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Posted on Sep 9, 2020
Exhaust mandrel benders have been around for a while. Machines are one of the most popular machines. And there are many good reasons.
The size of the exhaust pipe usually determines the correct mandrel bending machine. The machine handles exhaust pipes from 3/4 "to 3" in diameter. This series of pipe bending equipment uses a simple but robust designed machine that can be configured with a single stack of tools or multiple stacks of pipe bending dies and can handle complex tools and multiple bends.
This tube bender comes with up to four sets of tools that give you incredible design and flexibility on the shop floor. With multiple stacks, you can bend pipes in unlimited ways, offering designers the ability to create more complex parts. Multi-stage tooling levels make this machine more versatile and reduce changeover times
For large-volume applications, some machines allow partial changeover when bending straight parts by quickly replacing the mandrel and collets. Operators can then start machining parts of a different diameter on a different stack of tube bending dies as the machine can handle multiple stacks.
Additional enhancements include the first patented Double Blade System (DBS) to automate bending and cutting processes in a single tube bender. Another popular option, wall bending with 1D control, is specifically used in the manufacture of converter intake manifolds and pipes in automotive exhaust systems where the wall thinning factor must be controlled to ensure that the pipe can withstand the high system pressure.
To help explain the 1.5D and 1D bending nomenclature:
Benders are rated in D of Bend or (D). What does that mean? Well it relates to the CLR (Center Line Radius) and the tube OD (Outer Diameter or Outside Diameter) and (ID – Inner Diameter or Inside Diameter)
D = CLR/Tube OD
Examples would be:
1D = 2″ CLR/2″ Tube OD
1.5D = 3″ CLR/2″ Tube OD
2D = 4″ CLR/2″ Tube OD
If the bending machine is 1.5D rated, the ratio of the parts to be bent on it must be according to the formula.
One of the options available is the double blade severance cutter, which allows operators to make several small parts out of one long tube more quickly while saving waste between parts. The first blade makes a small cut so that the second blade causes less damage to the roundness of the pipe when cutting. The end result is a more consistent part because the part is not distorted.
Circus strongmen in the 19th century bent steel with their bare hands to show their incredible strength - but you don't need to wear a leotard to do simple DIY jobs around the house. Most people are able to bend soft metals such as copper and aluminum with their bare hands. So next time you need to bend some piping for a project, you could rush to the hardware shop to grab a pipe bender, or you could simply give your muscles a workout.
There are some restrictions on bending metals without the use of a machine. Of course, humans have their limitations and you will probably only be able to bend softer metals. Aluminum and copper are soft enough to bend without much effort, but with alloys like stainless steel, things will get much harder. Another thing to keep in mind is the type of bend you will achieve. Softer metals will give a U-shaped bend, while harder metals will look more like a "V".
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With bare hands
If you need a rough pipe bend and have limited resources, you can just use your bare hands. Most people can bend pipes up to an inch thick, but no more, and you may need tools or some extra help. Before bending the pipe, it's a good idea to wrap the ends with something you will need extra grip and protect your hands. Leather is one of the best materials for this type of work. Just cut some into strips and wrap them around the ends of the strip - you can choose other materials like thick fabric, but they won't provide the same leverage. Then firmly grasp the ends and choose the most comfortable position to bend, for example, grip the hand with the barbell straight ahead.
One of the most common ways to bend pipes without a machine is by using a torch. The extreme heat is concentrated on the area you want to bend, making it malleable. There are many ways to use heat to bend pipes, which we describe below. Before starting any technique, make sure you select it where you want to bend. It's also a good idea to create a bend template and measure the pipe relative to it on the fly. Most people use cheap wood materials like MDF to create large-scale templates.
Secure the pipe in a vice so that it cannot move. Make sure there is a decent amount of space on either side of the area you want to bend for a good grip when bending. Use the torch to constantly heat up the area you want to bend. Be sure to heat the entire area, not just one side of the pipe as this will help it bend evenly. When the tube is red hot, gently start bending it. You can do this with your hands, but wear thick gloves as the pipe will be very hot. If you are having difficulty getting the lever, try to use the key. Or use another piece of pipe as leverage. If you still have difficulty bending the pipe, have someone help you. Sometimes it is easier if one person heats the pipe and the other bends.
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