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Three-Dimensional Tube Forming Processes with a New Hydraulic Bending

Machine Using Parallel Kinematics

Article  in  TRANSACTIONS OF THE JAPAN FLUID POWER SYSTEM SOCIETY · January 2010

DOI: 10.5739/jfps.41.74

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 3D Tube Forming and Applications of a New Bending
Machine with Hydraulic Parallel Kinematics

Technical Paper:

3D Tube Forming and Applications of a New Bending

Machine with Hydraulic Parallel Kinematics
Hiroyuki Goto∗ , Yutaka Tanaka∗∗ , and Ken Ichiryu∗∗∗
∗
Technical Research Institute, Japan Society for the Promotion of Machine Industry
1-1-12 Hachiman-cho, Higashikurume-shi, Tokyo 203-0042, Japan
E-mail: goto@tri.jspmi.or.jp
∗∗ Faculty of Engineering & Design, Hosei University

2-17-1 Fujimi, Chiyoda-ku, Tokyo 102-8160, Japan

∗∗∗ Kikuchi Seisakusho Co., Ltd.

2161 Miyama-cho, Hachioji-shi, Tokyo 192-0152, Japan

[Received February 2, 2012; accepted April 23, 2012]

This research presents a new versatile bending ma-
chine and its practical applications. The proposed ma-
chine uses a new method. When tubes are fed into the
fixed and mobile dies, they are bent by shifting the rel-
ative position of the mobile die. The bending radius
is controlled by the relative distance and orientation
between the mobile die and the tube. The bending an-
gle is controlled by the length of the fed tube. This
forming process has a big advantage. A change in
the expected bending shape will need no change in the
tooling system but only a new definition of the motion
of the active die and the length of the fed tube. Ac-
tive die movements are controlled by a 6-DOF Parallel
Kinematics Mechanism (PKM) with a hydraulic servo
drive. Making use of the hydraulic PKM serves not
only to achieve a complete motion along six axes but
also to obtain the high dynamic motion of the bending
machine. Application examples show that the bend-
ing machine can be applied to a designer’s furniture
and universal designed products. Until now, these pro-
cesses have been difficult to achieve using a conven-
tional bending machine.
Keywords: parallel kinematics, hexapod, hydraulic
servo, tube bending
piece is fixed on the bending form by a clamping die. As
the bending die rotates, it draws the work-piece against
the pressure die. The pressure die may remain fixed or
move with the work-piece to eliminate the friction of slid-
ing contact. These machines handle about 95% of tube
bending operations [1]. The press bending method uses
simple tooling and is quick and easy to set up. The major
advantage of press bending is its high production capa-
bility but it has less accuracy than the rotary-draw bend-
ing. Roll benders use the basic principal of force applied
among three rotating rollers. Three forming rollers of
approximately the same diameter are used. They are ar-
ranged in a pyramid in either vertical or horizontal planes.
Execution of bends on a roll bender, just as is the case with
most other benders, requires a skilled operator to run the
machine.
In addition to these conventional techniques, a new
flexible CNC bending machine that is based on the MOS
bending method [2] has been developed. MOS bending
is a versatile and flexible method for a free-form circu-
lar tube. This method cannot, however, bend a square or
rectangular tube. Hydroforming of space frame compo-
nents has an increasing need for three-dimensional free-
form bending profiles of non-circular tubes.
This paper presents a new flexible bending machine for
non-circular tubes and profiles that are difficult to bend
using conventional bending machines.

1. Introduction
Bent tube products are employed in manufacturing
many kinds of products such as fluid arrangements, fur-
niture, transport apparatus, and mechanical parts, as re-
quired for the reduction of production cost and weight.
(a) Rotary-draw bending, (b) Press bending, and
(c) Roll-bending, have been commonly used for basic
bending methods of tubes [1]. Rotary-draw bending is the
most standard method used on rotary-type bending ma-
chines, which can be powered, manual, or numerically
controlled. Rotary-draw bending consists of the rotating
bending form, clamping die, and pressure die. The work-
2. Basic Concept
The applied basic concept is shown in Fig. 1 and Ta-
ble 1 [3]. The relative distance between the center line of
the fixed die and the center of the mobile die is called off-
set u. A tubular work-piece is pushed from the fixed die
into the mobile die by pushing load Fp , and then it is bent
as shown in Fig. 1. For this machine, distance V between
the exit of the fixed die and the center of the mobile die is
changed. Near the mobile die, the tube is pushed by the
mobile die as shown by arrow F in Fig. 1. Work load F
depends on the magnitude of offset u. At this time, bend-

Int. J. of Automation Technology Vol.6 No.4, 2012 509

Goto, H., Tanaka, Y., and Ichiryu, K.

