Working Procedure of Orbital Forming

1. Preparation of Components

• All components are cleaned to remove oil, rust, and contaminants.
• The correct workpiece and tooling are selected based on required geometry.

2. Workpiece Positioning and Clamping

• The part is placed accurately in the fixture.
• Proper clamping is applied to ensure stability during the forming cycle.

3. Tool Head Alignment

• The orbital forming head is set at a small tilt angle (typically 3°–6°).
• This angular setting enables progressive, localized deformation instead of direct vertical pressing.

4. Initiation of Forming Cycle

• The forming head begins rotating while gradually descending onto the workpiece.
• Contact occurs in a small, continuously moving zone, minimizing stress concentration.

5. Progressive Metal Flow

• As the tool orbits around the axis, controlled radial and axial deformation occurs.
• The material flows smoothly into the required shape—such as a rivet head, flange, or collar—without excessive force or heat generation.

6. Monitoring and Control

• Forming continues until predetermined parameters such as height, diameter, and shape are achieved.
• Stroke control or force sensors are often used to ensure accuracy and repeatability.

7. Cycle Completion and Part Removal

• Once the forming operation is complete, the tool retracts.
• Clamping is released, and the finished component is removed for inspection.

Outcome

Orbital forming results in a precise, smooth, and defect-free formed head or flange with:

• Low forming forces
• Excellent dimensional control
• High repeatability