Selected according to tube OD(outside diameter) and CLR (center line radius) requirements.
Manufactured of hardened steel and with the fixed clamp jaw welded or screwed into the bending die to obtain best possible transition between the radius and the straight part. The bending die should be a good fit onto the machined register on the bend head, and must always be securely fastened down.
2.Clamp Die
Selected according to tube OD and match the Bend Die.
Manufactured of hardened steel. Recommended clamping length: three times the tube diameter. For shorter clamping lengths the groove can be fluted to obtain a better grip. In other cases the groove can be milled for bend in bend configurations. The clamp die should be adjustable for vertical alignment and parallel contact along its length.
3.Pressure Die
Selected according to tube OD and match the CLR (centre line radius) of the Bend Die.
Manufactured of hardened steel,pressure die length is critical and is determined by bending radius,bending degree and tube OD. Formula:assuming that full 180 degree bends are required: CLR x 3.14 ÷ 180 x 195 + 3 x tube OD Example: 1” OD tube x 4” CLR 4” x 3.14 = 12.56” ÷ 180 x 195 = 13.60” + 3” = 16.60” The Die should be adjustable for vertical alignment.
4.Mandrel
Selected according to tube OD,tube thickness,bending angle and bending radius.Recommended for small radii and thinner wall thickness.
Manufactured of hardened steel or Ampco Bronze. When setting up Ball Mandrels it is important to ensure that the leading end of the shank is on Centre Line when bending.The Balls should be forward of this point. IMPORTANT: Setting of the Mandrel should be carried out with the Mandrel fully forward not retracted.
5.Wiper Die
Selected according to tube OD,bending radius for use with a ball mandrel. Recommended for small radii and thinner wall thickness.
Manufactured of hardened steel or Ampco Bronze. The purpose of a wiper die is to stop wrinkles from forming on the inside of the bend at the tangent point.
6.Collet
Selected according to tube OD. Collet only used on CNC machine.
Marking on tube centreline a) Check the alignment of Pressure Die and Clamp b) Check dimension of tube in relation to tool set c) Check to ensure all tools are free of dirt and scale – if not clean all tools d) Check that tube is clean and free of oil and grease
Hump at the end of a bend a) Mandrel advanced too far forward – reset to tangent b) Check free movement of Pressure Die
Deep scratches in bend/Wiper Die Area a) Increase rake or relief of Wiper Die b) Check Wiper Die edge for pitting or scores – if present recut or replace c) Check that Wiper Die is not dry, Lubricate if required
Tool marks on tube in clamp area a) Check alignment of Clamp b) Check Pressure of Clamp on Tube c) Check that Clamp is clean and free of oil and grease
Wrinkling in bend area a) Check condition of Wiper Die – if worn recut or replace b) Decrease rake on Wiper Die c) Advance Wiper closer to tangent point and check that position is correct and that Wiper is secured correctly
Tube breakage in bending a) Check that elongation of material is suitable for bending b) Check Clamp and Pressure Die settings c) Check position of Mandrel d) Check that Pressure Die is moving freely
Tube collapses either with or without wrinkling through full bend a) Check for Clamp Slip b) Check that there is sufficient Pressure Die Boost c) Check position of Mandrel
Wrinkles on bend with all tools in correct position
a) Check Mandrel size and fit b) Increase Pressure Die force
Excessive springback a) Check that Pressure Die is not holding the tube back during bending b) Check ductile strength of tube and programme overbend to compensate
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