Installing Bushings Using the Flanging Method
Plain Bearing Bushes Are Set by Flaring and Flattening
The flaring and flattening process, also known as flanging, is the forming of tubular fasteners, such as plain bearing bushings, to create a circumferential reinforcement or contour. Flanging provides centering, passages through cavities, channels and bearings.
Bushings are widely used in automotive, industrial, and household appliance manufacturing. In these industrial sectors, the process is often automated in order to increase the speed and efficiency of production and to ensure consistent quality.
How Does the Flaring and Flattening Process Work?
Pre-Flanging (Flaring)
The bushing is inserted into a pre-punched hole in the sheet, usually from the bottom. A pre-flanging module folds the protruding edge of the bushing at a 45-degree angle. This creates a circumferential reinforcement. Automatic tolerance compensation ensures that variations in sheet metal thickness or bushing wall thickness do not affect quality.
Flanging (Flattening) and Calibration
The next step is to bend the protrusion of the fastener parallel to the component surface. To do this, the flanging tool presses the flared part of the bushing fully against the sheet metal, flattening it to 90 degrees. At the same time, the inner diameter of the bush is calibrated to ensure it meets the required specification. The tool also compensates for any positional tolerances in the sheet metal.
Presence Detection
An optional presence detection system checks that the bushing is correctly installed. A test mandrel presses against the bushing. It triggers a proximity switch to confirm the installation of the bushing. If the bushing is missing, the system detects the problem and can prevent further assembly errors.
Challenges in the Flanging Process
Controlled Forming
The required contours and reinforcements can be achieved with maximum precision using a special flanging tool. The precise shape ensures that the bearing bush is stable and secure in the component.
Fit Accuracy
It is also important to achieve an accurate fit between the bushing and the component. This fit accuracy is critical to the operation of the bearing, as it allows for even load distribution.
Minimizing Tolerances
By minimizing unwanted tolerances, the performance of the bearing bush is increased. A low tolerance ensures smooth motion of the bearing and contributes to a longer service life.
Material Selection
Different bushing materials place different demands on the flanging process. Extensive material analysis and pre-production testing can help identify the optimum material for bushes.
Advantages of Automated Bushing Installation
Consistent flanging results: Automated systems ensure that each bushing is flanged to the highest precision, eliminating the variability associated with manual processes.
Improved dimensional control: Automatic calibration compensates for positional and material tolerances to ensure bushings perform as specified.
Presence control systems ensure that all bushings are correctly installed, preventing faulty components from reaching the end product.
Automated assembly ensures repeatable quality for high-volume production and increases the reliability of the production process.
Automated assembly lines are significantly faster, increasing overall production and efficiency. Downtime is reduced and the throughput in high-volume production is increased.
Employees are exposed to less machine-related stress, which increases workplace safety.
Case Study
Automated In-Die Assembly of Bushings
The goal of this project was to automate the assembly of a 0.5mm wall plain bearing bushing and a special rivet fastener in a progressive die. A key requirement was to accurately flange the bushing and calibrate its inside diameter during the in-die process.
Optimization Through In-Die Assembly
The original plan was to assemble these components outside the press in separate production steps. However, we were able to eliminate the need for separate steps and use our in-die automation modules to assemble both fasteners directly under the press.
Reducing the additional processing steps provided several benefits:
- Significant cost savings through streamlined production
- Increased efficiency and precision in fastener assembly
The result was a fully automated solution that optimized the manufacturing process for our customer. By leveraging our expertise in complex in-die assembly situations, we were the only supplier capable of successfully implementing this kind of project.
Request for Quotation
Would you like us to call you back? Leave your telephone number or e-mail, and we will get back to you as soon as possible!
