑heads offer an
infinitely adjustable horizontal stroke
within a 3mm to 25mm range.
Typical cycle times for an Articulating
Roller‑head range from 4‑10 seconds
depending on the application.
As a replacement for welding or
crimping, Roller Forming can reduce
production time and assembly costs,
while improving consistency, strength,
and aesthetic appeal. Send us your
sample parts and let Orbitform’s
Application Engineers see if Roller
Forming is right for you.
SYSTEMS
ASSEMBLY EQUIPMENT SOLUTIONS
Orbitform designs and builds
assembly equipment, including
Riveting, Forming, Welding,
Conveyors, and Custom Assembly
Systems. Orbitform manufactures
its own line of assembly
components, made in the USA since
1984. Services include Assembly
Analysis, Tooling Development,
and low-volume production runs.
MADE IN THE USA
TOOLING
PROJECTION WELDING
POWERHEADS &
ASSEMBLY COMPONENTS
www.orbitform.com
ROLLER FORMING A GROOVE
14
1600 Executive Dr, Jackson, MI
(517) 787-9447
Assembly Solutions for Manufacturing Since 1984
Riveting, Forming, Welding, Projection Conveyors, Systems
An automotive part supplier needed to increase their
production throughput. They contacted Orbitform to
automate their manufacturing process.
The challenge was to integrate a
vibratory part feeder, inspection
system, assembly station, and two
Okuma machining centers to create
an automated production cell.
Orbitform engineers examined both
our Palletized and Low Back-Line
Pressure conveyor lines. Orbitform’s
Palletized conveyor line uses pallets
with fixtures to carry each part
between stations and even allows
assembly operations to be performed
on the conveyor. But after running
simulations, engineers selected
Orbitform’s Low Back Pressure (LBP)
conveyor to meet the customer’s
high production volumes. The LBP
conveyor allows parts to ride directly
on the conveyor roller chain and
allows parts to buffer with minimal
contact force, assuring parts are
always in queue for machining.
To further reduce assembly time,
Orbitform engineers designed an
8-station dial, including a four-spindle
orbital riveter to simultaneously form
four tenons to secure a mounting
bracket to the part prior to machining.
The part was then inspected and
placed on Orbitform’s LBP conveyor
for transfer to the machining center,
where the assembled parts remained
in queue until a Denso robot arm
loaded them into the Okuma. After
machining, the parts returned to the
conveyor via the Okuma’s gantry for
transfer to a final inspection station.
By automating their production using
Orbitform’s Low Backline Pressure
Conveyor our customer significantly
increased the output from their
existing Okuma’s surpassing their
production goals, while enhancing
operator efficiency by allowing them
to run multiple machining centers
concurrently. Solution Delivered.
Assembly Solutions for Manufacturing Since 1984
15
The Orbitform Journal
www.orbitform.com
800-957-4838
IT ALL STARTS WITH THE CUSTOMER’S PART
RIVETING
FORMING
CONVEYORS
SYSTEMS
ASSEMBLY EQUIPMENT SOLUTIONS
Orbitform designs and builds
assembly equipment, including
Riveting, Forming, Welding,
Conveyors, and Custom Assembly
Systems. Orbitform manufactures
its own line of assembly
components, made in the USA since
1984. Services include Assembly
Analysis, Tooling Development,
and low-volume production runs.
MADE IN THE USA
TOOLING
PROJECTION WELDING
P: (800) 957-4838
W: www.orbitform.com
16
1600 Executive Dr,
Jackson, MI 49203
POWERHEADS &
ASSEMBLY COMPONENTS
www.orbitform.com
1600 Executive Dr, Jackson, MI
Assembly Solutions for Manufacturing Since 1984
(517) 787-9447