Common tube bending challenges and tube bending solutions

It is often said that metal bending is both an art and a science. Success in the arts and sciences usually requires trial and error before success. Here are some common tubes bending challenges-and successful tube bending solutions.

Springback

Challenge: After bending, metals such as stainless steel will try to restore their original, unbent shape. This is called rebound. When stainless steel is bent, the inner area of the bend compresses, and the outer area stretches. The density of molecules inside the bend is greater than the density of molecules outside the metal. Compared to a lower compression force, a higher tension tries to force the metal back to a flat position. Manual tube benders sometimes over-bend the required bending angle to accommodate springback. This strategy may result in imperfect bends.

Solution: For our internal tube bending work, this is not a problem because they are performed on a CNC tube bending machine. We don't need to overcompensate for bending for springback, because there is no risk of springback when bending correctly on a CNC machine tool.

Damaged or weakened mandrel and/or tool

Challenge: The mandrel provides stability for the bending tool and internal pressure for bending. Precise mandrel tube bending can achieve perfect, strong, and repeatable bending.

The challenges of mandrel bending include:

• Humps at the end of      a bend

• Humps from mandrel      balls

• Tube collapse

• Tooling breakage      from too much pressure

•  

These will lead to failure of the elbow. Improper or weakened tools will not produce perfect bends. Worn tools are the number one enemy of tube benders. A common mistake is to try to use the power of the machine to replace the correct tool settings. This may damage the machine and tools. The perfect bend is challenging enough. When you use it in combination with worn and/or improper tools, even regular bending operations can fail.

Solution: Zechin can ensure that the mandrel tools we use on the tube bender are functioning properly and are free of malfunctions, because even the most experienced technicians will encounter difficulties if they do not have the right tools. Our spindles and tools undergo regular maintenance inspections to ensure perfect performance. Our CNC tube benders provide fast, consistent, high-quality pipe bending, while eliminating many default values that may be caused by welds (such as hump).

For our experienced team, tube rupture is not a risk. We know which material is best for each job. For elbows, we most often choose to use 300 series stainless steel. Not only does it produce flawless bends, but it is a cleaner metal than most metals.

Lubricating

Challenge: Lubricant is used to coat the inside of the tube, as well as the curved mandrel and the outside diameter of the tube and the doctor blade die. Its main function is to reduce friction during tube bending. Lubrication is also the key to the success of the elbow. Failure to use proper and sufficient pipe bending lubricants can cause some serious challenges during the bending process-including costly damage to the machine itself.

Solution: Failure to use proper and sufficient tube bending lubricant will cause serious challenges in the tube bending process. The use of lubricants on the machine can reduce friction during the bending process, reduce the accumulation of waste, and provide a longer service life for your tools.

In order to obtain the perfect tube bending effect, it is always the best practice to keep the machine well lubricated.

Zechin uses fluids that do not contain sulfur and chlorine additives. The lubricant must be water-soluble to minimize the wear of tools and bending dies. When storing bent parts, using appropriate lubricants can also minimize corrosion.

We currently use two types of fluids:

• Houghto-Draw 7000 series

• IRMCO limit

Cost

Challenge: Speaking of cost, if you want to build a new tube bending production line, cost is of course a challenge. Considering only the cost of basic equipment (such as a high-quality pipe bender), you will consider investing more than $10,000. Other expenses include but are not limited to:

• Hardware and software

• Machine training

• Machine tools

• Lubrication

• Repair parts

• Machine maintenance and support

Solution: The costs we mentioned above are not necessary for your next tube bending work, because we have absorbed them. In addition, bending tube is one of Zechin’s long-term expertise, which is why we rarely encounter the above-mentioned challenges when performing work for our customers.

You may be surprised to find that automatic tube benders provide efficiency and usually do not require welding or multiple accessories. We have impressive machines, updated software and hardware, well-trained technicians, suitable tools and materials, and regularly scheduled maintenance to keep everything in top condition.

All we need now is the details of your work, and we are ready to start working.

Contact us: info@zec-industrygroup.com