Experienced help with your tube fab and tooling needs
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Experienced help with your tube fab and tooling needs
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Here is how to use the tube bending correction chart: The vertical columns are symptoms, the horizontal rows are possible causes. Go down the column of symptoms until you see a familier problem and click on the intersection.
a1 Wrinkling caused by slippage - Not enough clamp force to overcome drag from mandrel/wiper die or pressure die (assist). It is better to first identify the reason for the slippage and correct it before increasing the clamp die force. b1 Wrinkling caused by excessive boost - pressure die assist is forcing too much material towards the tangent point e1 Wrinkling caused by mandrel behind tangent - mandrel is not in position to iron out the wrinkles and needs to come forward f1 Wrinkling caused by wiper die behind tangent - wiper die is not in position to iron out the wrinkles and needs to come forward h1 Wrinkling caused by worn or oversized tube grooves - bend die and or pressure die are worn and not squeezing the tube at the tangent point, or clamp die is worn and allows slippage k1 Wrinkling caused by under sized tube - undersized tube slips thru the clamp die m1 Wrinkling caused by worn mandrel - mandrel tip is worn and not squeezing the inside wall of the tube at the tangent point allowing wrinkles n1 Wrinkling caused by worn wiper die - wiper die tip is worn and not squeezing the inside wall of the tube at the tangent point allowing wrinkles c2 Mandrel hump caused by insufficient boost - Drag from pressure die assist causes too much stretch on the outside of the tube which collapses the tube around the mandrel tip, increase the boost d2 Mandrel hump caused by mandrel beyond tangent - Mandrel tip is in the bend area (too far past tangent), it needs to be moved back g2 Mandrel hump caused by wiper die beyond tangent - Wiper die is too far forward and is pushing the tube and mandrel away from the bend die tube groove, it needs to be moved back a3 Scratches in the clamp area from slippage - Scratching is a symptom of slippage, please see the causes below c3 Scratches in the clamp area from slippage caused by drag from insufficient boost - c2 will also show up in this case, increase the boost g3 Scratches in the clamp area from slippage caused by drag from wiper die beyond tangent - scratching on the inside of the bend may show up also, move the wiper die back k3 Scratches in the clamp area from slippage caused by undersized tube - If the clamp die and or clamp straight are worn you may get slippage when the tube OD is at minimum c4 Mandrel ball bumps caused by insufficient boost - When boost is to low stretches and collapses inward on the mandrel and balls, increase the boost g4 Mandrel ball bumps caused by wiper die beyond tangent - Wiper die is too far forward and is pushing the tube, mandrel, and balls away from the bend die tube groove, it needs to be moved back k4 Mandrel ball bumps caused by undersized tube - If the tube wall thickness is running towards minimum bumps will be more prominent and harder to remove g5 Scratches on inside of bend caused by wiper die beyond tangent - If the wiper die is to far forward or has too little rake it will wear out quickly and can mark the inside of the bend n5 Scratches on inside of bend caused by worn wiper die - If the wiper die tip is worn or ragged the irregularities will mark the inside of the bend h6 Tool marks on centerline caused by oversized grooves - i6 Tool marks on centerline caused by undersized grooves - This looks like the tube was "pinched" at the top and/or bottom of the bend j6 Tool marks on centerline caused by oversized tube - l6 Tool marks on centerline caused by tool set misaligned - This will show up as a line or groove at the top and bottom of the bend that is biased, for instance, towards the inside on top and towards the outside on the bottom. This indicates a vertical tooling misalignment, adjust the clamp and pressure die positions to correct. b7 Springback, too little caused by excessive boost - Degree of bend and radial growth are affected by boost. If all bends are over bent (too many degrees)and there is a tende ncy to wrinkle there may be too much boost, try reducing the boost. c7 Springback, too much caused by insufficient boost - Degree of bend and radial growth are affected by boost. If all bends are under bent (too few degrees) and there is a tendency to collapse or flatten there may be too little boost, try increasing the boost. a8 Outside of bend collapses caused by slippage - c8 Outside of bend collapses caused by insufficient boost - e8 Outside of bend collapses caused by mandrel behind tangent - g8 Outside of bend collapses caused by wiper beyond tangent - m8 Outside of bend collapses caused by worn mandrel - a9 Tearing caused by slippage - c9 Tearing caused by insufficient boost - d9 Tearing caused by mandrel beyond tangent - g9 Tearing caused by wiper die beyond tangent - |