Bespoke Manually Operated Forming Tool
Customer Requirement
A customer approached us to provide a quotation for a Bespoke Manually Operated Forming Tool for aligning the cut ends of End Rings prior to the welding process.
The existing method relied on operators manually striking the rings against an anvil to bring the ends into alignment. This process presented a number of challenges, including potential health and safety risks to operators, inconsistency in alignment, and the possibility of damaging the product during handling. In addition, the rings exhibited a variety of overlap conditions that needed to be corrected before welding could take place, requiring a more controlled and repeatable solution.
Project Challenge
The key challenge was to develop a robust and reliable alignment system capable of accommodating multiple ring diameters, varying overlap conditions, and different ring thicknesses, while remaining easy to operate in a demanding production environment.
The solution needed to eliminate the requirement for impact-based alignment methods, improve operator safety, minimise the risk of product damage, and provide repeatable alignment results to support downstream welding operations.
CSD’s Bespoke Solution
CSD designed, manufactured, and commissioned a Bespoke Manually Operated Forming Tool.
Built for durability and long-term performance, the jig features a heavy-duty construction mounted on a fabricated steel support frame securely bolted to the factory floor. At the centre of the system is an aluminium tooling base plate that supports both the expansion and control mechanisms.
The expansion mechanism is designed to increase the ring diameter, allowing the ring ends to be positioned and controlled during the alignment process. To accommodate a range of ring diameters, the mechanism incorporates multiple manually adjustable and clearly labelled set points, enabling operators to quickly configure the jig for different production batches. Operation is achieved via a manual lever handle, while hardened steel rollers are used at all product contact points to ensure durability and minimise wear.
A dedicated control mechanism is integrated into the jig to accurately align the ring ends. The system includes two selectable set points to accommodate different ring thicknesses. Once the ring has been expanded, operators use manually operated lever handles to control and align the ring ends across multiple planes as the expansion mechanism is gradually released.
The completed solution provides a safe, repeatable, and efficient method of aligning End Rings, significantly reducing manual intervention while improving process consistency and product quality ahead of welding operations.
If you would like to find out how CSD can improve your manufacturing process please contact us.