Originally Published MPMN May 2006

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Roller Forming Puts New Spin on Fastening Materials

Corinne Litchfield

A metal-forming and -joining process has been added to a company’s orbital forming capabilities. The roller forming process developed by Orbitform (Jackson, MI) uses multiple rollers mounted on a rotating spindle. The rollers gently smooth and fold material into a seamless and solid form. By intersecting the workpiece on a precise contact line, the rollers gradually move material to the desired shape.

The process can be used in place of other fastening methods. It is suitable for forming large-diameter and thin-wall materials, as well as rolling or closing a lip. It can also be applied in situations where the rollers articulate as well as rotate, allowing for access into grooves and other areas.

Crimping and pressing can be simplified using the roller forming process. Forming a curl or lip with the technique can take less than 20% of the force normally required for straight crimping or pressing. It also allows for precisely controlled cold forming and simultaneous formation of inside and outside diameters.

Roller forming can be used in work cells and automated assembly operations. The system is strong enough to use with metal and aluminum

parts and versatile enough for appearance-sensitive plastic parts. Medical applications include joints on surgical instruments, circuit boards, and casters.

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