Category: CNC Tube

As explained in this bending tooling guide, each component plays a vital role in the successful operation of bending tooling. Essential components include the bend die, clamp die, pressure die, wiper die, and mandrel.

So, before diving into each bending tooling component, let us understand what tube and pipe bending is. 

What is Tube and Pipe Bending 

Tube and pipe bending is a manufacturing process. In this process, we use a machine for bending pipes and tubes. And try to get a perfect bending shape. It allows the production of shapes that are not achievable by other processes, such as roll forming, plate rolling, press brakes, or tube cutting. 

We use Tube and pipe bending processes in several applications in almost every industry, such as exhaust systems, headrests, etc. 

Each component plays a vital role in perfect bending in the bending tooling process, which we will discuss later in the same article. 

How do Tube and Pipe get bent? 

Bending tubes and pipes can be a daunting process for someone unfamiliar with the equipment, techniques, and safety requirements. The process requires specialised machinery, a trained, experienced operator, plenty of time, and attention to detail. 

Either manually or with automated machines, you can finish the tube and pipe bending process. It depends upon the type of manufacturing product. Tube bending machines are best suited for short-radius turns, while more sophisticated pipe benders make longer-radius bends. With a tube bender, you can make fittings such as tees and crosses, but you’ll need a pipe bender for elbows and other complicated shapes. 

As covered in this bending tooling guide, accurate calculations often determine the success or failure of any bending tooling setup. Before the tooling is installed, calculations establish the ideal bend radius and confirm whether your equipment can complete the required bend.

Moreover, the material you are using must not be bent cold in the bending tooling process. Cold bend dies only work for materials like iron and aluminium. If your material exceeds a hardness of 101 BHN, it cannot be produced with a cold die on a press brake. The more complex your material is, the more likely you will need an induction heater to heat the bar to make a bend. 

Perishable and Non-Perishable Components of Bending Tooling Sets 

Tube bending components consist of both perishable and non-perishable components. Perishable components will eventually have to be replaced, and non-perishable components are those you won’t have to replace. 

The two big pieces of perishable tooling are the wipers and the mandrel (Shank, body, nose, and ball mandrels all included). The non-perishable components include: 

• Bend Dies 
• Clamp Dies 
• Pressure Dies 
• Collet Pads 
• Wiper Holders 
• Wiper Posts 
• Bend Post
• Clamp Bolster 
• Bend Die Base 
• Clamp Adjuster 

Bend Dies 

It is a quick, cheap and easy way to produce extreme bends in thin-walled, low-conductivity metals. From the reverse side of the bend die, a blank is pushed through a groove. And then the metal’s composition is rolled into a thin sheet over the die surface and compressed. The blank is then made through the die with enough pressure to bend it, and finally falls off upon reaching the exit hole of the die. 

Clamp Dies 

It is one of the most common hydraulic tools. There are various types and sizes of clamp dies available. 

In CNC machines, it is a common tool. A clamp die can create pressure and hold stationary any part that goes through the machine while machining it. 

Ratcheting dies, snap-action dies, and clamping dies are synonyms of clamp die. The clamp die is essential in your bending tool kit, no matter what name it goes by. A clamp die can clamp together two die flanges to accommodate various sheet metal thicknesses without you having to resize the dies for each new material thickness. 

Pressure Dies 

We use pressure dies in high-volume, tight-tolerance, or high-output production applications. Only High-pressure machines can create these dies. They only work if they are at the correct pressure level. Otherwise, they could cause damage to the products. 

There are many pressure dies in bending tooling, each designed for a particular application or material type. Pressure dies are usually the last step in this process after a forming operation. And finally, it imparts the final bend profile on the formed metal blank or part. 

Wiper Die 

Wiper dies are bending die inserts and are mainly used for bending and forming operations. These dies are most commonly used in standard shapes and sizes and are made from high-quality tool steel. While their usage can vary within the industry, their function is consistent — to remove the smaller amount of material found on the top side of a sheet. Because wiper dies are designed to remove only the excess sheeting that presents an issue during bending, they act as a sacrificial die and will wear out quickly. 

Mandrels 

The mandrels in bending tooling allow a continuous bend of the pipe or tube to any desired radius. A hydraulic system operates it. In this process, you put a stack of mandrels inside the machine. The mandrel rotation arrangement works with the stack of mandrels according to the diameter and length of the products. 

Final Note 

This is certainly not a comprehensive guide to bending tooling, but it should help you determine if it’s the right option for your business. And as mentioned above, there are many more considerations than what we discussed here. Whether you end up opting for these tools or going with a different approach, keep in mind that the best decision is often the one that suits your specific business needs and budget. 

Delahenty Machinery 

At Delahenty Machinery, we make the highest quality bending tooling. Use our bending tooling guide to explore high-quality bending tooling that improves productivity, lowers manufacturing costs, and maintains exceptional quality. With a wide range of products and our exclusive package design philosophy, the right solution is only a call or click away. Contact us for more details.