Creating Stability in a Bushing Flare

The Benefits of Orbitally Forming a Flare

Forming a flare

Orbitally forming a flare is a unique process. As a forming force is applied, material flows to the path of least resistance, lead by the geometry of the peen tool. Finished form is dependent on the design of the surrounding assembly area, as well as the tooling needed for the process.

Dimensional Requirements

Recently, we were approached by a customer to flare their bushing assembly. Design engineers were working toward orbitally forming a flare for retention, dimensional requirements, and increasing the surface area of the formed tenon. Upon testing in our Solutions Lab, forming was very successful. The material flowed smoothly outward, creating the dimension requirements the customer required.


This is where our story begins.


Troublesome Finished Form

Orbitform was able to produce prototype parts in our lab for the customer to take into testing. These parts met all the specifications the engineers believed they required. However, upon testing, it was discovered that the finished form was troublesome.

Friction Required

The peen used in testing created a very smooth, shiny and visually appealing finished form, but the surface lacked the necessary friction to provide the necessary stability for the customer’s assembly. Unbeknownst to Orbitform’s engineers, assembling the bushing into its full component required a surface that provided friction or grip that simply was not there. This detail concerned the engineers. Could the current forming process provide the necessary finished form?

Tooling Design

The engineers once again turned to Orbitform’s Lab Technicians to find an answer. Upon review of the new functional requirement, our technicians worked to redesign the peen tooling to form rings into the tenon as it was being formed. In order to design the tooling, our engineers took the desired finished form and reverse engineered the design into the tooling.

Finished Form Requirement

Testing occurred once again within the lab to ensure the newly designed tooling was able to create the rings within the flare. This forming process determined that the height of the rings was extremely important: too low and stability was lost was lost in the assembly, too high and the rings cracked. Through several rounds of design and lab testing, Orbitform was able to determine the precise height of the rings for the finished form requirement. Through collaboration and testing, the desired functionality was achieved.

Machine Requirements

Once the design was successfully achieved, this orbital flaring process needed to be recreated for manufacturing. Orbitform worked directly with the bushing manufacturer to design and build a machine that fit their company specifications, volume, and required functionality.

Your Flaring Application

Forming a flare orbitally is a unique process that can achieve many functional requirements. Leveraging the cold forming process of moving the material to the path of least resistance allows Orbitform to control the finished form, no matter how unique it may be. We stand ready to work with you for development on your unique finished form for your flaring application.