The Genesis of Rollerforming as an Assembly Process

Rollerforming Assembly For Large Diameter Parts

Posted on 08/07/2017 | by The Orbitform Blog Team


Prior to the development of the rollerforming assembly process, Orbitform used peen tools to form ball joints made of cast material. Forming parts with large diameters is difficult, if not impossible, with a peen, because of scrubbing or galling issues. To form large diameter parts, the corresponding peen diameter used for orbital forming is prohibitively large to keep from breaking under the forces needed to complete the form. Debris, galling, and peen breakage result, thus the outer diameter cannot be formed appropriately.


Orbitform’s solution was the use of three rollers, equally spaced on a rotating tooling head, now referred to as a rollerforming head. A rolling motion is achieved instead of the orbital tool path commonly used with peens. It is possible to design a rollerforming head to the necessary diameter. With multiple points of contact, there is no angular movement of the workpiece, and tool breakage is virtually eliminated. Smooth and even pressure rolls the material with minimal scuffing, because the rollers form around a controlled diameter, instead of a single focal point.


Rollerforming also allows the use of a through spindle pressure pad. Through spindle pressure pads are a spring loaded accessory that compresses internal components or material before forming. The process can be further refined by adjusting the roller axles to an offset such as 45 degrees. In many situations the area that must be formed has some obstruction in the way that must be avoided in the vertical motion. To overcome this, Orbitform added the ability to articulate the rollers from outside to inside during the rollerforming process.


If you think this type of assembly process could help your manufacturing operation, please contact us by clicking here.