tube bending. objectives at the end of this training you will be able to: 1.explain the key features...
TRANSCRIPT
Tube Bending
Objectives
At the end of this training you will be able to:1.Explain the key features of the tube bender2.Layout tubing to make bends3.Use the tube bender to make a variety of bends4.Diagnose problems with tube bends5.Design tube runs for safety and maintenance
TurnPro Indexing Handle Tube BenderFeatures• Makes bends greater than 90° in a single operation
• Eliminates crossed handles• No assembly and reassembly of bender handles
• Durable Construction– Suitable for heavier wall tubing– Vise mountable
• 1/4, 3/8, 1/2 in. (6, 8, 10, 12 mm) sizes• Training available
TurnPro Indexing Handle Tube Bender
Tube Lock Hook
Alignment Marks
Bend Angle Marks
Indexing Lever Handle
Indexing Trigger
BenderDie
RollerHousing
Die Radius Indicator
Tube Selection and Preparation
Description Material Hardness Standard
Carbon SteelSoft Annealed,
Seamless72 HRB (130 HV) or less ASTM A179
304 Stainless Steel
Fully-annealed, seamless or welded and
drawn90 HRB (200 HV) or less ASTM 269 or A213
316Stainless Steel
Fully-annealed, seamless or welded and
drawn90 HRB (200 HV) or less ASTM 269 or A213
Selecting Tubing
TubeOD
Approx Bend Radius
Carbon Steel Wall Thickness Min/Max
Stainless Steel Wall Thickness Min/Max
1/4
9/16 0.028/0.065
3/4 0.028/0.065
3/8 15/16 0.035/0.065 0.035/0.083
1/2 1 1/2 0.035/0.083
Selecting Tubing
TubeOD
Approx Bend Radius
Carbon Steel Wall Thickness Min/Max
Stainless Steel Wall Thickness Min/Max
6 15 0.8/1.5
8 24 1.0/1.5
10 24 1.0/1 5 1.0/2.0
12 38 1.0/2 .2 1.0/2.0
Selecting Tubing
Selecting & Handling Tubing
• Check for– Clean– No scratches or gouges– Out of round ends– Burr– Seams
• Handling– Dragging– Capping– Uncoiling– Cutting
• Tube Cutter• Sharp saw• Cutting wheel
– deburr
Tube Installation
Bend Allowance
T - Tube OD
L - Length of straighttube required
R – Bend Radius
Bend Allowance - Fractional Tubing
T Tube OD R Bend Radius L
1/4 9/16 13/16
3/8 15/16 15/16
1/2 1 1/2 1 3/16
Tube Installation
Bend Allowance – Metric Tubing
Tube OD R Bend Radius L
6 15 21
8 24 23
10 24 25
12 38 31
Tube Installation
Laying Out & Bending Tubing
LayoutSequential Layout Example
3 in.
3 in.
Layout
Sequential Bend Method1. Add the lengths or all section together to estimate the overall length
of tubing required for the job.
2. Mark the starting point (reference mark) for your project. – Remember to make all marks completely around the tube.
3. Measure from the reference mark to the vertex of the first bend. – The vertex is the point where the center lines of the two legs of the angle
meet.
4. Bend the tube.
5. Using the vertex of the previous bend as the reference mark, mark the vertex for the next bend the next bend.
6. Repeat steps 3 and 4 for the next bend
Sequential Layout
Reference Mark
Vertex
Vertex
3 in.
3 in.
3 in.
1. Add the lengths or all section together to calculate the overall length of tubing required for the job.
Sequential Layout
2. Mark the starting point (reference market) for your project. Remember to make all marks completely around the tube.
Reference Mark
Sequential Layout
3. Measure from the reference mark to the vertex of the first bend. The vertex is the point where the center lines of the two legs of the angle meet.
Reference Mark 3 in.
Vertex
Reference Mark
Align Vertex MarkWith “L”
90° Bends – Reference Left
Sequential Layout
4. Bend the tube.
Reference Mark
90° Bends – Reference Left
Bend until 90 meets 0
Layout
VertexNew Reference
Vertex
3 in.
