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Bending Formulas For Tube Bending Tools
Bending Formulas For Tube Bending Tools
Inside radius:
Ri = R - ( T / 2 )
Outside radius:
Ro = R + ( T / 2 )
Wall factor:
Fw = T / W
"D" of bend:
Fd = R / T
Bend difficulty rating (the higher the value, the more difficult the bend is to make; rule of thumb only):
Where "Kr" = a constant for material rigidity (assign the same value to "Kr" as you would to calculate
pressure die length; a value of 2 is suitable for most applications; click here for more information) and
"n1" through "n4 " are values to adjust the weight of each factor in the equation (see below for our
recommended weighting):
General formula: Fb = [ ( n1 x Kr ) + ( n2 x Fw ) + ( ( n3 x B ) / 180 ) ) ] / [ n4 x Fd ]
Formula with recommended weighting: Fb = [ 2Kr + .2Fw + ( B / 180 ) ] / [ Fd ]
Note: A bend difficulty rating (calculated with our recommended weighting) of 7 or less indicates a bend that is
relatively simple to produce with the rotary-draw method. Factors in excess of 7 typically require either
additional precision in set-up or close attention during production in order to hold the set-up parameters.
Mb = Md x .998
Maximum set-up depth of mandrel nose relative to the line of tangency, as measured from nose end
(including nose radius):
S = [ ( R + ( T / 2) - W )2 - ( R + ( Md / 2 ) )2 ]1/2 + Mr
Lp = ( R x 3.14 x ( B / 180 ) ) + ( T x Kr )
We are frequently asked for formulas to calculate springback and radial growth. While there are
rules of thumb -- e.g., a radius will increase 1% for every "D" of bend -- they are not effective, as a
true formula would be, in reducing the prove-out needed to lock in the parameters of a machine
set-up.
Unfortunately, effective formulas for springback and radial growth have not been developed, because
the factors involved include not only tube and bend specifications but also machine settings --
especially the radial pressure and axial pressure applied by the pressure die to the tube and the
placement of the mandrel nose relative to the line of tangency. How an operator sets these things on
a particular make and model of machine alters where the neutral axis of a tube bend lies in
relationship to the centerline of the radius, and it is the location of the neutral axis that determines
how much springback and radial growth there will be. Moreover, springback and radial growth are
the result of fundamentally non-linear processes, which would make any effective formula that does
account for all these factors fairly complex. Presently, finite element analysis (FEA) is the only tool
up to this task, and it is not yet practical for everyday use in the bend shop.
Fortunately, the trial-and-error needed to adjust for springback and radial growth does not have to
be repeated for every set-up of a tube bend. By using the "Four-Step Set-Up Method" to employ the
"forward mandrel, low pressure" set-up for rotary-draw tube-bending, the parameters of a successful
set-up can be recorded and then duplicated with little or no trial-and-error to prove out future
set-ups of the same or similar tube bends.
MAIL TO: BEND TOOLING INC. ~ 1009 OTTAWA AVENUE, N.W. ~ GRAND RAPIDS, MICHIGAN 49503, U.S.A.
TOLL-FREE (U.S.A. & CANADA): 1-800-BTI-TUBE (1-800-284-8823) ~ WORLDWIDE: 616-454-9965
FAX: 616-454-9958 ~ E-MAIL: INFO@BENDTOOLING.COM
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