Fig. 1. Basic bending method.

Table 1. Bending parameters of tubes.

R Bend radius[mm]
u Offset[mm]
V Distance between dies[mm]
θ Angle of die[deg]
F Work load[kN]
Fp Pushing load[kN]
Lp Feed length[mm]

ing moment M = F cos θ · V + Fp · u operates on the tube

that is bent. Bending radius R is controlled by relative dis-
tance u between the mobile die and the tube. The bending
angle is controlled by length L p of the fed tube.
This forming process has a big advantage. A change Fig. 2. Schematic of bending machine.
in the expected bending shape will need no change in the
tooling system but only a new definition of the motion of Table 2. Specifications of bending machine.
the active die and synchronization of the pusher.
Bending tube with
10–60 [mm]
diameter: D
3. Machine Structure and Design Length of parts: L up to 2300 [mm]
Bending radii: R/D 3–∞ [ - ]
Figure 2 shows a schematic of the proposed bending Pushing force: Fp 150 [kN]
machine [3]. Table 2 summarizes specifications of the Pusher feed speed 0–0.1 [m/s]
bending machine. This machine consists of a mobile die Off set: u 0–100 [mm]
with a 6-DOF Parallel Kinematics Mechanism (PKM), a Angle of die: θ 0–25 [deg]
fixed die, a pusher and a mandrel.

3.1. Mobile Die and 6-DOF Hydraulic PKM
Active die movements are controlled by a 6-DOF hy-
draulic Parallel Kinematics Mechanism (PKM). Making
use of the hydraulic PKM serves not only to achieve com-
plete motion along six axes but also to obtain high dy-
namic motion of the bending machine.
3.2. Fixed Die
The mounting carries the rigid fixed die and must ab-
sorb the press force in conjunction with frame compo-
nents.
3.3. Pusher
The feed or pusher module creates the controlled feed
motion of the work-piece in the bending zone to generate
bending geometry. Feed motion is defined as a function
of the corresponding forming procedure. The pusher is
driven by a hydraulic servo motor. Rotary motion is trans-
formed into a translation motion upon a ball screw. Within
this module, feed forces of up to 150 kN and positioning
accuracy of ±0.1 mm are achieved in this machine. In the
prototype bending machine, profiles of up to a length of
2300 mm are formed. In order to avoid buckling, the pro-
file runs through a conduit that completely encapsulates
it. This conduit depends on the profile’s cross-section and
must be changed for another profile cross-section. The
conduit is split into left and right boxes in conjunction
with an automatic profile feed module. The conduit is
opened manually.
3.4. Mandrel
The mandrel is a tool inserted in tube or pipe near the
bend tangent. This tool is used not only to diminish buck-

