Heavy Duty American Made Rotary Draw Tube Benders

All Electric CNC Tube Benders

Distributed Exclusively in North America By Horn Machine Tools, Inc.

Horn Metric Series Benders

Horn Machine Tools, Inc. Madera, CA. - Indianapolis IN. St. Paul, MN
Mandrel Bending Basics
www.hornmachinetools.com

Tel: 559-431-4131

Rotary Draw Mandrel Bending

Tube forming process where the tube is drawn over a mandrel and formed around a radius die while supported on all sides ID and OD

Shown here:

HMT #2E CNC

Difficult Bending Applications

HMT can provide the solution to fit your exact need

5 OD x 5.5 CLR S/S 304 x .065 WT

1.5 OD Brass on 1xd CLR x .035 WT

2.25 OD x 2.25 CLR Inconel x .028 WT

Tight Radius Thin Wall Square or Rectangle

Tight Radius Thick Wall Boiler Tube

Controlled Wrinkle HVAC Heater Tubes

Mandrel Bending Concepts

Three Main Concepts

The tube must be supported on all sides, ID and OD. A balance of pressure must be achieved, so material can be put into a plastic state and not deform. Tube must Flow over the mandrel

Tube must be supported on all sides, ID and OD.

If there is any unsupported area of the tube, the material will flow into that area and cause a defect.

Bend

Wiper

Mandrel

Clamp

Pressure Die

Tooling in unclamped position

Tooling in clamped position

A balance of pressures must be achieved

2 Bend

Strive for: Balance pressures between all five dies Avoid: Over-pressure adjustments which cause resistance or drag Under-pressure adjustments which allow tube escape Containment
Wiper

Mandrel

Clamp 3

Pressure Die

1- Wiper Rake Angle 2- Wiper Tip Adjustment 3- Mandrel Adjustment

4- Clamp Die force 5-Pressure Die force 6-Pressure Die assist force

Tube must Flow over the mandrel.

Shank Lube Port Work Shoulder Balls

Tube Bending Distortion

Wall Thinning and Ovality

Inside wall thickens Ovality

Distortion of the natural axis As shown by the weld seam Outside thins out Wall Thinning

Normal Wall Thinning = 8-15% Normal Ovality = 10-20%

Mandrel Bending Components

Machine Tooling Set-up Material Lubrication

Bender Type and Condition Design and Condition of tools Proper Set-up and Adjustment Material Type and Quality Proper Type and Amount

Horn Bender Size Range

Made in USA

HMT #1

HMT #1-1/2

HMT #2

Up to 1 IPS Pipe or 1.5 tube

Up to 1.5 IPS Pipe or 2 tube

Up to 2 IPS Pipe or 3 tube

HMT #3

HMT #4

Up to 3 IPS Pipe or 5.5 tube

Up to 4 IPS Pipe or 6 tube

Complete Size Range 10mm to 150mm Single and multi-stack

CNC Benders Twin Head Benders Robot Benders

16mm

20mm

30mm

40mm

65mm

76mm

100mm

150mm

Twin Head

HORN Metric Series Benders

Series TSR Series TDRE TBRE TMRE Series TNC/TNCPB

Single Tool Stack CNC benders

Multi Tool Stack CNC benders Push bending & rolling

Single and Multi-Axis NC benders

Series F

Series EMR/MBRE

Horn Metric Series

18mm to 175mm Capacity NC and CNC Tube Benders

Twin Head CNC benders

Left\Right multi-stack CNC benders

TNCPB Capacity Range: Up to 2 A50TNCPB Up to 3 A75TNCPB Up to 3.5 A89TNCPB Up to 4 A100TNCPB

Horn Metric Series TNCPB

Standard TNCPB Features: Drop Away Clamp Servo Plane of Bend Control Distance Between Bend Stops Mandrel & Wiper Pressure Die Assist

A89TNCPB SEMI-AUTO 3 AXIS BENDER

SERVO CONTROLLED PLANE OF BEND CARRIAGE

HORN TNCPB METRIC SERIES TUBE BENDERS

OFFER VALUE PRICED THREE AXIS BENDING OF COMPLEX TUBE SHAPES WITHOUT THE FULL CNC MACHINE COST.

