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Tube Bending Guide
Tube Bending Guide
Tube Bending Guide
Horn Machine Tools, Inc. Madera, CA. - Indianapolis IN. St. Paul, MN
Mandrel Bending Basics
www.hornmachinetools.com
Tel: 559-431-4131
Shown here:
The tube must be supported on all sides, ID and OD. A balance of pressure must be achieved, so material can be put into a plastic state and not deform. Tube must Flow over the mandrel
Bend
Wiper
Mandrel
Clamp
Pressure Die
Strive for: Balance pressures between all five dies Avoid: Over-pressure adjustments which cause resistance or drag Under-pressure adjustments which allow tube escape Containment
Wiper
Mandrel
Clamp 3
Pressure Die
4- Clamp Die force 5-Pressure Die force 6-Pressure Die assist force
Distortion of the natural axis As shown by the weld seam Outside thins out Wall Thinning
Bender Type and Condition Design and Condition of tools Proper Set-up and Adjustment Material Type and Quality Proper Type and Amount
HMT #1
HMT #1-1/2
HMT #2
HMT #3
HMT #4
16mm
20mm
30mm
40mm
65mm
76mm
100mm
150mm
Twin Head
Series F
Series EMR/MBRE
Standard TNCPB Features: Drop Away Clamp Servo Plane of Bend Control Distance Between Bend Stops Mandrel & Wiper Pressure Die Assist
A89TNCPB
Most economical
Spool Die
Multi-Stack Dies
One Piece
Flange Style
Partial Platform
Typical spool type bend die with flat back type insert, standard design, economical to make
Premium type concentric bore insert, best for difficult applications, advanced design, expensive to make
Clamp Die
Gap
Clamp Die shown interlocked with Bend Die. Set-up Notes: Alignment of clamp die and bend die tube grooves. Square-ness of clamp die to bend die, top to bottom, side to side. Must have a gap between the dies, not bottomed out. Correct force applied to hold the tube from slipping. No excessive force applied that will cause die tilt or clamped thru mandrel
Pressure Die Close Force Avoid using excessive pressure die close force, this causes resistance in the bend process
Gap
Aluminum Bronze mandrel For bending stainless and Other alloy materials Note single ball mandrel, With normal pitch
Hard chrome steel mandrel For bending carbon steel or Non-ferrous materials. Note 4 ball mandrel, with Close pitch.
Replacement cost is lower Replacement time is quicker Initial investment higher (Holders) Allows close tangent positioning by CNC May not be suitable for some difficult applications
May be re-sharpened (30% of new cost) Works well for difficult set-ups Easy for rookies! Longer tangent positioning length by CNC No special holder required, fits all benders.
1) Determine the Wall Factor WF 2) Determine the D of Bend 3) Consult Chart to determine proper die set-up. (next page)
Wall Factor
1 M1 M 1W M 2W M 3W M 3W M 3W M 4W M 4W M 4W M 4W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W
1.25 M1 M 1W M 1W M 2W M 3W M 3W M 3W M 3W M 3W M 4W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W
1.5 M1 M1 M 1W M 1W M 2W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W U TW 1 0 W U TW 1 0 W
2 M1 M1 M1 M 1W M 2W M 2W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W U TW 1 0 W U TW 1 0 W
2.5 P P M1 M1 M 1W M 2W M 3W M 3W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 7 W TW 9 W TW 1 0 W U TW 1 0 W U TW 1 0 W
3 P P M1 M1 M1 M 2W M 3W M 3W M 3W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 6 W TW 9 W TW 1 0 W U TW 1 0 W U TW 1 0 W
P M1 M1 M2 M 2W M 2W M 2W M 2W M 3W M 3W M 3W M 3W M 4W TW 4 W TW 6 W TW 8 W TW 1 0 W U TW 1 0 W U TW 1 0 W
Selection P=Plug Mandrel M1 = 1 ball M2 = 2 ball T = Thin wall UT = Ultra Thin wall W = Wiper
Purple shaded area = Standard mandrel, Yellow shades area = Thin Wall Mandrel Blue shaded area = Ultra Thin Wall Mandrel
Collets
Flange style Bolt in collet pads 3-5 minute Change out time
Materials
Material
Aluminum Soft T-zero grade Aluminum Hard T-4 to T-6 Copper Brass Carbon Steel Aluminized Steel Stainless 300 series Stainless 409 Inconel Titanium
Bending Properties
May be formed down to 1 x d radius. When forming on tight radius, bend Speed must be slow. Light pressure used. T4 may be formed down to 2xd radius, T6 may be formed down to 3xd. Forming on tighter radius may cause orange peel and cracking Same principles as aluminum, soft copper bends very well, harder grades require larger radius. May be formed to tight radius down to 1xd when properly annealed Most common materials used C.R.E.W. and H.R.E.W. can be formed down to 1xd radius. DOM and harder materials formed down to 2-3xd. Common material for exhaust applications. May be formed down to 1xd. Quality of material varies with batches and mills. Can load up on tools. Can be formed down to 1xd, quality of material very important, A269 series is excellent. Lubrication very important. Less expensive version used for exhaust applications, quality varies widely. Uses less pressure than Stainless 300 Used for high temperature exhaust applications, very difficult to form. Tooling, material and set-up are crucial. Material used for aircraft and some exhaust applications. Forms similar To stainless
Gel
Water soluble Gel type paste, used for steel, Aluminum, & non Ferrous. Part # 460-80A Non Water Soluble oil used for Stainless Steel. Part# How-to-Draw 3105
Heavy Oil
Horn Machine Tools, Inc. Madera, CA. - Indianapolis IN. St. Paul, MN
Contact us for help with your Tube Bending Application Visit us on the Web at Tel: 559-431-4131 Fax: 559-431-4431 Representatives and Application Assistance nationwide
www.hornmachinetools.com