an unbiased approach - assembly magazine unbiased approach with orbitform's core processes 30...

An UnbiAsed ApproAch with Orbitform's Core Processes

30YEARS EXPERIENCE

OVER

Orbital Forming

Impact Riveting

Roller Forming

Radial Forming

Hot UpsetFlush Self Piercing Rivet

ALL UNDER ONE ROOF!

22 Assembly Equipment Solutions for Manufacturing Since 1984

WHAT IS OUR UNBIASED APPROACH?With multiple forming and fastening options you are not limited to one assembly process. Through necessity and ingenuity we have compiled a variety of processes that allow Orbitform to determine the optimum choice for your part assembly.

ASSEMBLY PROCESSESOrbital Forming

Radial Forming

Impact Riveting

Roller Forming

Hot Upset Forming

Flush Self-Piercing Riveting

331600 Executive Drive • Jackson, MI 49201 • (517) 787-9447 • www.orbitform.com

What is Orbital Forming?

A low force cold forming process that uses a peen tool on a rotating spindle. The peen tool is on a line of contact with the work piece and gradually moves the material to the desired form.

Why Choose Orbital Forming?

• 80% less force than staking/pressing

• Minimal rivet shank swell

• Controllable forming process

• Can form vast array of materials

• Forming parameters flexible to support many applications

• Powerhead “lubed for life” bearings – low maintenance

• Peen never leaves workpiece during forming process

• Fast tool changeover

Case Study

When spot-welding failed, an automotive parts supplier contacted Orbitform to attach a hardened steel gear to a metal stamping. Orbitform engineers suggested adding an extrusion and orbitally flaring the extruded lip overt the gear, eliminating the need for a costly fastener.

ORBITAL FORMINGOrbital Forming

PEEN

STROKEADVANCE

4-6


What is Radial Forming?

Similar to orbital—a non-impact process of cold forming that uses a peen tool to move in a rosette pattern and gradually move the material to the desired form.

Why Choose Radial Forming?

• 80% less force than staking/pressing

• Works with small, delicate rivets

• Good for small diameter fasteners/posts (1/8" and smaller)

• Minimal to no side load force during forming process

• Fast tool changeover

• Controllable forming process

• Can form vast array of materials

• Shank swell characteristics

Case Study

An auto parts manufacturer approached Orbitform inquiring about how to replace their existing press machine with an orbital process. The assembly included a metal plate and stamping, fastened together by a rectangular tab that needed to completely fill a rectangular hole. When the Solution Lab attempted to orbitally form the tab, the 360° motion tended to twist the tab and not completely fill the hole. A lab technician suggested radial forming. The rosette pattern that this process uses allowed the material of the tab to be pushed out from the center to completely fill the rectangular hole.

RADIAL FORMINGRadial Forming

3 - 5°

PEEN


What is Impact Riveting?

A rivet/fastener is automatically fed and inserted (shank leading) through holes in selected parts to form a head on the tendon end and secure/join components together.

Why Choose Impact Riveting?

• Fast cycle times (process speed)

• Rivet variety for the perfect form: solid, semi-tubular, & clinching

• Single and multi-point machines

• Automatic rivet feeding

• Shank swell of rivet in joint

Case Study

A furniture company developed a part that is stronger, more ergonomic and easier for the end user to assemble, for one of its product lines. One of the challenges with this application is, of the 3 pockets where the forming takes place the deepest measures approximately 1.5" deep. In the average impact forming process the jaws will guide the rivet to just above rollset pin, the driving tool will then strike the rivet and create the form. In this application the jaws do not fit into the pocket and the rivet must be guided into place by the driver tool and the roll set pin.

IMPACT RIVETINGImpact Riveting


What is Roller Forming?

Non-impact process using a spinning rollerhead with two or more rollers, to apply a symmetrical force to a round work piece, allowing its material to flow to a desired finished form.

• Static—Roller head tooling is “fixed” in position, rotating as the powerhead advances to complete forming

• Articulating—Roller head is dynamic, with the roller tooling moving inward to complete forming

Why Choose Roller Forming?

• Works with brittle material

• Provides strong joint hold

• Articulating can form around an area where obstruction is presented from top down

• Can form around parts up to 6" in diameter

• Precision control

Case Study

An electrical sensor manufacturer was multi-point crimping a metal cap over a heat sensor. Stress risers at the crimp points allowed moisture inside, damaging components. Orbitform engineers' roller formed the cap for a tighter seal with 360° of retention.

ROLLER FORMINGRoller Forming

LIP

static form articulating form

GROOVE


What is Hot Upset Forming?

Fastens parts through precision heat and pressure applied to the work piece, allowing the material to flow and achieve maximum hole fill in the joint, and the desired finished head form.

Why Choose Hot Upset Forming?

• Forms hardened material

• Greater percentage hole fill

• High torque joints

• Minimal vibration decreasing risk of joint fatigue

• Minimal risk of material cracking

• Forms exotic metals

Case Study

An equipment manufacturer was welding a hardened steel rod into a hex hole to prevent rotation, but welding annealed the rod, and vibration caused some joints to fail. Orbital forming did not flow enough material in the joint to prevent rotation. Orbitform applied the hot upset process, creating a high torque joint with 99% hole-fill at a lower temperature than welding.

HOT UPSET FORMINGImpact Riveting


What is Flush Self-Piercing Riveting?

Joins two or more metals/materials by piercing through them with an hourglass like fas-ner that is the same length as the metals when stacked together.

Why Choose Flus Self-Piercing Riveting?

• Reduces utility cost compared to spot welding

• Pierces metal (steel or aluminum)

• Fastens dissimilar metals/materials

• Fastens thick metal min: .07" max: 0.36"

• No touch up or refines on painted parts when rivets are pre-painted

• Aesthetically appealing

Case Study

With the ever-increasing quest for efficiency by reducing operating expenses and increasing capacity, one process that is not only a bottleneck but also one that carries considerable regulatory compliance is the finishing of the product.

By eliminating the need for post-paint operations by using a pre-painted fas-ner, the costs of regulatory compliance is reduced, plus manufacturers save the capital burden of the painting facilities in addition to the labor costs associated with handling, cleaning, spraying, and drying operations. By utilizing pre-painted materials, the manufacturer allows products to hit the market quicker and at a lower manufacturing cost.

FLUSH SELF-PIERCING RIVETINGFlush Self

Piercing Rivet

Punch Set

Coin


At Orbitform, it all starts with the customer’s part in our Assembly Solutions Lab. Our application engineers know the best way to optimize an assembly process is by assembling your sample parts. Product engineers receive invaluable feedback, suggestions for part features, and a more efficient and cost effective process.

SEND US YOUR SAMPLE PARTSFOR ASSEMBLY ANALYSIS

SOLUTIONS LAB

an unbiased approach - assembly magazine unbiased approach with orbitform's core processes 30...

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