In the world of precision manufacturing, the roller forming process plays a crucial role in creating strong, reliable assemblies. Roller forming is a non-impact forming process that uses rotating rollers to apply symmetrical force, forming cylindrical parts with precision and consistency. This method is highly versatile, offering solutions for manufacturers working with delicate, brittle materials or those looking for increased accuracy in forming parts. At Orbitform, we provide two key applications of roller forming: Static Roller Forming and Articulating Roller Forming. While both are designed to enhance manufacturing processes, each has unique strengths suited for specific roller forming applications.
What is Roller Forming?
Roller forming involves a spinning roller head with multiple rollers applying force evenly around a part, typically cylindrical. It can form lips, grooves, and other features with precision. This process can replace traditional press crimping, offering uniformity and the ability to work with delicate materials. Unlike crimping, which uses multi-point pressure that can lead to stress points or cracks, roller forming applies continuous 360° force, eliminating these risks. This non-impact process ensures precision and reduces the likelihood of material damage, particularly for delicate or brittle components, while delivering aesthetically superior results. For manufacturers seeking improved accuracy, durability, and consistency, roller forming offers a clear advantage over crimping.
Static vs. Articulating Roller Forming: Which is Right for Your Assembly?
What is Static Roller Forming?
Static Roller Forming is a non-impact process where the rollers are fixed in place while applying pressure to form the part. This is ideal for creating uniform lips around cylindrical parts without any movement of the roller head itself.
When Would You Use Static Roller Forming?
This method is best suited for applications where there are no obstructions, and the forming process can take place in a continuous, uniform manner. It’s ideal for parts that require a precise, 360° retention like caps or closures for various cylindrical components.
Challenges Solved by Static Roller Forming
Manufacturers who need to form delicate materials can rely on the static roller forming process to eliminate stress cracks and other damage. The uniform force applied by the fixed rollers ensures accuracy and consistency, making it ideal for forming lips or sealing joints around cylindrical parts. With the ability to form a wide range of diameters, from 1/8" to over 10", this process offers flexibility across different applications.
Thru-Spindle Pressure Pad: Applies a pre-load clamp to the part before and during the forming process for consistent quality and accuracy, and can even validate part presence or stack-up.
Replaces Crimping: By applying 360° retention, static roller forming eliminates the risk of stress cracks often associated with multi-point crimping, while enhancing efficiency and aesthetics.
Applications for Delicate Materials: Static roller forming is non-impact, meaning it can handle brittle or fragile materials without causing damage.
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What is Articulating Roller Forming?
Articulating Roller Forming differs from its static counterpart by featuring roller heads that can articulate radially inward to form the sides of the part. This unique movement allows the roller heads to navigate around obstructions or form parts from the inside out, offering versatility for more complex geometries.
When Would You Use Articulating Roller Forming?
This process is ideal for applications where obstacles or obstructions prevent the rollers from making contact with the part from above. Additionally, articulating roller forming excels in forming grooves, especially in scenarios that require the rollers to form parts radially.
Challenges Solved by Articulating Roller Forming
The articulating capability is perfect for manufacturers dealing with parts that have complex geometries or obstructions. By advancing the rollers radially, articulating roller forming allows for precise formation even when space is limited.
Forming Grooves: This process is ideal for parts that need grooves formed, with the rollers advancing in from the side to create the necessary features. One common application is forming an O-Ring groove, which requires precision and consistency to ensure the seal's effectiveness. Articulating roller forming allows for uniform groove creation, ensuring that O-Rings fit securely, providing reliable sealing in critical applications, such as automotive, medical, and aerospace components.
Navigating Obstructions: Articulating roller heads can clear obstructions and close in on parts, making them ideal for more complex assembly processes.
Infinite Adjustment: With adjustable center distances and analog readouts, the articulating roller heads allow for flexibility in forming parts with varying diameters on the same machine, reducing the need for multiple setups.
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Choosing the Right Roller Forming Process for Your Application
Both Static and Articulating Roller Forming are powerful solutions designed to meet different manufacturing needs. Static Roller Forming is ideal for uniform, cylindrical parts where precision and consistency are key, while Articulating Roller Forming offers versatility for more complex parts that require forming around obstructions or creating grooves. By understanding the specific benefits of each method, manufacturers can choose the right solution to enhance their production efficiency and product quality. Contact us today to discuss how our Static or Articulating Roller Forming solutions can enhance your manufacturing process and meet your specific assembly needs.