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Mandrel and Wiper Die Selection Guide

The values on this chart are fairly conservative. The following factors can reduce the number of mandrel balls required and/or the need for a wiper die:

  • Operator skill and experience
  • Machine condition
  • Bend lubrication type
  • Use of "heart" or elliptical shaped tool sets
  • Use of grooves in the bend die that form wrinkles on the inside of the bend

The CLR Ratio is the centerline radius of the bend divided by the tube outside diameter.

The Wall Ratio is the tube outside diameter divided by the tube wall thickness.

KEY:

P IS A PLUG MANDREL (NO MANDREL BALLS)
"X" B IS THE NUMBER OF BALLS ON THE MANDREL
C "X" B IS A CLOSE PITCH MANDREL
XC "X" B IS AN EXTRA CLOSE PITCH MANDREL
W IS A WIPER DIE

e
CLR Ratio
=====>
e
e
e
e
e
Wall Ratio
1
1.5
2
2.5
3
4
5
10
P
P
P
P
P
--
--
15
1BW
1BW
1B
P
P
--
--
20
2BW
1B
1B
1B
P
P
--
25
3BW
2BW
1BW
1B
1B
P
--
30
3BW
2BW
2BW
1BW
1B
1B
P
35
3BW
3BW
2BW
2BW
2BW
1BW
1B
40
4BW
3BW
3BW
3BW
3BW
2BW
1BW
50
4BW
3BW
3BW
3BW
3BW
2BW
2BW
60
4BW
3BW
3BW
3BW
3BW
2BW
2BW
70
C5BW
C5BW
3BW
3BW
3BW
3BW
2BW
80
C5BW
C5BW
C5BW
C4BW
3BW
3BW
3BW
90
C5BW
C5BW
C5BW
C4BW
C4BW
4BW
3BW
100
C5BW
C5BW
C5BW
C5BW
C4BW
4BW
3BW
125
C6BW
C6BW
C5BW
C5BW
C5BW
C4BW
4BW
150
C6BW
C6BW
C6BW
C6BW
C5BW
C4BW
C4BW
200
XC6BW
XC9BW
XC9BW
XC8BW
XC8BW
XC8BW
XC8BW


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