Good Uses for Mandrel Benders

Posted on May 17, 2021

Mandrel Bender

The mandrel benders were a solution to stop transporting and turning the pipe. The new type of machine turned the angle bar with the bending head around the pipe and moved axially along its length. The spatial twist of the pipe and the intermediate lengths between the bends prevented the machine from moving the pipe and therefore was not subject to the tamping effect. The only movement comes from the bending process itself.

In several industries, bending piping and tubing is important. In the automobile industry to shipbuilding, aircraft, aviation, and much more, some tube and pipe bending applications are used. To mitigate the ovality found in thin-walled tubes when twisted, the mandrel benders are used. They also help remove folds in the radius of the inner bend.

Aviation and aerospace are two other industries that rely heavily on the bending of the highest quality tubing. Bends have to be correct in these industries and there is no room for mistakes. Mandrel tube benders allow these industries to perform extremely precise bends. In aviation, making bows with the highest accuracy is particularly important. For the industrial bending of rods, tubing, square and rectangular profiles, some benders are fine. Mandrel benders can bend profiles as small as 1.5x the diameter down to a centerline radius.

In many industries, a number of mandrel pipe benders have proved themselves. No matter what bending tube, pipe, or profile you choose to create, some will deliver a bending machine that will achieve your targets and surpass your standards. The suggested uses for tube bending include the automotive sector, vehicles for advertising, building ships, architectural services, industrial sector, cosmonautics & aviation, just to name a few.
 

Bending with Mandrel Bender

Like other production processes, the methods of bending pipes vary in complexity. There are, essentially, applications where the pipes are so small and the bends are so simple that manual bending is suitable. The focus is on manual benders and dedicated hydraulic or pneumatic benders, while fully programmable benders play a central role in sophisticated end-of-spectrum automatic benders.

Two key factors are understanding how the bending requirements have changed over the decades and how bender producers have responded. Many leading automobile firms and automotive manufacturers relied on manual methods to bend brake and fuel lines before the early 1980s - workers bent the lines on wooden gauges or at most, on manual lever benders by hand. The effect of the bending was unpredictable and was caused by several factors, such as the operator's ability level, as the bending speed affected the final shapes of the tubing.

The use of a traditional bending machine for this application has failed because the user had to assist it by hand during the bending phase while bending a line longer than 6 feet (2 meters) in length. The bending motion would otherwise cause the pipe to be whipped. Human assistance was needed for precise bending. With automation, CNC, the CNC twin-head bending system for bending fuel and brake pads, an invention from 1985, altered all that. The method splits the 20-foot (6 m) line length into two halves. This decreased the length of the free thread effect; machine processes - bending, turning, and transporting the lines - continued to cause this problem.
 

:: Read More: What You Need to Know About the Exhaust Mandrel Bender
 

Applications with Mandrel Bender

The mandrel benders were a solution to stop transporting and turning the pipe. The new type of machine turned the angle bar with the bending head around the pipe and moved axially along its length. The spatial twist of the pipe and the intermediate lengths between the bends prevented the machine from moving the pipe and therefore was not subject to the tamping effect. The only movement comes from the bending process itself.

The double-head feature allowed to divide the number of folds into two sides that work independently of each other. The most advantageous case is to make two symmetrical finished products from one length of the raw pipe. The machine has already reduced cycle times compared to manual bending. If the application was symmetrical, automation further reduced the cycle time. In some cases, a mandrel bender cut it in half.

However, a twin-head machine requires a minimum pipe clamping length. Ideally, the clamp length is in the center of the bends and is at least 7.875 inches (200mm). In some cases, 4.5 inches (115 mm) is sufficient. For bending pipes with shorter clamp lengths with straight pipe up to 6.5 feet (2 m) long, a single-head bender was developed which works on the same bending principle, except that for straight sections the machine moves the pipe axially. However, this does not contribute to a significant amount of the resulting whip effect.
 

Do you need a fixed bender or a programmable mandrel bender?

Flexible CNC bending machines quickly gained popularity in Germany, but single-purpose machines (mechanical benders) were used in other countries, especially in the USA and Canada. This type of machine bends only one size of pipe or pipes with a certain contour. Bending movements are usually performed by pneumatic cylinders; each cylinder and each component of the tool produces only one precise bend.

The great advantage of these machines is that the investment costs are much lower than for flexible, programmable CNC machines. In some cases, they are also faster. However, with the slightest modification of parts - which is a common occurrence in the development phase - a single-purpose machine must be scrapped and replaced with a new machine.
 

Raw Material

In addition to the actual bending quality, two additional points are important for a good-quality bent pipe. First, it is always necessary to use pipes that meet the specifications of the end product. This may seem obvious, but in some cases, incoming pipes differ little, if at all, in appearance. Although they are labeled, different batches of tubing may mix up when separated. Manufacturing a single part from different raw materials can result in out-of-spec parts.

Secondly, the quality of the pipes must be optimal. When it excludes more than two pieces in a row, the computer can be programmed to automatically pause and produce an error code. Then to decide if the incorrect package was loaded, search the incoming pipes.
 

Monitoring the Bending Process

Another concern is that various materials of different lengths are processed by one processing unit. The cameras are movable and shift with the magazine as it moves to check that by moving from one part to another the right stock length is being filled.

With the appropriate lighting device, the cameras can be attached to the sidewalls of the warehouse and then placed automatically along with the warehouse. It removes the need to change or concentrate manually. This ensures that only component tolerances and measurements need to be "learned" by the cameras once and can later remember the stored details. It is possible to do twenty-two sensor assessments on each hand. For all the others, one primary sensor acts as the reference sensor, meaning that all sensors immediately shift relative to the primary sensor for the mandrel bender.
 

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