Orbitform LLC
Menu

All Parts Filed Under Orbital Heads

Orbital Vs Radial

What’s the difference?

We hear it all the time – what is the difference between orbital and radial riveting. It’s an important subject to discuss when designing a new assembly and looking for the right fastening or forming process. To help you better understand each process and find the right solution, we have put together a few comparisons to consider.

Forming a tenon

The most obvious difference in orbital and radial riveting is the tool path of the peen. With orbital riveting, the peen is held at a fixed angle, typically 6°, and rotates over the fastener in a circular motion. As it rotates along the tenon, it gently forms the material. The 6° angle uses up to 80% less force than a press and creates approximately a 10% sideload. Radial riveting is quite different. The radial peen tool begins in the center and forms outward in a fleurette design. This process creates less side load but requires more force as it travels directly over the tenon.

Common uses and considerations

Due to the forming force required, radial riveting is most often used with small and delicate parts, such as endoscopic medical tools or inside watch components. As the size of the rivet increases, so too does the forming force, making it harder for radial riveting to be completed on larger diameter rivets due to the tooling path. As the tooling path travels directly over the top of the rivet and approaches 0 °, shank swell is increased due to the increased forming force, which can limit the joint’s ability to articulate. With orbital riveting less forming force is required due to the angle of the peen and tool path. The indirect force applied to the tenon creates less shank swell and can allow for articulating joints. The range of assemblies benefiting from this type of riveting include pinion gears, industrial sprinklers, striker wires, etc. etc.

Maintenance

The largest consideration manufacturers should consider is the long-term cost of maintenance and tooling to be used for each type of forming. The tooling path of radial riveting is quite larger than that of orbital riveting. It takes 13 rotations of fleurettes to complete one full 360 ° pass with radial riveting, whereas an orbital path only takes one. For this reason, the internal components between the two types of powerheads differ greatly. Orbital heads include three industrial standard bearings held in place by a snap ring. Maintenance includes removing the snap ring, cleaning, greasing and replacing the bearings. This process, on average, takes around a half hour and should be completed every 40 hours of part contact. The bearings are a standard bearing that can be found at any tool supply shop, meaning you are able to replace bearings quickly in an emergency. The total cost to replace all internal components for an orbital head is minimal. Conversely, radial riveting requires more internal components to create the tool path. The range of movement creates friction and heat, causing internal components to break down quicker. It is critical to grease the internal bearing, pre-load spring and thrust cup every 40 machine hours (not contact hours as in orbital riveting) to limit heat. Also, the rubbing of the pre-load spring and thrust cup to create the florets and rotation creates galling and increased wear. As these components break down, required maintenance and machine downtime due to maintenance increases. Due to the complexity of the components, the cost of replacing internal components of a radial head is three to four times that of orbital riveting.

Making the choice

When choosing between orbital and radial riveting, total cost of ownership, joint function, size, forming force required, and future machine maintenance costs must be taken into consideration. The financial obligations and time required for maintenance are not to be taken lightly, as it can greatly affect your throughput. As you approach the initial design phase of a new project, call the experts at Orbitform to discuss your assembly requirements to determine the appropriate riveting process. Our Applications Engineers and Lab Technicians stand ready to work with you to find the best solution for your assembly.

Filed Under

How to TUNE-UP Your Orbital Riveter

Orbitform Powerheads with interchangeable Spiral Cartridges. Orbitform Powerheads with interchangeable Spiral Cartridges.
Permanently assembling parts using an orbital process offers many advantages including: 80% less force required than a conventional press, a low profile aesthetically appealing head-form, low cost fasteners, a high strength joint, and the option to allow a joint to rotate. Proper machine setup and maintenance is critical in achieving a desirable head form and consistent results.  With over 25-years of experience, Orbitform’s application engineers and service technicians have seen what can happen on the factory floor.  Here are a few tune-up tips to keep your orbital assembly equipment running smoothly, and producing quality parts. ALIGNMENT: To assure a quality head form it is critical that the center of the orbital head be aligned with the center of the rivet being formed.  A misalignment can produce undesired results, rejected parts and possible damage to bearings and the orbital head. Alignment issues can come from: the fixture, the part, and/or the machine setup.  The easiest method to check the alignment is with Orbitform’s Orbital Alignment Kit.  Typically on a 1/4” diameter rivet, the center of the orbital head should be within 0.004” Total Indicator Runout from the center of the rivet. THE PEEN:
Orbital Diagram Orbital Head, Peen Holder, and Peen.
The peen is the perishable tooling that touches the rivet or part being formed.  Make sure the peen-holder turns freely inside the orbital head.  The peen is held in place with a magnet or set screw and should be easy to remove.  Apply an anti-seize lubricant to its shank at least once a week. Check the peen for excessive wear.  Never sharpen or machine a worn peen.  Changing the length of the peen changes its point of contact, which can affect the resulting head form, and possibly lead to bearing failure.  Always replace worn tooling.  Make sure new tooling meets the standards for hardness, polish, and coating set by the manufacture. Check if the peen is too hot to touch after forming.  Excessive heat can lead to or indicate bearing failure.  A hot peen may mean it’s hitting the part too hard or dwelling on the part too long and/or not rotating properly.  The flow control on the Powerhead’s exhaust may need to be adjusted to increase or decrease the Powerhead’s advance rate. LUBRICATION: Orbitform’s Powerheads are lubed for life and require little preventative maintenance.  However, the orbital head should be inspected and greased after approximately 100 hours of forming time.  Do not confuse this with 100 hours of machine operation.  If a part takes 5 seconds to form, that would be one minute of forming-time for every 12 parts, one hour for 720 parts, or 72,000 parts for every 100 forming-hours.  Be careful not to over grease the orbital head. Typically, a single shot from a hand pump is all that’s needed.  Over greasing can create extra drag on the bearings and restrict the peen-holder from rotating freely. AIR: Orbitform’s Powerheads are rated to 100 psi of air pressure.  We generally size our Powerheads based on the air pressure available in the plant.  If the pressure on the factory floor drops, the Powerhead’s force will be diminished; this can effect cycle-time, and the overall head-form.  Verify the recommended air pressure is within the machine’s specification. Just as important as air pressure is air volume.  The more air-driven equipment added to a production line the greater the overall volume of air needed to run them.  Air pressure may be within limits, but the machines may be starved for air, which can affect cycle-time and forming results.  This is especially true when forming multiple rivets with quick forming cycles.  Make sure the lines can deliver the required volume of air; if not an accumulation tank may be needed. An orbital riveting or forming process can solve many challenging assembly requirements; a well-tuned machine is the key to consistent forming results and quality parts. Orbitform Group 1600 Executive Dr. Jackson, MI 49203 (517) 787-8447 www.orbitform.com