510 Int. J. of Automation Technology Vol.6 No.4, 2012


Fig. 3. Inverse kinematics of Stewart-Gough platform.
ling, but also to reduce wall thickness alterations, distor-
tion and torsion of the cross-section. On the proposed ma-
chine, the mandrel is attached to a rod anchored at the rear
of the machine. The rod incorporates a lateral and longi-
1/2
tudinal adjustment capability to position the mandrel in
relation to the bend radius and at the point of the bend.
4. Kinematic Modeling
Figure 3 is a vector diagram of the 6-DOF hydraulic
PKM. This PKM is known as a Stewart-Gough platform
or hexapod [4, 5]. Six identical limbs connect the moving
platform to the fixed based by spherical joints Bi and Ai ,
i = 1, 2, . . ., 6, respectively. Each limb consists of an up-
per member and a lower member connected by a prismatic
joint such as a hydraulic cylinder. Hydraulic cylinders
are used to vary the lengths of prismatic joints and there-
fore to control the location of the moving platform. For
the purpose of analysis, two Cartesian coordinate systems,
and frames A(x, y, z) and B(i, j, k), as shown in Fig. 3, are
attached to the fixed based and moving platform, respec-
tively. Transfer from the moving platform to the fixed
base is described by position vector P of centered P and
trotation matrixA RB of the moving platform. Let I , j and
k be three unit vectors defined along the i, j and k axes of
the moving coordinate system; the rotation matrix is then
written as:
⎡ ⎤
ix jx kx
A
RB = ⎣ iy jy ky ⎦ . . . . . . . . (1)
iz jz kz
Elements of A RB must satisfy the following orthogonal
conditions:
i2x + i2y + i2z = 1 . . . . . . . . . . . . (2)
jx2 + jy2 + jz2 = 1 . . . . . . . . . . . (3)
kx2 + ky2 + kz2 = 1 . . . . . . . . . . . (4)
ix jx + iy jy + iz jz = 0 . . . . . . . . . . (5)
ix kx + iy ky + iz kz = 0 . . . . . . . . . (6)
Int. J. of Automation Technology Vol.6 No.4, 2012
3D Tube Forming and Applications of a New Bending
Machine with Hydraulic Parallel Kinematics
jx kx + jy ky + jz kz = 0 . . . . . . . . . (7)
As shown in Fig. 3, let ai = [axi , ayi , azi ]T and B bi =
[bxi , byi , bzi ]T be position vectors of points Ai and Bi , re-
spectively. We write the vector-loop equation for the ith
limb of the platform as follows:
Ai Bi = p + A RB B bi − ai . . . . . . . . (8)
The length of the ith limb is obtained by taking the dot
product of the vector Ai Bi with itself:
 T  
di2 = p + A RB B bi − ai p + A RB B bi − ai (9)
 T  
di2 = pT p + B bi B bi + aTi ai
   T
+2pT A RB B bi − 2pT ai − 2 A RB B bi ai (10)
where di denotes the length of the ith limb. Taking the
square root of Eq. (10). we obtain:
   T  
di = Ai Bi  = pT p + B bi B bi + aTi ai
A   T
+ 2pT RB B b i − 2 p T a i − 2 A RB B b i a i
. . . . . . . . . . . . . . . . . . (11)
for i = 1, 2, . . ., 6. Hence, corresponding to each given
location of the moving platform, there are generally two
possible solutions for each limb. A negative limb length
is physically not feasible, however. When the solution of
di becomes a complex number, the location of the moving
platform is not reachable.
5. Control System
Figure 4 shows a schematic of the control system. The
PKM with 6-DOF using six electro hydraulic servo cylin-
ders has high rigidity and support. This feature is widely
used for a driving device with multiple degrees of freedom
that has a heavy load and needs a large drive force. These
hydraulic PKMs focusing on major acceleration forces are
flight simulators, which require a high degree of dynam-
ics in their guidance behavior. For the hydraulic PKM in
the bending machine, however, the focus is on high posi-
tioning accuracy and load rigidity.
PKMs require a sophisticated CNC and number of ad-
ditional software functions. The open system architecture
of numeric control with a Microsoft Windows-based PC
enables the NC kernel to adapt to the inverse kinematics
calculations of the PKM. Conventionally, kinematics cal-
culations were implemented offline on an external PC by
means of a so-called postprocessor. If transfer is imple-
mented online in the system, however, the user benefits
from the following advantages ;
(1) The machine can be programmed in the coordi-
nate system of the work-piece, independently of the
PKM.
(2) No special post-processor is required.
511
Goto, H., Tanaka, Y., and Ichiryu, K.

Fig. 5. Results of square tube bending (aluminum).

Fig. 4. Schematic of hydraulic control system.

(3) Existing NC programming (G-code) can be used

(4) Interpolation is available.

(5) Programming input and positions are displayed in

conventional Cartesian coordinates.

In the proposed machine, the computing power of the

Microsoft Windows-based PC is sufficient to implement Fig. 6. Results of circular tube bending (aluminum).
even complex mathematical algorithms in real time.

6. Experiments

6.1. Basic Bending

In order to evaluate the performance of the proposed
bending machine, basic bending was performed. Fig. 5,
Fig. 6 and Fig. 7 show an overview of basic bending.
Bending radius R of the tube is decided by the magnitude
of offset u. The relationship between offset u and bending
curvature 1/R is shown in Fig. 8 as a parameter of mate-
Fig. 7. Results of circular tube bending (steel).
rial shape. Relationships are obtained from bending ex-
periments. Flexural rigidity, Young’s modulus and other
material properties vary with changes in materials and di-
mensions of tubes. Bending radius R therefore fluctuates
even though offset u does not change, but this bending
machine bends the tubular work-piece into a certain bend-
ing radius by adopting a suitable relationship of u and R
for the tube, even though tubular material or dimensions
change.

