The Multi-Radius Right- and Left-Hand Tube Bender executes continuous, high-precision bending for complex tubular components by integrating clockwise and counterclockwise rotation with multi-stack tooling on a single automatic cycle.
Key Benefits
Collision-Free Geometry:
Eliminates tube flipping during processing, preventing structural interference with the machine frame or floor.
Single-Setup Processing:
Consolidates multiple bend radii and alternating directions into one pass, eliminating manual material transfers.
Material Waste Reduction:
Servoelectric torque sensing compensates for batch springback during every bend stroke.
Fast Tooling Transfers:
Servo-driven stack switching changes multi-radius levels in under 2 seconds.
How It Works
The machine feeds raw tubing through a multi-stack collet driven by direct-drive AC servomotors. Based on the programmed drawing, the bending head rotates horizontally while adjusting the vertical die stack. Linear position encoders send real-time coordinates to the numerical controller, running draw-bending or roll-bending sequences continuously without stopping.
Right- and Left-Hand Bending Capability
Flips 180 degrees horizontally to switch between clockwise and counterclockwise rotation within the same program.
Produces asymmetrical geometric shapes where extended tube tails would otherwise collide with the machine bed.
Completes complex symmetrical and non-symmetrical profiles without releasing the collet clamp.
Key Technical Features
Multi-Stack Tooling Post: Houses up to 6 die levels for varying radii, wiper dies, and forming tools on a single spindle.
Direct-Drive All-Electric Axes: Eliminates hydraulic temperature fluctuations, maintaining positioning consistency down to ±0.05 mm.
Real-Time Springback Compensation: Detects material resistance variations per batch and adjusts bend angles on the fly.
3D Offline Simulation: Pre-checks part programs to verify machine clearance limits before physical trial runs.
Boosted Mandrel Extraction: Synchronizes mandrel retraction speed with bend progression to prevent wall collapse.
Technical Specifications
|
Parameter |
Unit |
Value |
|
Tube Capacity (OD × Wall) |
mm |
38 × 2.0 – 89 × 4.5 |
|
Max. Bending Radius (CLR) |
mm |
250 |
|
Min. Bending Radius (CLR) |
mm |
1.0 × OD |
|
Bend Angle Accuracy |
deg |
±0.05° |
|
Axis Repeatability |
mm |
±0.05 |
|
Max. Feed Speed |
mm/s |
1200 |
|
Max. Head Rotation Speed |
deg/s |
180 |
|
Servo-Controlled Axes |
Count |
9 – 12 |
Bending Capacity
Draw Bending: Achieves Centerline Radii down to 1.0 × Outer Diameter using wiper dies and flexible internal mandrels.
Roll Bending: Forms continuous large-radius curves on upper stack rollers without changing die hardware.
Compound Bending: Completes zero-straight length transitions between adjacent bends using custom clamp inserts.
Tube Materials
Carbon Steel:
Seamless and welded structural tubes.
01
Stainless Steel:
Austenitic and ferritic grades including 304 and 316L.
02
Aluminum Alloys:
Structural tubing including 6061-T6 and 6063-T5.
03
Copper Alloys:
High-conductivity tubing for thermal assemblies.
04
Nickel Alloys:
High-temperature aerospace-grade tubing.
05
Applications of Multi-Radius Right- and Left-Hand Tube Bender
Vehicle Exhaust Systems: Forms complex routing paths without intermediate welds.
Aerospace Fluid Lines: Processes high-strength alloy tubes requiring consistent wall thickness.
Cooling Equipment Coils: Shapes serpentine heat exchanger tubing with alternating bend directions.
Furniture Frames: Produces symmetrical tubular legs and armrests in a single sequence.
Structural Space Frames: Bends tubular chassis members within tight dimensional tolerances.
Machine Configuration
Bed Structure:
Heavy-gauge stress-relieved welded steel frame.
Control Unit:
Industrial PC-based numerical controller with touchscreen interface.
Drive Mechanism:
Multi-axis absolute AC servomotors with planetary gearboxes.
Motion Guides:
Hardened linear ball guides on all sliding axes.
Lubrication System:
Automatic centralized pump servicing linear slides and pivot bearings.
Optional Equipment
Automatic Loading System: Bundle loader with servo arms for continuous raw material feed.
Seam Alignment Sensor: Optical scanner identifies and positions tube weld seams before bending.
Internal Lubrication Unit: Micro-dosing pump sprays lubricant inside the tube during processing.
In-Line Punching Module: Servo-driven punch mechanism creates holes during the bend cycle.
Tooling & Dies
Bend Dies: Hardened tool steel or bronze for non-marking surface requirements.
Clamp Dies: Serrated or smooth grip inserts matched to surface finish standards.
Wiper Dies: Solid or tipped configurations to prevent inner-radius wrinkling.
Mandrels: Multi-ball flexible units sized for specific tube wall thicknesses.
Pressure Dies: Follower-type dies with micro-adjustment force control.
Why Choose Us
Machine beds undergo thermal stress relief and precision milling to hold axis alignment under continuous load.
Every unit undergoes a 72-hour continuous test run at full capacity before factory release.
Die sets are engineered, machined, and verified using customer-specified tube samples prior to delivery.
Complete inspection logs and wiring diagrams accompany every shipment.
How to Choose the Right Configuration
To select the correct machine configuration, evaluate these operational requirements:
Outer Diameter & Wall Thickness: Establishes required torque output and motor frame sizing.
Minimum Centerline Radius: Determines whether standard draw bending or mandrel-assisted bending is necessary.
Unfolded Tube Length: Defines the required effective bed length and mandrel rod length.
Part Geometry Complexity: Dictates the total stack count and servo axis count needed to prevent tool interference.
FAQ
Q: How does dual-direction bending eliminate manual handling?
A: The bending head rotates clockwise or counterclockwise automatically within the programmed sequence, forming alternating bends without requiring an operator to pause the machine and flip the tube manually.
Q: What is the difference between draw bending and roll bending on this machine?
A: Draw bending wraps the tube around a fixed die to produce tight radii down to 1.0 × Outer Diameter. Roll bending pushes the tube through adjustable rollers on an upper stack level to create variable large-radius curves on the same part.
Q: How does the software prevent machine collisions?
A: The controller includes 3D collision modeling. It simulates the machine frame, tooling stack, and tube motion prior to physical operation, identifying potential contact between the workpiece and the machine structure.
Q: Can this machine process thin-walled stainless steel without wrinkling?
A: Yes. Combining multi-ball mandrels, precision-fit wiper dies, and servo-boosted pressure dies prevents outer wall flattening and inner wall wrinkling on thin-walled materials.
Q: What maintenance routine is required for all-electric bending machines?
A: Daily maintenance involves inspecting tooling surfaces and verifying automatic lubrication levels. Linear guides and drive screws require periodic greasing according to the maintenance schedule.