Filed Under

HS-750

Orbitform Orbital Heads Last

Through proper care and maintenance, it is possible to keep your orbital head running as smoothly as the day your purchased it and with Orbitform's lubed-for-life orbital heads you know the performance will stay optimal for years.

Orbitform Peen Tools Fasten Your Assemblies

Orbital heads come with a peen tool. The peen is the tool that actually contacts the rivet being upset or the post being formed. There are a wide variety of standard peens used with Orbitfom orbital heads to help enhance your assembly process. Orbitform peen tools are designed for the specific purpose your forming or assembly application requires. Some peens ensure a certain aesthetic appearance while others flare or crimp the work piece involved. Orbitform offers many peen configurations including: conical form peen, flat form peen, captured form peen, crown form peen, flare form peen, eyelet form peen, ring stake form peen, and crimping form peen.

Orbitform Orbital Head Options

  • Standard orbital heads with 6 degree peen angle for minimum required forming force
  • Long reach orbital heads with 3 degree to 6 degree peen angles for difficult to reach rivets or posts
  • Gold series orbital heads with upgraded, heavy duty sealed bearings when you are forming harder materials
  • C-Frame orbital heads for difficult to reach rivets where an overhang or other obstruction prevents a standard, straight down riveting process
  • Multi-point orbital heads for forming several rivets at once with a custom orbital head equipped with several peens
  • Multi-spindle orbital heads for forming several rivets at once with a custom orbital head equipped with several spindles, each spindle with a peen
  • Radial riveting heads for certain applications where the part being formed is fragile, small, or otherwise more conducive to the radial forming process
Please contact Orbitform so we can help you choose the proper peen and orbital head combination for your forming, flaring, or assembly project.

Filed Under

GL-730

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

GL-610

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

GL-320

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

GS-720

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

GS-520

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

GS-330

Gold series orbital heads are an available upgrade with certain Orbitform orbital forming, orbital fastening and orbital riveting machines. The gold series orbital heads from Orbitform are designed for orbital riveting and orbital forming hardened materials that would cause standard orbital forming heads to wear out quickly. The gold series orbital heads provide a greater thrust capacity in comparison to the standard orbital heads due to the robust design and upgraded bearings. The heavy duty design allows the gold series orbital heads to last longer when riveting under challenging material conditions and when your assembly process presents a difficult forming, fastening, or riveting application. The gold series is available with the standard 6 degree peen or the extended reach 4 degree peen tool.

Filed Under

HS-1000-6

Orbitform Orbital Heads Last

Through proper care and maintenance, it is possible to keep your orbital head running as smoothly as the day your purchased it and with Orbitform's lubed-for-life orbital heads you know the performance will stay optimal for years.

Orbitform Peen Tools Fasten Your Assemblies

Orbital heads come with a peen tool. The peen is the tool that actually contacts the rivet being upset or the post being formed. There are a wide variety of standard peens used with Orbitfom orbital heads to help enhance your assembly process. Orbitform peen tools are designed for the specific purpose your forming or assembly application requires. Some peens ensure a certain aesthetic appearance while others flare or crimp the work piece involved. Orbitform offers many peen configurations including: conical form peen, flat form peen, captured form peen, crown form peen, flare form peen, eyelet form peen, ring stake form peen, and crimping form peen.

Orbitform Orbital Head Options

  • Standard orbital heads with 6 degree peen angle for minimum required forming force
  • Long reach orbital heads with 3 degree to 6 degree peen angles for difficult to reach rivets or posts
  • Gold series orbital heads with upgraded, heavy duty sealed bearings when you are forming harder materials
  • C-Frame orbital heads for difficult to reach rivets where an overhang or other obstruction prevents a standard, straight down riveting process
  • Multi-point orbital heads for forming several rivets at once with a custom orbital head equipped with several peens
  • Multi-spindle orbital heads for forming several rivets at once with a custom orbital head equipped with several spindles, each spindle with a peen
  • Radial riveting heads for certain applications where the part being formed is fragile, small, or otherwise more conducive to the radial forming process
Please contact Orbitform so we can help you choose the proper peen and orbital head combination for your forming, flaring, or assembly project.

Filed Under