6.2. Helix Bending

An application in bending of a square tube with a spiral
shape is given to demonstrate the feasibility of the pro-
posed machine. From Frenet-Serret’s formula, the defini- Fig. 8. Relationships between u and 1/R.
tion of Fig. 9 and Table 3, radius r and pitch p in the helix
are denoted by:
κ where κ is the curvature of the helix, and τ is the tor-
r= 2 . . . . . . . . . . . . . (12) sion of the helix. Substituting the parameter in Fig. 1 into
τ + κ2
  Eqs. (12) and (13), we obtain:
1 2u
p = 2π r −1 . . . . . . . . . (13) κ= . . . . . . . . . . . . (14)
κ V 2 + u2

512 Int. J. of Automation Technology Vol.6 No.4, 2012

 3D Tube Forming and Applications of a New Bending
Machine with Hydraulic Parallel Kinematics

Fig. 9. Definition of helix.

Table 3. Definition of helix parameters.

κ Curvature[ - ]
τ Torsion[ - ]
p Pitch[mm]
r Radius[mm]
l length[mm]
β Angle of helix[rad]
Fig. 10. Experimental results of helix bending.
θz
τ= . . . . . . . . . . . . . . . (15)
V
 π π
θ  = sin−1 (κ ·V ) − ≤ θ  ≤ . . . (16)
2 2
where V is the distance between dies, θ  is the orienta-
tion of the mobile die and θz is the torsion angle of the
mobile die. From these relationships, the bending ma-
chine can bend a square tube with a spiral shape. Figs. 10
and 11 show the results of helix bending with a square
aluminum tube. Experimental results and theoretical cal-
culations are in reasonable agreement. Experiments show
that the bending machine can be applied to square pipes
with a spiral shape.

7. Practical Applications
7.1. Universal Design
The human body has very complex threedimensional
shapes. Medical equipment parts, such as handrails
should therefore be made to fit such body shapes. When Fig. 11. Simulation of helix bending.
a handrail is made using a conventional bending machine,
the bending process is very difficult and many days are
needed for preparing dies. If the new bending machine
is used, a complexly shaped handrail is easily produced
after a little trial bending. Fig. 12 shows typical experi-
mental results of 3D bending. Experimental results show
that the bending machine can be applied to many kinds of
products such as furniture, universal-designed products,
and automotive parts. Until now these manufacturing pro-
cesses have been difficult to achieve using a conventional
bending machine.

7.2. Novel Interior Goods and Furniture Fig. 12. Handrails of medical equipment.

The new bending machine has no limit on designer re-

quests about shapes compared to the conventional bend-

Int. J. of Automation Technology Vol.6 No.4, 2012 513

Goto, H., Tanaka, Y., and Ichiryu, K.

Fig. 13. “STROKE vase.”

Fig. 16. Novel pipe sofa.

The geometrical relationship between the moving plat-

form and the length of six limbs of the PKM has been
formulated. The electro hydraulic servo control system
for the bending machine has also been proposed. The hy-
draulic PKM has focused on high positioning accuracy
and high load rigidity. Experimental results show that
Fig. 14. Vase production.
the bending machine can be applied to designer’s inte-
rior goods, universal-design products and novel furniture.
Up to now, this production process has been difficult to
achieve using a conventional bending machine.

Acknowledgements
We thanks Messrs. Takeyoshi Iguchi, Hidenobu Saito and Yuu
Ishikura of Kikuchi Seisakusho Co.,Ltd., for their assistance in
experiments. This work was supported in part by JKA through its
promotion funds from “Japan Keirin Race (Biycle Racing),” and
by NEDO promotion funds.