A89TNCPB

Typical Tooling Layout

Tooling & Set-up Bend Die

Keyway Thru Hole

Centering pocket Centerline Radius

Centerline Height Bend die with square block insert

Best for difficult applications

Most economical

Interlock for Clamp and PD

Bend die with concentric bore insert

Non-Interlock Bend die

One piece bend die with no insert

Tooling & Set-up Bend Die Types

Spool Die

Multi-Stack Dies

One Piece

Flange Style

Partial Platform

Tooling & Set-up Bend Die Inserts

Typical spool type bend die with flat back type insert, standard design, economical to make

Premium type concentric bore insert, best for difficult applications, advanced design, expensive to make

Tooling & Set-up Clamp Die

Clamp Die

Clamp Die Force

Tooling & Set-up Clamp Die

Strive for optimum clamp length and grip surface combination. The more aggressive the grip surface, the shorter the clamp length can be.

Gap

Clamp Die shown interlocked with Bend Die. Set-up Notes: Alignment of clamp die and bend die tube grooves. Square-ness of clamp die to bend die, top to bottom, side to side. Must have a gap between the dies, not bottomed out. Correct force applied to hold the tube from slipping. No excessive force applied that will cause die tilt or clamped thru mandrel

Tooling & Set-up Pressure Die

Pressure Die Assist Force

Pressure Die

Pressure Die Close Force Avoid using excessive pressure die close force, this causes resistance in the bend process

Tooling & Set-up Pressure Die

Gap

Pressure Die Shown Interlocked with Bend Die

Tooling & Set-up Mandrel

Plug type mandrel, for Easy bending applications

Aluminum Bronze mandrel For bending stainless and Other alloy materials Note single ball mandrel, With normal pitch

Hard chrome steel mandrel For bending carbon steel or Non-ferrous materials. Note 4 ball mandrel, with Close pitch.

Tooling & Set-up Ball Mandrels

2 1

Tooling & Set-up Mandrel Assembly

Tooling & Set-up Mandrels

Tooling & Set-up Mandrel Info

Mandrel Clearance Typical mandrel to tangent settings

Normal (2D) Moderate (1.5D) Difficult (1D)

.015 to.025 /side .008 to.015 /side .004 to .008/side

Tooling & Set-up Wiper Dies

Insert type wiper die tips Square back type wiper

Replacement cost is lower Replacement time is quicker Initial investment higher (Holders) Allows close tangent positioning by CNC May not be suitable for some difficult applications

May be re-sharpened (30% of new cost) Works well for difficult set-ups Easy for rookies! Longer tangent positioning length by CNC No special holder required, fits all benders.

Tooling & Set-up Wiper Dies

Inserted Wiper tip and holder

Various square back Wipers

Mandrel & Wiper Selection

1) Determine the Wall Factor WF 2) Determine the D of Bend 3) Consult Chart to determine proper die set-up. (next page)

Mandrel & Wiper Selection

Determine the wall factor and D of bend on previous page Then select the appropriate mandrel/wiper configuration from the chart below. These are recommendations based on average conditions. D of Bend

Wall Factor
1 M1 M 1W M 2W M 3W M 3W M 3W M 4W M 4W M 4W M 4W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W

10 15 20 25 30 35 40 45 50 60 70 80 90 100 125 150 175 200 225 250 275

1.25 M1 M 1W M 1W M 2W M 3W M 3W M 3W M 3W M 3W M 4W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W

1.5 M1 M1 M 1W M 1W M 2W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W U TW 1 0 W U TW 1 0 W

2 M1 M1 M1 M 1W M 2W M 2W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 5 W TW 6 W TW 7 W TW 1 0 W U TW 1 0 W U TW 1 0 W U TW 1 0 W

