A company which makes solenoids for the electrical industry faced a difficult problem when they needed to assemble a device which is composed of an outer steel shell that has to be assembled over a delicate and brittle powder-metal inner core.
The steel outer case was designed with cut-out tabs around its upper rim and, during assembly, these tabs must be crimped over the inner core to enclose it safely and securely inside the casing.
The solenoid manufacturer had originally intended to use a press to assemble these components but this plan hit a snag.
Bending the steel tabs over the inner core requires considerable pressure but, unfortunately, the cut-outs between the tabs weaken the structure of the casing.
It quickly became apparent that the amount of downward pressure, that was needed to complete the task, was both distorting the casings and also fracturing the fragile inner cores of the solenoids.
Orbital Forming seemed to offer a possible alternative way to assemble these components so the solenoid manufacturer consulted Taumel.
Taumel's Orbital Forming has the advantage that it can accomplish tasks using much less forming pressure than a conventional press.
For this customer, Taumel designed a special orbital forming tool, with a recessed end sized to fit the solenoid's casing. This tool closes the tabs smoothly and safely over the solenoid's core without deformation.
Further advantages of Taumel's Orbital Forming tools include reduced tool abrasion (because they require less forming force) and the very pleasing discovery that their machines work noiselessly too.
Close-up of the special orbital forming tool, with a recessed end sized to fit the solenoid's casing. This tool closes the tabs smoothly and safely over the solenoid's core without deformation.