Often in the household there is a need for bending metal shaped pipes. No construction on the site can do without giving the profile the necessary shape, regardless of whether it is a greenhouse, a canopy or a pipeline of complex configuration. It is impossible to carry out such work accurately and smoothly without using a special device.
Many use industrial equipment for these purposes, but this is an expensive solution to the problem. Therefore, craftsmen are trying to make a homemade pipe bender for a profile pipe with their own hands, which can fully meet the requirements of the owner. Such a device will avoid creasing and deformation of the pipe, if necessary, give it a certain bending radius.
Features are flexible profile pipes
Regardless of the profile of rolled metal, the essence of its bending is to give the material a certain shape. Full or partial bending of the profile pipe is carried out mainly in two ways: by exerting only pressure on the desired length of material or by pre-heating the pipe section for bending.
When performing the bending process on a metal pipe at the same time act:
- compression force, which is directed to the inner surface of the material;
- tensile force, the action of which is carried out from the outside of the bending section.
Under the influence of these multidirectional forces, certain difficulties arise that are characteristic of a profile type material:
- The outer wall of the metal pipe is subjected to tension. At some point, there is a danger that it may not withstand and burst.
- On the inner side of the pipe under the influence of compression forces, wrinkles resembling corrugations can occur, which significantly reduce the conductivity of the material.
- The possibility of losing the correct location axis. Individual parts of the pipe after bending can be in different planes of the product.
Therefore, when bending a profile pipe, it is necessary to take into account not only the mechanical characteristics of the material, but also the cross section, wall thickness and the required bending radius.
Pipe bending methods
Heating the bending point with a gas burner increases the ductility of the metal pipe. But regarding the heating of the pipe bending place, there are regulatory recommendations only for the round section. But when determining the method of bending pipes of rectangular or square section, one has to rely on the experience and advice of experienced craftsmen. So:
- Profile pipes up to 10 mm high can be bent without preheating the bend.
- In the case when the profile is more than 40 mm, it will be necessary to heat the metal before bending the pipe.
Cold bending pipes
It is possible to bend profile thin-walled pipes without preliminary heating manually. To avoid undesired pipe deformation, these operations are recommended using sand filler, which is poured into the pipe and protects it from fracture. You can also insert a spring into the cavity of the pipe, which increases work efficiency.
But in practice, the craftsmen try to use home-made pipe benders for the profile pipe, which allow you to get almost any bending radius of the material without much physical effort.
Device Features
From the name "pipe bender" it follows that this device is designed to help a person bend pipe parts regardless of material (steel, plastic, aluminum and others). The bending angle can vary up to 180 degrees.
You can make a homemade pipe bender for a profile pipe with your own hands, based on drawings and diagrams of professional devices. However, every craftsman is able to make some design changes aimed at improving the quality of the operation.
The main criteria for bending a profile pipe are: the method of bending and the type of drive device.
Unit classification by drive type
One of the most important criteria by which to make homemade pipe benders is the type of unit by the type of drive unit.
The following devices are available:
- Units of electromechanical type. They are considered the most convenient to use. With their help, you can get the most accurate bending radius, while minimizing the deformation of the profile. The electronic devices present in such pipe bender systems make it possible to accurately calculate the required pressing force.
- Hydraulic apparatus. They can be stationary and manual. They are used more often in industrial enterprises, since hydraulic homemade pipe benders for large diameter pipes are very difficult to maintain at home.
- Bending of profile pipes of a small cross section is often carried out by hand-held devices. It is these units that are easiest to do with your own hands. They use mechanisms that are manually actuated to apply force to the pipe.
Bending methods
According to the necessary impact on the product during work, homemade manual pipe benders for a profile pipe can be classified by the following methods:
- The method of winding, in which the pipe is pressed against the roller of the device, and then a stop element is installed at the bend. When the roller rotates, the pipe wraps between it and the stop. The template itself and the bent workpiece must be movable.
- The easiest way to bend a profile pipe is by running. The template in such a device remains stationary. The workpiece is firmly clamped, and the pinch roller, rotating, bends the pipe.
- The rolling or rolling method is more complicated. It involves the use of a central roller and two support. The central roller relative to the supporting elements is installed in accordance with the expected bending radius and tightly presses on the profile pipe.
