A new joining process was developed by the company to complement its orbital forming product line. Rollerforming uses multiple rollers mounted on a rotating spindle to gently smooth and form material into a seamless, solid form. The rollers intersect the workpiece on a precise contact line, gradually moving material to the desired shape. The process is capable of forming parts with large diameters and thin-wall materials, which may be difficult to do with other fastening methods. The process is also advantageous when used to roll or close a lip. In addition, the process can be applied to applications where the rollers articulate as well as rotate, permitting access into grooves and other areas. The fastening process replaces typical crimp tooling, which can be problematic in part appearance and in process control reliability. Forming a curl or lip with the new process often takes less than 20% of the force normally required for straight crimping or pressing. The process can crimp and seal using multiple rollerheads, and can cold form with very precise control. It can create a finished look on assembled parts while forming inside and outside diameters simultaneously.
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