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All Parts Filed Under Radial Riveting

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

R-750

Orbitform’s modular R-750 radial riveting bench machine is manufactured and assembled at Orbitform’s factory in Jackson, Michigan, USA. The radial riveting bench machine is available with many standard features and the radial forming bench machine can be customized with options to help monitor, control, and improve the assembly process. Orbitform’s application engineers listen and seek the appropriate answer for each specific assembly process being considered. Orbitform can design and build a complete turnkey assembly system including controls, safety, fixtures, errorproofing, and more.

Standard Features and Specifications for Radial Riveting or Radial Forming Applications:

Touch Screen monitor on Orbitform Equipment
  • Powerhead with electric motor and radial head with peen developed and tested for each application
  • Column and base assembly with 5" (127 mm) vertical powerhead height adjustment and t-slot base. These features allow for flexibility in machine setup and fixturing. A standard bench machine can easily be configured to an assortment of different assembly applications.
  • HMI touch panel for enhanced diagnostics
  • Directional valve with dual pilot operated (PO) check to prevent powerhead drifting
  • Dual low actuation force palm buttons for cycling the machine
  • Pneumatic solenoid valves to assist with smooth and exact fluid motion
  • Filter-regulator unit with gauge to keep the air supply clean and protect the machine’s components
  • Digital adjustable dwell timer
  • Resettable cycle counter to keep track of machine cycles
  • Electrical enclosure with disconnect switch
  • Illuminated power on selector switch
  • Programmable Logic Controller

Bench Machine Options:

Electrical Options

  • Light curtains for operator safety
  • PLC expansion for an additional I/O
  • Low-profile LED worklight to enhance the lighting of the work area
  • Home limit switch to acknowledge when the tool is fully retracted

Mechanical Options

  • Precision machine base 24"W x 24"L x 30"H (610 mm W x 610 mm L x 760 mm H)
  • Precision machine base with casters
  • Guarding for operator safety
  • Air line lubricator
  • Custom part fixturing designed and built by Orbitform allowing a turnkey riveting solution
  • Pneumatic fixture slide to allow for simpler part loading
  • Offset motor mount to allow for a shorter machine height and/or to allow for a through spindle pressure pad
  • Gear reducer to reduce the RPM to allow for the optimal forming speed
  • Spindle brake to control the tool position or to stop the tool rotation for certain applications
  • Radial alignment kit to help you set up the machine if the machine configurations change

Error Proofing, Process Monitoring, Process Control Options

  • Process Intelligence Package: Load Cell, LVDT (Linear Variable Displacement Transducer), Touch Screen
  • Pressure pad (standard, height sensing, or programmable height sensing) to secure the work piece prior to forming or assembly, to assist with assembly process monitoring / process control, or to confirm part presence prior to continuing the assembly process

Filed Under

RL-750

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

RS-750

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

MR-750

Orbitform’s modular MR-750 powerhead is assembled with top line components and is manufactured and assembled at Orbitform’s factory in Jackson, Michigan, USA. The orbital riveting powerhead comes with many standard features and the orbital powerhead can be customized with several options to help monitor, control, and improve the orbital forming application being developed. Orbitform’s application engineers will listen and ask relevant questions in order to best specify the appropriate options to improve the assembly system being analyzed.

Extended stroke requirements?

Applications with similar orbital riveting or orbital forming force but requiring extended vertical clearance for part loading may benefit from the extended stroke Orbitform powerhead model M-753.
  • The M-753 Orbitform powerhead has a total tool stroke distance of 3.0 in (76 mm) that is adjustable between 0 in to 3.0 in (0 mm to 76 mm).

Standard Features and Specifications for Orbital Riveting or Orbital Forming Applications:

  • Electric motor with pre-wired 4-pin and 5-pin "mini-change" male connector (alternate voltage specifications available upon request)
  • Orbital head
  • Peen developed and tested for each application
  • Home switch to acknowledge when the tool is fully retracted
  • Limit switch to acknowledge when the tool is extended to the desired position
  • Deceleration switch
  • Orbitform powerheads are “lubed-for-life” with lifetime bearing and seal lubrication which allows for reduced lifetime maintenance expense and increased orbital forming equipment uptime. (The forming heads of Orbitform’s competition require diligent preventive maintenance in order to stay in operation for more than a few months.)
  • Stroke adjustment knob on top of the powerhead with indicator mounted on the side of the powerhead to help you establish the stroke distance of the machine

Powerhead Options:

Electrical Options

  • 12 ft. motor cable with 4-pin "mini change" 90 degree female connector to allow you to quickly and easily connect the motor to your power supply control panel
  • 12 ft. limit switch cable with 5-pin “mini change” to allow you to quickly and easily connect the limit switch to your control panel

Mechanical Options

  • Offset motor mount to allow for a shorter machine height and/or to allow for a through spindle pressure pad
  • Gear reducer to reduce the RPM to allow for the optimal forming speed
  • Spindle brake to control the tool position or to stop the tool rotation for certain applications
  • Anti-rotate device to prevent the peen from rotating during certain assembly or forming applications
  • Powerhead mounting plate with ± 1 inch (25.4 mm) adjustment to allow for simpler, front flange mount integration of the Orbitform powerhead into your assembly system
  • Orbital alignment kit to help you set up the machine if the machine configurations change
  • Standard bench machine column (bench machine base is also available) to support the powerhead. The bench machine column and base can be combined to provide a complete ready to use machine.
  • Standard pedestal machine column and base assembly
  • Fabricated straight column to be engineered specifically for your automated assembly application
  • Fabricated c-frame column to be engineered specifically for your automated assembly application

Error Proofing, Process Monitoring, Process Control Options

  • Pressure pad (standard, height sensing, or programmable height sensing) to secure the work piece prior to forming or assembly, to assist with assembly process monitoring / process control, or to confirm part presence prior to continuing the assembly process
  • Loadcell force monitoring to assist with assembly process monitoring / process control / error proofing
  • LVDT (Linear Variable Displacement Transducer) for stroke position monitoring. The LVDT is externally mounted.

Forming options

  • Radial head for radial riveting or radial forming assembly applications when the radial forming process is preferred
  • Multi-point or Multi-spindle head for orbital riveting or orbital forming of multiple rivets at the same time
  • Static rollerhead for roller forming or roller assembly applications
  • Articulating rollerhead for roller forming or roller assembly
  • Press head powerhead configuration and press tooling to allow the powerhead to act as a press for pressing parts together into any assembly

Filed Under

RL-500

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

RL-310

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

RL-240

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

RL-125

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under

RS-500

Orbitform Radial Heads Last

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

Orbitform Peen Tools Fasten Your Assemblies

Radial 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 radial 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 Radial Head Options

  • Standard radial heads with 5 degree peen angle for minimum required forming force
  • Long reach radial heads with 3 degree to 5 degree peen angles for difficult to reach rivets or posts

Filed Under