- With the crossbow method, the workpiece is pressed against two stationary rollers and bent using a template placed on the stock.
All these methods, except for rolling, can lead to a gap in a thin-walled pipe, therefore, when performing work, special accuracy and accurate calculation of the bending parameters are required.
Making a simple fixture
The simplest homemade pipe bender is a template type device. It is a wooden structure, since the template for it is made of wooden boards, which are 2-3 cm thicker than the size of the bent workpiece.
Boards must be cut with a slight slope so that the profile does not slip when pressed. The size of the semicircle is selected in accordance with the radius of the bend. Prepared boards are attached to each other and to the base in any convenient way. At the same time, a stop element is installed on the edge of the template, on which the pipe will rest. The gap between them should be slightly larger than the profile size.
Of course, the advantage of a homemade pipe bender (pictured) is its simplicity and cheapness, however, if you need to bend the pipe from a different angle, you need to make another template.
The principle of operation of the device
After making a homemade manual pipe bender, you must:
- Insert one edge of the profile pipe between the template and the stop.
- Grasp the other end of the workpiece and smoothly bend it according to the template.
- For reinforcement, a strong rod can be inserted into the workpiece or a larger diameter pipe can be put on. This will create an additional lever and make the bend better and more accurate.
To avoid fracture of the pipe, do not start bending from the center of the template.
Another option for using a simple template is to use metal hooks instead of a wooden semicircle. A positive quality of such a device is the ability to rearrange the hooks, which will allow you to change the radius of bending.
A simple template device is mainly used for working with aluminum or copper profiles. If necessary, handle a steel thick-walled blank of a homemade pipe bender, you can use a manual winch.
Hand Snail Bender
The bending technology in such a device implies the use of the circular bending method, which can eliminate the risk of cracking or creasing of the profile pipe. The bending of the pipe occurs when a roller is rolled over it, which presses the workpiece to the main wheel.
Home-made manual profile pipe bender – snail consists of several parts:
- pinch roller;
- Working wheel;
- bearing fork;
- base of fixture.
Phased device manufacturing
Having prepared all the necessary materials for work according to a previously thought out drawing, you can proceed directly to the assembly of the device.
In order to prevent some inaccuracies and errors, you need to make a homemade pipe bender with your own hands in stages:
- First of all, it is necessary to turn a roller and an impeller on a lathe. It is not worth saving on these details, you need to make a trench for a large section of the profile, as well as a bearing seat.
- In the same way, you need to prepare the shafts for these devices. The thickness of the rollers should correspond to the diameter of the bearing used. You can make a device without a bearing, but in this case it will be more difficult to work with a homemade pipe bender.
- The next step will be the manufacture of sheet metal back wall and side surfaces, as well as a lever for the mechanism.
- Then you need to drill holes for the roller and wheel, and also weld all the parts of the fork, paying particular attention to the rectangular design. It is better to weld the lever of the device from a pipe.
- The final step will be to mount this structure on a massive base, first you need to weld the axis of the stationary impeller. And the assembled fork is installed on this bed.
- To fix the profile retainer, you need to weld a small square piece of metal.
Hydraulic Profile Bending Machine
The process of making a homemade pipe bender for a hydraulic type profile pipe is quite laborious. To make such a device with your own hands, you will need:
- shoe;
- hydraulic jack;
- channel;
- metal plates;
- three clips.
First you need to make a structure from the channel, equipped with a shoe and a roller. Then the device frame is made. The platform of the machine is reinforced with metal plates. After that, a jack is installed and fixed.
The rollers are placed in the channel at the same height and are bolted. A shoe is installed at the very bottom. All these elements are placed depending on the required bending radius.
Pipe bending technology
The process of working on such a machine cannot be called too complicated. It will take in a certain sequence to perform just a few actions:
- Insert the workpiece into the shoe and secure it on both sides.
- Next, slowly turn the jack handle.
- The force from the hydraulic device is transmitted to the pressure roller, which bends the workpiece.
The bending operation can be interrupted at any time. To release the workpiece, you need to turn the jack handle a few turns in the opposite direction.
Of course, the process of making a pipe bender cannot be called simple. This will require many technical knowledge and the ability to use welding. But still, an independently made device for bending a profile pipe will bring the master a lot of positive emotions.