The Precision Rotary Draw Tube Bender delivers tight-radius, deformation-free bends on round, square, and profile tubes through rigid mechanical clamping and closed-loop servo control. Built for high-volume manufacturing environments, this machine controls tube ovality, wall thinning, and angular springback across various metals, including stainless steel, titanium, aluminum, and carbon steel.
Key Features
Multi-Axis CNC Motion Control: Coordinates bending, feeding, and spatial rotation via absolute optical encoders.
Closed-Loop Springback Compensation: Calculates and corrects material elasticity variations in real time to maintain angle consistency.
Direct-Drive Rotary Draw Head: Eliminates mechanical backlash during heavy torque bending operations.
Hydraulic Mandrel Extraction System: Prevents inner-wall wrinkling and supports thin-wall tube integrity during tight center-line radius bends.
Quick-Change Tooling Interface: Reduces downtime between production runs through standardized alignment pins and hydraulic clamping.
Industrial Touchscreen Interface: Stores up to 10,000 bending profiles with 3D simulation and collision detection capabilities.
Technical Specifications
|
Specification Parameter |
Value / Unit |
|
Max. Outer Diameter (OD) |
63.5 mm (2.5 in) |
|
Min. Outer Diameter (OD) |
6.0 mm (0.23 in) |
|
Max. Wall Thickness (Steel) |
4.0 mm (0.157 in) |
|
Max. Wall Thickness (Stainless Steel) |
3.0 mm (0.118 in) |
|
Max. Bending Radius (CLR) |
250 mm (9.84 in) |
|
Min. Bending Radius (CLR) |
1.0 D (depending on wall factor) |
|
Max. Bending Angle |
190° |
|
Bending Angle Repeatability |
±0.05° |
|
Feeding Accuracy |
±0.05 mm |
|
Rotation Accuracy |
±0.05° |
|
Bending Speed |
Up to 110°/sec (adjustable) |
|
Max. Tube Over-Bed Length |
3000 mm / 4000 mm / 6000 mm |
|
Operating Pressure |
14 MPa |
How It Works
Rotary draw bending secures the leading edge of the tube between a bend die and a clamp die. As the bend die rotates around its axis, it draws the tube through a stationary pressure die and wipers.
Feeding & Orientation:
The carriage moves the tube longitudinally along the bed and rotates it to the precise spatial plane.
Clamping & Mandrel Insertion:
The hydraulic clamp die seals the tube against the bend die, while an internal mandrel positions inside the bend zone to support the inner diameter.
Draw Bending:
The bend die rotates to the programmed angle. The pressure die advances along a linear guide to counter radial forces and prevent wall collapse.
Mandrel Retraction & Unclamping:
The mandrel retracts slightly before the rotation completes to eliminate drag marks, followed by clamp release and part unloading.
Applications of Precision Rotary Draw Tube Bender
Automotive Exhaust & Fluid Lines: Produces smooth-flow manifolds, fuel lines, and structural tubular components.
Aerospace Conduit Systems: Forms titanium and stainless steel tubing for rigid fuel, hydraulic, and environmental control lines.
HVAC & Refrigeration Loops: Shapes copper and aluminum distribution headers with minimal internal restriction.
Medical Equipment Frames: Manufactures high-finish mobility aid structures, surgical tables, and diagnostic unit frames.
Architectural & Industrial Railings: Delivers consistent curved profiles for structural handrails and custom metal enclosures.
Machine Configuration
Heavy-Duty Cast Iron Frame:
Annealed frame structure minimizes stress and vibration during maximum-torque operations.
Servo Motors & Gearboxes:
Dedicated AC brushless motors control key motion axes.
Linear Guide Rails:
Hardened profile rails ensure smooth carriage transport and high positional accuracy.
Centralized Automatic Lubrication:
Delivers oil automatically to guide ways, ball screws, and rotating pivots.
Integrated Hydraulic Unit:
Temperature-controlled oil reservoir with high-pressure variable displacement pumps.
Safety Light Curtains:
Encloses the swing area to protect operators during auto-cycle operations.
Bending Capability
|
Tube Material |
Max OD x Wall (mm) |
Min CLR Capability |
|
Mild Steel |
63.5 x 4.0 |
1.0 D |
|
Stainless Steel |
50.8 x 3.0 |
1.25 D |
|
Titanium Alloy |
38.1 x 2.0 |
1.5 D |
|
Aluminum |
63.5 x 3.5 |
1.5 D |
|
Copper / Brass |
60.0 x 3.0 |
1.0 D |
Optional Equipment
Multi-Stack Tooling Post: Allows mounting of multiple radii or combination draw/roll bend tooling on a single setup.
Automatic Mandrel Lubrication System: Injects fluid directly through the mandrel rod to extend tool life and improve inner surface quality.
Seam Detection Sensor: Identifies longitudinal weld seams optically to position them away from high-stress bend zones.
Robot Arm Interface: Standardized communication protocols for integrating automated material handling systems.
Punching & Notching Station: Hydraulic punching module for secondary hole creation prior to bending.
Tooling & Dies
Bend Die:
Hardened steel tool defining the main radius of the bend.
01
Clamp Die:
Moves with the bend die to lock the tube securely during rotation.
02
Pressure Die:
Supports the outer wall of the tube as it is drawn into the bend radius.
03
Wiper Die:
Positioned behind the bend die to clear the inner radius gap and prevent wrinkling on thin-wall applications.
04
Mandrel:
Inserted into the tube interior to maintain cross-sectional roundness and limit wall flattening.
05
Why Choose Us
Factory Testing Protocols: Every unit undergoes a 72-hour continuous dry-run test followed by full-capacity sample bending validation prior to dispatch.
Standardized Components: Key structural and electrical elements use global industry standards to simplify long-term maintenance and replacement.
ISO 9001 Quality Management: Production facilities follow strict quality control standards from raw material verification to final calibration.
Technical Documentation: Shipments include full engineering schematics, maintenance manuals, and detailed spare parts catalogs.
FAQ
Q: What is the minimum bend radius achievable on thin-wall stainless steel tubing?
A: With a fully supported tooling setup-including a segmented ball mandrel and a fitted wiper die-the machine achieves a center-line radius down to 1.0 times the outer tube diameter while keeping ovality under 5%.
Q: How does the control system handle material springback variations between tube batches?
A: The system allows operators to input material elasticity parameters or calibrate angles using test-bend data, ensuring target tolerances remain consistent across different material lots.
Q: What information is required to select the correct tooling for a project?
A: Tooling selection requires five primary inputs: Material Grade, Outside Diameter, Wall Thickness, Centerline Radius, and Maximum Bending Angle.
Q: Can this machine perform both push bending and draw bending in the same cycle?
A: When configured with the optional Multi-Stack Tooling system and roll-bending control module, the machine can execute fixed-radius draw bends and variable-radius push bends within a single program sequence.