5. Measure and mark the next segment.
Sequential Layout
Tip – Mark the vertex of the next bend to help alignment
Vertex 1
45° Bends
Vertex Mark
30° Alignment
Bend until 45 meets 0
45° Bends
Sequential Layout
Vertex
6. Bend the tube
Bend Calculations
Layout Calculations
Offset Calculations
3.5 x 1.414 = 4.494 or approx. 5 in.
?
3.5
Offset BendAngle
Offset BendAllowance
22 ½ 2 .613
30 2 .000
45 1 .414
60 1 .154
Layout Calculations
Offset Calculations
Layout Calculations
Offset Calculations
3.50 x 1.414 = 4.949 or approx. 5 in.
Solution
3.5
5
Layout Calculations
3 in.
3 in.
3.5 in.
Reference Mark
1/4 in. OD Tubing
Adjustment (Gain)Calculations
Original Calculation11 1/2 in.
Layout Calculations
Adjustment (Gain)Calculations
Layout Calculations
Reference Mark
3 in.
6 3/16 in.
3 in.
in.
Adjustment (Gain)Calculations
3 in. + 3.5 in. – 5/16 in. = 6 3/16 in.
6 3/16 in. + 3 in. – 5/16 in. = 8 7/8
3.5 in.
New Calculation9 1/2 in. – (2 x 5/16) = 8 7/8 in.
More Bending
Bends Greater than 90°
Bends Greater than 90°
Bend until 0 meets 180, then a little more for spring back
Right Reference Bends
3 in.3 in.
3 in.
Reference Mark
9 in. Tubing
Align Vertex Markwith R
Reference Right Bends
90° Bends – Reference Right
Changing Planes
90°
90°
Multi-Plane Bends
2 1/2 in.
2 1/2 in.4 in.
30° x 30°
90°2 1/2 in.
Multi-Plane Bends
15°30°
45°
60°
75°
90°
15°30°
45°
60°
75°
90°
Bend Direction
0°
Multi-Plane Bends
Bend Direction
15°30°
45°
60°
15°30°
45°
60°
75°
90°
75°
90°
0°
Multi-Plane Bends
15°30°
45°
60°
15°30°
45°
60°
75°
90°
75°
90°
0°
Multi-Plane Bends
15°30°
45°
60°
15°30°
45°
60°
75°
90°
75°
90°
0°
Imperfect BendsCommon causes of imperfect bends
May be caused by:• Not having the mandrel forward
far enough in the tube• Bending thin wall tubes without
a mandrel• Trying to bend too short a radius• Bending smaller diameter tubing
in a larger radius block.
Sometimes produced when thin wall tube is bent without a support mandrel.
May be caused by the tube slipping in the bender. A kinked bend may also result from the use of non-annealed tubing.
Installing Tube Runs
Installing Tube Runs
• Avoid creating ladders• Run tubing close to the wall• Use support hangers every 3 – 5 ft.• Support valves, transmitters etc, independent
of the tubing• Run tubing vertically
when possible
Installing Tube Runs
Stagger Connections
Installing Tube Runs
Installing Tube Runs
Avoid straight line connections whenever possible
Installing Tube Runs
Avoid straight line connections whenever possible
Installing Tube Runs
Bend up staggers for easier access and maintenance
Expansion
Installing Tube Runs
Installing Tube Runs
Installing Tubing Runs
Installing Tube Runs
Installing Tubing Runs
Installing Tubing Runs
Final Exercise
Tube Bender Training
1 3/8
6
1 3/8
18
6
150° 150°
15°/90°15°/90°
30° 30°
15°2 3/42 1/2
Final Exercise
1
2
3
4
5
6
7
Final Exercise
Vertex # Distance to Bend° Rotation° Direction
Reference 0
1 1 3/8 30° 0°
2 6 15° 90° Left
3 2 ½ 150° 90° Right
4 18 150° 0°
5 2 3/4 15° 90° Right
6 6 30° 90° Left
7 1 3/8
A Better Hook
Overall Length – 9 in.
3/4
1 1/4 1 1/4
1 1/2
1 1/2
1 1/4
60°
60°
60°
45°
45°
Quantity 500
Thanks