Orbital Forming

Orbital Forming

More than just create the fasteners, orbital forming machines can be used to install the mechanisms and create secure joints intended to last for the lifetime of the part or product. Adjustable pressure, stroke and cycle times allow for customized precision handling in such varied fields as aerospace, automotive, rail, transport, trucking, electronic and semi-conductor construction among others. The process of orbital forming is clean, quite, non-impact and vibration free making it a much sought after alternative to more disruptive procedures such as welding, upsetting, peening, crimping and riveting. The tool works in a fashion similar to impact or compression forming, but it rotates both an upper and lower die at a fixed angle in order to apply both axial and radial pressures. Parts and fastenings are formed in a matter of seconds to exact specifications and with no disruption of the material grain structure.

Virtually any malleable material can be formed through this orbital process, with most machines capable of shaping materials up to 35C on the Rockwell scale for hardness. Most ferrous and nonferrous metals such as stainless steel, zinc, aluminum, brass and copper are included in this as well as some specially engineered thermoplastics. To create rivets, nuts and bolts from these materials, special orbital tooling is a required. The form tool itself is mounted in a special revolving spindle apparatus that holds it at a specific angle, but allows it to rotate in its bearings. The spindle advances and brings the tooling to the work surface where pressure is applied in predetermined amounts. This contact remains constant as the spindle rotates. The entire process takes just a matter of seconds to complete in most small applications, though slightly longer for large component forming. Because the orbital motion enacts metal deformation at a lower level of force than most other cold forming processes, it allows precision cold working without disruption of the molecular structure of the metals and materials to be altered. The pressure of the tool does, however, compress the grain creating slightly work hardened products. Annealing can relieve these internal stresses if they are too great or incompatible with the intended use of the part.