Works with metal products often involve operations that allow them to change their shape. To create structures with specific characteristics, in particular, cutting, folding and bending may be required. The latter kind of operations is one of the most difficult. This is especially true for the processing of pipes for which it is necessary to maintain throughput. That is, the internal space at the inflection point should provide the optimal volume of passage of the working medium. A mandrel pipe bender, which performs its function in different modes, including automatic, helps to cope with this task qualitatively.
General information about the mandrel pipe bender
In the classic version, this tool focuses on working with thin-walled pipes. This means a certain specialization of its function, but there are quite a few areas in which such pipes are used. At the same time, the very work with thin-walled products imposes a great responsibility on the tool used, since any deviation from the technique of the operation may spoil the workpiece. In this regard, the most sensitive manual mandrel pipe bender, which is used in the household or by workers in small workshops. As for materials, most mandrel models are able to work effectively with copper, stainless steel and aluminum. Depending on the material of the pipe, the equipment settings are also selected. It already depends on the design features of a particular unit and its functionality.
Device and principle of operation
The base of the machine is usually represented by high-strength steel alloys. Functional equipment with a head is often made of cast iron - this is the most subject to wear part, which provides the bending moment. The designs differ in the ways of performing the clamping action - there are upper and finger clamps. In the first case, the operator has the ability to linearly move the pipe due to the gap between the locking mechanism and the processing surface. The finger mandrel pipe bender, in turn, does not imply the load on the lever. Some designs use a hydraulic booster to improve performance. During the work cycle, the clamp bar follows the workpiece to be machined, and then takes its initial position. The hydraulic cylinder clearly regulates the manipulation of the strap, setting also the plane of rotation of the product. Physically, actions are implemented through one or more drives.
Varieties
Three types of pipe benders with a mandrel mechanism are distinguished. These are the mentioned manual, semi-automatic and fully automated models. All of them are united by the fact that the principle of providing mechanical action is realized by means of roller tooling, on which, in fact, the workpiece is wound. Hand tools are characterized by low power and the need to connect the operator to the direct work process. Again, the user controls the operation of the hydraulic system. A semi-automatic mandrel pipe bender is more convenient in operation, which entrusts the operator with only a part of the working actions, the list of which can vary depending on the design. Automated machines not only can perform the entire work cycle on their own, but also interfaced with other equipment. Such models are often integrated into full-fledged production lines, in which bending is only one of the operations in the overall manufacturing process.
Features of CNC models
These are the same automated lines, but supplemented by numerical program control. What does this mean in practice? The role of the operator in semi- and automated machines is usually minimized, but still it is. In this case, it consists in the fact that the staff sets a special program for the automatic operation of the machine. The mechanisms operate independently, but strictly according to a given algorithm. In particular, a CNC mandrel bender can be programmed with parameters such as clamping pressure, mandrel location, turning speed of the bending unit, etc. At the same time, the machine memory can save various data on the characteristics of finished pipes, which further simplifies the technique product quality assessment. Thus, for example, defects, deviations from standard indicators and other product features are recorded.
Positive feedback on working with the tool
Experienced users of equipment that is used in working with metal products, note several advantages of drone units. First of all, this is the exception of the characteristic undulation or corrugation, which is formed when using other devices for bending - as a rule, not specialized. The second positive point is that the deformation is not accompanied by a thickening or narrowing of the walls. Again, unprofessional bending often leads to stretching of the metal, and this is dangerous from the point of view of further operation of the product at critical facilities. The advantages that an automatic mandrel bending machine with the same CNC have are also highlighted. Such equipment allows you to get not just an accurate bend, but relatively high-speed qualitative deformation in mass production.
Negative reviews
Aggregates for folding with a mandrel mechanism require careful maintenance. The mechanics in this case are represented by complex mating elements that need constant maintenance. In addition, many operators of such installations note their limited capacity in terms of working with multi-format pipes. As a rule, one machine in the basic configuration can serve workpieces in a narrow size range - this also applies to wall thickness and overall diameter. Along with this, users point out the fact that the mandrel pipe bender takes up a lot of space on the work site, not to mention its significant mass. Accordingly, the cost of transportation and installation.
Price issue
The simplest manual models from the budget segment can cost about 50-70 thousand rubles. As a rule, they work with small-format pipes, realizing the bending moment through physical effort. The middle segment is represented by units with automation elements. This can be a functional and productive mandrel pipe bender, the price of which will be about 200-300 thousand, depending on the configuration. The higher the autonomy and optional content, the higher the cost. Automated CNC machines are available for 500-700 thousand and this is not the limit. Equipment of this class is often developed with an initial bias towards industrial use at the facilities of specific enterprises.
Homemade pipe bender device
The unit is usually formed by a massive metal frame to which other functional units and components are attached. The shaft of the housing is equipped with bending multi-grooved rollers, clamping blocks and eccentric elements. The last components of the snap and will act as clamps of the workpiece. Also, to perform the operation, an emphasis is required, from which the direction of the pipe will be set. This system is most often composed of pressure pads, staples and wedges. So that you can effectively control the mandrel pipe bender with your own hands, a guide assembly formed by a screw and a special steering wheel is introduced into the design.
Conclusion
Metal pipes rarely deform already in the workplace. Typically, the same bend is performed in the factory according to a given design or in a standard format. Nevertheless, there are situations when, during the installation operations, the operational execution of this procedure may be required. For this case, and designed manual mandrel pipe bender. In some modifications, it allows you to carry out work even in the field, which often saves time on installation activities. More reputable automated plants do not require regular movement - they are just used as part of factory equipment when you need to get a high-quality result when processing a large number of workpieces.