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Posted on Dec 28, 2020
In the square pipe bending process, the square tubes are compressed slightly inside and therefore the material can flow. Materials like square tubes or rectangular pipes can be shaped with or without a mandrel. The operation without mandrel is quicker and more cost-efficient than mandrel bending. However, square pipe bending which used a mandrel can provide more perfect finishes and appearances of the products.
A square pipe bending machine, which is also called a square pipe bender, square tube bender, or square tube bending machine, is used for permanently forming the pipes or tubes into desired profiles. A large range of pipes and tubing can be bent with square pipe bending machines, such as square, rectangular, and the basic round type. The bending machines used only for round pipes are standard benders, however, bending square tubes with square cross-sections should take place in advanced bending machines which are designed to accommodate different square pipe cross-sections. Many manufacturers of square pipe bending machines recommend the customer to send the pipes in order to design or adjust the customized square pipe bending machine for them. The pipe bending process can be subdivided into form bound bending type and free-from bending process. In form bounding bending, the stocks are bent by customized dies, producing more complex shapes and various types of ductile metal pipes. As for the free-form bending, the bender forms the profiles of pipe products kinematically.
In the square pipe bending process, the square tubes are compressed slightly inside and therefore the material can flow. Materials like square tubes or rectangular pipes can be shaped with or without a mandrel. The operation without mandrel is quicker and more cost-efficient than mandrel bending. However, square pipe bending which used a mandrel can provide more perfect finishes and appearances of the products. Some characteristics of stocks will also affect the efficiency of the bending process, including the thickness of square pipes, tooling, and lubricants in pipe bending machines. These factors should be considered to optimize the bending operations and ensure the high quality of tube products.
:: Read More: What Is an Electric Pipe Bending Machine?
There are various automatic pipe benders used for square pipe bending, most of the machines work electromechanically. Pipe bending machines are typically driven by a pneumatic or hydraulic system or powered by an electric servo motor. CNC pipe bending machine equipped with presses and rollers to bend the tubes along the forming process. An ideal square pipe bending machine should be able to provide the best consistency and rapid forming operation and also eliminate the errors in production lines at each stage. Essential elements in a pipe bending machine include bend die, clamp die, pressure die, wiper dies, and the optional mandrel. These dies used in pipe bending should be made from hardened steel except the soft alloy dies which are used to prevent damaging the materials.
The bend dies in a bending machine are also known as bend formers. The die is an essential component in the square pipe rotary draw bender. Steel pipes are clamped to the bend die during the drawing process. Clamp dies can push the steel pipes onto the bend dies and consistently keep the stock from slipping.
Typically, wiper dies are made from softer alloys like aluminum and brass to get rid of any scratch or damage to the bent steel pipes. Wiper die is used for smoothing the surface and preventing any hump or wrinkles that might occur on the inner surface of steel pipes during the bending process, which works directly after the bend dies.
As mentioned in the previous section, although mandrel is optional in square pipe bending, using one can optimize the final appearance of the products. For example, a square pipe rotary draw bending machine with a mandrel is greatly suitable for square pipe shaping. The goal of the mandrel is to prevent the steel pipes from collapsing especially when the square tubes have thin walls or are shaped on a small radius. Mandrel bending can keep the original square contours of the materials and only perform minimal wall thinning.
There is a wide range of bending machines that are suitable for square pipe bending, the more popular types of which include the rotary draw bending machine with or without mandrel, induction bending machine, roll bending machine, and compression bending machine. The best square pipe bending machine choice still depends on actual bend specifications as well as the application and desired profiles.
Square pipe bending in rotary draw-type bender is precise because the die sets have a consistent “centerline radius”. Rotary draw bender is available with indexing plates to be used in a wide range of applications like automotive parts and handrail production. A CNC rotary draw bending machine can perform complex shaping and critical bends for square pipes.
An induction bending machine is available for bending large to small radius steel pipes as well as tubes with thinner walls. There is no mandrel in the induction bending machine. At the bending point, the induction coil is placed around a small section of straight pipes. The bender can perform high precision bending at different angles.
The square pipe will be forced through specially customized rolls that apply pressure to the workpieces and perform gradual bending to form the desired shapes. Roll bending machines are suitable for producing longer strips of pipes and gentle bends, creating only little deformation in the cross-section of straight pipes.
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