2.5 P P M1 M1 M 1W M 2W M 3W M 3W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 5 W TW 7 W TW 9 W TW 1 0 W U TW 1 0 W U TW 1 0 W

3 P P M1 M1 M1 M 2W M 3W M 3W M 3W M 3W M 3W M 3W M 3W M 3W TW 5 W TW 5 W TW 6 W TW 9 W TW 1 0 W U TW 1 0 W U TW 1 0 W

P M1 M1 M2 M 2W M 2W M 2W M 2W M 3W M 3W M 3W M 3W M 4W TW 4 W TW 6 W TW 8 W TW 1 0 W U TW 1 0 W U TW 1 0 W

Selection P=Plug Mandrel M1 = 1 ball M2 = 2 ball T = Thin wall UT = Ultra Thin wall W = Wiper

Purple shaded area = Standard mandrel, Yellow shades area = Thin Wall Mandrel Blue shaded area = Ultra Thin Wall Mandrel

For machines equipped with Plane of Bend positioning.

Collets

Collet pads bolt Into the face of the master collet

Flange style Bolt in collet pads 3-5 minute Change out time

Quick Change collet pads 30 sec Change out time

Uses a pneumatic Tool to change collet pads

Materials
Material
Aluminum Soft T-zero grade Aluminum Hard T-4 to T-6 Copper Brass Carbon Steel Aluminized Steel Stainless 300 series Stainless 409 Inconel Titanium

Bending Properties
May be formed down to 1 x d radius. When forming on tight radius, bend Speed must be slow. Light pressure used. T4 may be formed down to 2xd radius, T6 may be formed down to 3xd. Forming on tighter radius may cause orange peel and cracking Same principles as aluminum, soft copper bends very well, harder grades require larger radius. May be formed to tight radius down to 1xd when properly annealed Most common materials used C.R.E.W. and H.R.E.W. can be formed down to 1xd radius. DOM and harder materials formed down to 2-3xd. Common material for exhaust applications. May be formed down to 1xd. Quality of material varies with batches and mills. Can load up on tools. Can be formed down to 1xd, quality of material very important, A269 series is excellent. Lubrication very important. Less expensive version used for exhaust applications, quality varies widely. Uses less pressure than Stainless 300 Used for high temperature exhaust applications, very difficult to form. Tooling, material and set-up are crucial. Material used for aircraft and some exhaust applications. Forms similar To stainless

Lubrication for tube bending

Brand Tower Oil (312) 927-6161 Type Oil Used For Water soluble oil used for Steel, Aluminum, & non ferrous. Part # 4100

Irmco (847) 864-0255

Gel

Water soluble Gel type paste, used for steel, Aluminum, & non Ferrous. Part # 460-80A Non Water Soluble oil used for Stainless Steel. Part# How-to-Draw 3105

Houghton International (610) 395-8440

Heavy Oil

Summary of Mandrel Tube Bending

The successful mandrel bending operation:
Correct machine for the application Correct tooling for the application Correct material and lubrication Trained operators Good preventative maintenance Training program for operators

Hot tips for the operator:

Keep the machine and tooling in good working order Stay in contact with the OEMs of machine and tooling Make good set-ups a priority Make one adjustment at a time Dont use excessive pressure to cure problems Explore new technologies and techniques

Heavy Duty American Made Rotary Draw Tube Benders

All Electric CNC Tube Benders

Distributed Exclusively in North America By Horn Machine Tools, Inc.

Horn Metric Series Benders

Horn Machine Tools, Inc. Madera, CA. - Indianapolis IN. St. Paul, MN
Contact us for help with your Tube Bending Application Visit us on the Web at Tel: 559-431-4131 Fax: 559-431-4431 Representatives and Application Assistance nationwide

www.hornmachinetools.com