Shaped tubes of square or rectangular cross-section are widely used in construction and repair. Of them made gazebos, sheds, greenhouses, frames for various structures, fences. To give an element a curved shape, using a special device - bender.
Complex spatial structure produce specialized workshops on high-precision high-power machines. At home, the more often used hand tools for industrial manufacturing or homemade. If you want to bend a few elements, tube bender for profile pipe is advisable to make their own hands. Simple reliable tool to cope with the task better than the factory, the cost several times cheaper.
The operating principle of the tube bender
Bending machine for bending pipes at an angle up to 90 °. Such treatment of the hard-metal element avoids welding nozzles and create threaded connections.
When bending the principle of cold mechanical deformation. The material is not subjected to the adverse effects of high temperature. Metal rollers are placed between the static apparatus and the movable pressure roller exerts a force, the bending profile at the desired angle.
To avoid deterioration of performance and failure of metal, limited bending radius of the tube.
Its minimum value depends on the type of material - steel, copper, aluminum - and wall thickness. In this section of the thinning does not exceed 20-25%. As a result, plastic deformation becomes curved profile without sacrificing strength.
To get a corner plot configuration, use the local influence. The force applied dot. Bending is formed by extrusion.
Profilegib different from conventional bending tool for a round pipe, as for the deformation profile, more resistant to bending loads. To produce arcs or arches preform is pulled in a rolling machine with one or more rollers and a large bending radius.
Types benders and construction
Construction industry produces contour-shaping machines in a wide range. They are intended for the treatment of metal with different technical characteristics and specific tasks.
Hand
Compact mobile devices used for the manufacture of the elements arc shaped tubes of small dimensions. Hand Tools is powered by the muscular effort of man.
Variety of manual benders:
- leading to the central shaft;
- with movable extreme roller;
- turning.
The manual bending tool with the drive shaft includes a central base, the two support rollers and one movable. Exposure to regulate the pressure collar screw inserted into the upper portion of the mechanism.
The pipe is pulled through the shaft by hand using the handle and attached to the axes of the chain rollers. The pressure increase, lowering the pressure bolt. Profile gradually bent and acquires the shape of an arc.
Hand profilegib can be equipped with movable extreme roller. It is fixed to the frame, connected to the frame strong hinges.
Lift height change jack, lifting edge of the table. Handle for pulling metal attached to a central fixed castors.
To produce sharply bent portions of the pipe 20x20, 30x20 and 40h20 mm with a wall thickness of 1.5 mm is used manual rotary benders. They allow to bend the profile at an angle of 360 °.
The device is fixed to the frame or the table horizontally, the metal structure is inserted into the bore size. the long arm is crimped profile turning around the bending template and the form.
hydraulic
In such benders effort forced a hydraulic motor. Hydraulic pressure transmitting portion of the pipe to 12 tons, enabling even larger bend the workpiece.
Hydraulic benders are commercially available in two versions:
- Manual. The pipe is inserted into a removable template suitable size - supporting shoe, which securely locks the product in bending. Cylinder actuated handle is returned to its initial position by means of the check valve. Portable tool, used for processing profiles up to 50 mm.
- With the electric drive. More powerful devices allow to bend the pipe section up to 150 mm and a wall thickness of 3 mm. Electric motors are provided with two-stage telescopic cylinders. Thanks to this great effort developed at the end of the stroke.
Hydraulic benders have high productivity and treated structure with high accuracy. To impart the desired bending angle of the workpiece on the device is a graduated scale.
Electromechanical
Electric roller professional profilegib - tech equipment for the production of curved thin and thick metal structures. It allows you to automate a lot of work.
Electromechanical benders may be manual or stationary. The first is used for bending pipes with a diameter of 50 mm under conditions where the available power. Second - Overall machines with powerful engines to be installed in industrial plants. They are controlled by CNC operators.
Profile bending form one or more shafts. By way bending distinguish benders:
- Spooling - member is bent by rotation around a fixed pulley;
- obkatyvali - curvature parts attached movable roller when passing it to the pressing pattern;
- Rolling - profile drawn through a three roller, two of which are stationary and the third one is moved relative to the other;
- embossing - works by type crossbow retractable plunger flexes preform with a nozzle formed by a pipe of a certain size.
Steel profiles often bent rolling machines, where the force is more evenly distributed.
The roller benders rolled square or rectangular section experiences less deformation, which preserve the stability of the walls.
