What are the two main types of roller forming?
Orbitform offers Static and Articulating Roller Forming, each designed for specific application needs based on part geometry and material characteristics.
Does a part need to be round to be roller formed?
No, roller forming can accommodate oval shapes, provided the roller width ensures contact with the area to be formed.
Does a part need to be a complete 360-degree circle for forming?
No, roller forming can work on parts with interruptions, such as notches or other features, allowing for flexibility in part design.
How does the forming force of static roller forming compare to press crimping?
Roller forming uses at least 80% less force than press crimping, depending on material properties and finished geometry, as multiple rollers distribute force efficiently.
What pressure pad options are available for roller forming heads?
We offer mechanical spring-loaded and thru-spindle pressure pad options, each suited for different forming needs.
What is the purpose of a thru-spindle pressure pad?
The thru-spindle pressure pad applies a clamp or preload to the assembly before and during forming, ensuring consistent contact and reliable results.
What feature supports the thru-spindle pressure pad in the powerhead?
An offset motor drive is necessary to create clearance for the thru-spindle pressure pad, enabling optimal function.
What is the largest rod diameter for use with a thru-spindle pressure pad?
The maximum rod diameter for this assembly is 5/8”, based on spindle clearance.
What is the standard rotation speed for roller forming heads?
Typical rotation speed ranges from 300 to 600 RPM, adjusted based on material type, hardness, and part geometry.
What can a roller head be mounted to?
Roller heads are typically mounted to pneumatic, servo, or hydraulic powerheads, and occasionally to CNC machines, drill presses, or lathes.
What equipment options does Orbitform offer for roller forming?
Options include load cells, LVDTs, and pressure pads for enhanced control and monitoring during forming.
Can force and distance be monitored in articulating roller forming?
Yes, we use an internal draw-bar actuating cylinder package in the powerhead to track force and distance.
What is the direction of force application in static roller forming?
Static roller forming applies force downward, or “axially,” on the part.
What direction does the force apply in articulating roller forming?
In articulating roller forming, force is applied radially, or inward, to form the part.
How many mounting positions are available for a static roller form head?
Static roller form heads can be mounted in three positions: vertical top-down, vertical bottom-up, and horizontal.
How many rollers are used in a static roller head?
Static roller heads can have 2 to 6 rollers, with 3 being the most common for standard applications.
Can articulating roller heads be used in static applications?
Yes, articulating roller heads can be used in servo applications for parts with features that limit access, like slipper valves.
