Are you experiencing a higher-than-desired number of scrap parts? Are parts failing during testing, or worse, in the field?
When selecting a permanent assembly process, there are multiple options. In most cases, however, there is an optimal process for each part. Process selection is based on factors such as:
- Aesthetic and functional requirements
- Fastener choice and material
- Part geometry
- And more
Evaluating these factors and testing prototypes is critical to determining the optimal process to achieve the desired results.
Over the years, Orbitform has worked with manufacturers across many industries to analyze their assembly challenges and replace their existing assembly process with the optimal equipment solution. Some of the most common process replacements include:
- Replacing screwdriving with riveting or forming for a permanent solution and lower cost fastener
- Replacing crimping with roller forming for a smoother form
- Replacing orbital forming with hot upset forming for a stronger joint
- Replacing press forming with orbital forming for higher control and consistency
- Replacing welding with riveting for faster cycle time
Orbital Riveting vs. Press Forming
One of the most common process replacements is replacing a press with an orbital riveter. Orbital riveting, or orbital forming, is a gentler forming process than pressing due to the rotating path of the tool that massages the rivet material into place. This results in less force being required to form the rivet or workpiece. Orbital riveting is also a more controlled process as the force and speed can be adjusted based on the functional requirements of the joint. There is also a lower risk of material fractures or cracking during forming, as well as a more aesthetically pleasing finished form.
Assembling Sample Parts for Testing and Force Validation
Recently, a measurement instrument manufacturer came to Orbitform to discuss a process change. They were using a press to assemble their parts, but experiencing inconsistent forms that were causing some parts to fail during their torque test. They wanted to explore switching from press forming to orbital riveting.
Our sales team visited their facility within a day of their initial inquiry to review the application and collect sample parts for testing. Utilizing our Solutions Lab, we assembled a few parts for the manufacturer to test to determine if the resulting finished form had enough retention to pass their torque test. We also determined the force required to form the parts to identify the required powerhead. Once they confirmed that the samples passed their torque test, we shipped them an orbital riveting powerhead and standard column within two weeks, thanks to our inventory strategy.
Manufacturers experiencing high numbers of scrap parts or part failures may need to evaluate their current assembly process. At Orbitform, we partner with manufacturers to find the optimal assembly process for each application. If you are looking to improve your assembly process and achieve better outcomes, we invite you to contact us today. Let's discuss your current process, explore potential changes, and work together to elevate your assembly capabilities.