Manual bender for profiled pipes with their own hands
To bend a tube with a profile cross section small size without bending tool, masters use the desired curvature of templates made of metal or wood. The preform is pressed by hand to the edge of the segment, rigidly fixing one end.
Thin-wall element can be deformed in a hot state. Preheat portion blowtorch to a temperature of 350-400 ° C and by applying a manual force profile impart an arcuate shape.
If you use simple methods do not allow parameters of the product can be designed for manual roller bender shaped tube. With it, the arch is made to the arc and canopies, greenhouses and other structures of complex shape.
The necessary materials and tools
To make the device, you will need:
- channel №8 and №10 for rigid frame;
- 2 rollers of hardened steel with steps for the profiles of different heights or limiting rings;
- roller with notches for the movable shaft;
- ready housing units;
- 2 or 3 gears or "stars";
- steel chain;
- clamping screw;
- thin tube to the gate;
- lever;
- welding machine;
- drill;
- "Bulgarian";
- hammer.
Still need pins, screws, threaded bushings, washers. For the treatment of the finished structure will need paint and grease.
Blueprints
Drawing - a foundation that will help make bender without blunders. When consuming the metal is especially important.
The Internet has finished drawings. With enough experience, they easily understand and adjust to their capabilities.
Imagine the approximate bending tool device can be in the study of the factory counterpart, and then develop a detailed outline of his model.
Stages of construction assembly
The sequence of operations for the manufacture of home-made roller bending tool:
- Cut a channel size uprights and bases.
- Drill holes in the frame members under the mounting clips.
- Boil of channel supporting frame with racks.
- Cut and weld of channel body with holes for mounting the drive roller. The shaft must rotate easily inside.
- Secure clamping screw to the resulting box via bearings. At the top of the screw to drill a hole under the gate.
- Inserted between the rack enclosure with the drive roller. The design should be free to move vertically. Top cover fasten with a nut screw.
Driving of the pressing mechanism - Screw the bearing assemblies to the frame.
- Insert the gate in the opening of the pressure bolt.
- On the axle shafts from the outside to spread the gears on the key or a tapered split sleeves and nuts. The third "star" attached to the rack. Wear chain compressed onto the sleeve to the handle.
- Conduct pilot tests, if necessary, make adjustments.
The last step - to disassemble, clean metal burr, paint the fixed parts, assemble. Nodes that are subject to friction during operation, process lithologic or other grease.
To bend the workpiece, it is placed on the fixed rollers, the presser screw is lowered until it stops and is pulled via the handle spinning alternately in one and the other side.
After each rolling screw tightening collar. When the arc acquire sufficient curvature screw nut fixed nut. This will allow to bend a few arches of the same radius.
This homemade benders can even be used for professional purposes. He "overpower" profiles up to 60x60 mm tubes 3 or simultaneously with the cross section 20 mm in width.
Details of manufacturing process of a manual machine can be seen here
hydraulic tube bender
Using a hydraulic bending tool greatly simplifies both operation and its design. The simplest device is a frame with two supporting rollers. Mechanical action on the profile provides the jack with a nozzle-shoe.
Hydraulic device designed for corner bending, since the deforming force is transmitted to the portion of small length.
Tools, materials and drawing
For the self-production of hydraulic tube bender will require:
- "Bulgarian";
- welding machine;
- hydraulic jack;
- channel and corner of the rack;
- shoe stop;
- rollers or guides.
assembly steps
Driving assembly for a simple hydraulic tube bender:
- Cut-size frame area and weld a support pad with racks.
- Welded to the frame horizontal bed of channel.
- To control the bending radius in the frame to drill several holes.
Traverse for adjusting pipe bend radius - Set the rollers to the desired position.
- Wear shoe on the rod of the jack, set gidromehanizm to the bottom of the frame.
To bend the workpiece, it is placed between the pad and the support rollers. Gradually increase the load of the jack lever.
When the desired bending angle is obtained, open the bypass valve cylinder, the piston of the jack is lowered and the finished part removed.
For thin-walled profiles used machinery load capacity of 5-8 tons to bend powerful pipe hydraulics should have a great opportunity -. 12 m.
Video about the production of hydraulic tube bender:
Homemade hydraulic tube bender can be easily disassembled. The jack can be replaced by more convenient and powerful. To make it easier to perform all the operations, sometimes the design is adapted for horizontal operation.
The most common defects are flexible hydraulic tube bender - the formation of depressions, corrugations, cracks or breakage of the profile. To avoid this, it is recommended to use factory-made shoes. They are made of solid steel, aligned and uniformly transfer the load on the pipe wall.