References:
Fig. 15. “STROKE vase.”
ing machine. Designers can therefore display their ability
to create new design concepts more easily with the ma-
chine we have developed. Figs. 13, 14, and 15 show de-
signers’ image sketches and a vase product as an example.
Fig. 16 shows a novel pipe sofa.
[1] G. Miller, “Tube Forming Processes: A Comprehensive Guide,”
Soc. Manuf. Eng., Michigan, pp. 69-150, 2003.
[2] M. Murata, “Effects of Die and Material of Circular Tube in MOS
Bending Method,” Trans. of Japan Soc. Mech. Eng. Series C,
Vol.62, No.601 pp. 292-297,1996. (in Japanese)
[3] H. Goto, K. Ichiryu, and Y. Tanaka, “Three-Dimensional Tube
Forming Processes with a New Hydraulic Bending Machine Us-
ing Parallel Kinematics,” Trans. of The Japan Fluid Power System
Society, Vol.41, pp. 74-79, 2010. (in Japanese)
[4] D. Stewart, “A platform with six degrees of freedom,” Proc. Inst.
Mech.Eng., Vol.180, Part 1, No.15, pp. 371-386, 1965.
[5] L.-W. Tasai, “Robot Analysis: The Mechanics of Serial and Parallel
Manipulators,” John Wiley & Sons Inc. New York, pp. 153-154,
1999.

8. Conclusions
In this paper, a new flexible bending machine for tubes
and profiles that are difficult to bend using a conventional
bending machine has been proposed. This system has uti-
lized a 6-DOF hydraulic PKM as a controlling mobile die.

514 Int. J. of Automation Technology Vol.6 No.4, 2012

 3D Tube Forming and Applications of a New Bending
Machine with Hydraulic Parallel Kinematics

Name: Name:
Hiroyuki Goto Ken Ichiryu

Affiliation: Affiliation:
Deputy Director, Technical Research Institute, Director, Mechatronics Laboratory, Kikuchi
Japan Society for the Promotion of Machine In- Seisakusho Co., Ltd.
dustry

Address:
1-1-12 Hachiman-cho, Higashikurume-city, Tokyo 203-0042, Japan
Brief Biographical History:
1987- Hitachi, Ltd. Information and Telecommunication Systems Division
1990- Technical Research Institute, Japan Society for the Promotion of
Machine Industry (JSPMI)
Main Works:
• “Design of a Six Degree-of-Freedom Tripod Parallel Mechanism for
Flight Simulators,” Int. J. of Automation Technology, Vol.5, No.5,
pp. 715-721, 2011.
Membership in Academic Societies:
• The Japan Fluid Power System Society (JFPS)
• The Japan Society of Mechanical Engineers (JSME)
• The Society of Instrument and Control Engineers (SICE)
Address:
2161-21 Miyama-cho, Hachioji, Tokyo 192-0152, Japan
Brief Biographical History:
1959- Joined Hitachi Research Laboratory of Hitachi, Ltd.
1986- Hitachi Construction Machinery Co., Ltd.
1996- Professor of Tokyo University of Technology
2005- Joined Kikuchi Seisakushyo
Main Works:
• “Electro-Hydraulic Control,” Nikkan Kogyo Shinbun, 2004.
• “Development of 3-Dimensional Pipe Bending Machine with a New
6-DOF Parallel Link for Industrial and Educational Purpose,” Proc. of the
13th Int. Conf. on Mechatronics Technology (ICMT2009),
CD-ROM(ISSN2094-330X), 2009.
Membership in Academic Societies:
• The Robotic Society of Japan (RSJ)
• The Japan Fluid Power System Society (JFPS)
• The Japan Society for Precision Engineering (JSPE)

Name:
Yutaka Tanaka

Affiliation:
Professor, Faculty of Engineering and Design,
Hosei University

Address:
2-17-1 Fujimi, Chiyodaku, Tokyo 102-8160, Japan
Brief Biographical History:
1985-1991 Research Associate, Precision and Intelligence Laboratory,
Tokyo Institute of Technology
1992-2002 Associate Professor of Hosei University
2002- Professor of Hosei University
Main Works:
• “Design and Fabrication of Micro Pump for Functional Fluid Power
Actuation System,” Next-Generation Actuators Leading Breakthroughs,
Part III, Micro Actuators, pp. 153-164, Springer, 2010.
• “Development of Pneumatic Parallel Force Feedback,” Int. J. of
Automation Technology, Vol.4, No.4, pp. 380-387, 2010.
• “Design of Six Degree-of-freedom Tripod Parallel Mechanism for Flight
Simulator,” Int. J. of Automation Technology, Vol.5, No.5, pp. 715-721,
2011.
Membership in Academic Societies:
• The Japan Society of Mechanical Engineers (JSME)
• The Japan Fluid Power Systems Society (JFPS)
• The Society of Instrument and Control Engineers (SICE)

Int. J. of Automation Technology Vol.6 No.4, 2012 515

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