What is Roller Forming, you ask?
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 Roller Forming applications are between 3/8″ and 6″ in diameter. Wall thickness can vary from 1/32″ to over 1/4″ 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.
Roller Forming can:
Cold form with precise control
Satisfy cosmetic requirements on assembled parts
Form both inside and outside diameters simultaneously
Be used in work cells and automated assembly