Dorn pipe bender: description, device, types and reviews

2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16

Working with metal products often involves operations that allow you to change their shape. To create structures with certain characteristics, in particular, cutting, folding and folding may be required. The last type of such 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 point of inflection should provide an optimal amount of passage of the working environment. A mandrel pipe bender helps to cope with this task qualitatively, performing its function in different modes, including automatic.

General information about mandrel pipe bender

In the classic version, this tool is focused on working with thin-walled pipes. This means some specialization of its function, but there are quite a lot of 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 performing the operation can ruin the workpiece. In this regard, the most sensitive manual mandrel pipe bender, which is used in the household or by workerssmall workshops. In terms of materials, most mandrel models are able to work effectively with copper, stainless steel and aluminum. Depending on the material of the pipe, equipment settings are also selected. It already depends on the design features of a particular unit and its functionality.

Design and principle of operation

The basis of the machine is usually represented by high-strength steel alloys. Functional tooling with a head is often made of cast iron - this is the most wear-prone part, which provides the bending moment. The designs differ in the way the clamping action is performed - there are top and finger clamps. In the first case, the operator has the ability to linearly move the pipe due to the gap between the fixing mechanism and the processing surface. The finger mandrel pipe bender, in turn, does not involve exerting loads on the lever. Some designs also use a hydraulic booster to improve performance. During the work cycle, the clamping bar follows the workpiece being processed and then assumes its original position. The hydraulic cylinder clearly regulates the manipulation of the bar, also setting the plane of rotation of the product. Physically, actions are implemented through one or more drives.

Varieties

There are three types of mandrel pipe benders. These are the mentioned manual, semi-automatic and fully automated models. All of themthey are united by the fact that the principle of mechanical action is implemented by means of roller equipment, on which, in fact, the workpiece is wound. The hand tool is characterized by low power and the need to connect the operator to the direct workflow. Again, the user controls the operation of the hydraulic system. More convenient to use is a semi-automatic mandrel pipe bender, which imposes on the operator only a part of the working steps, the list of which may vary depending on the design. Automated machines can not only perform the entire work cycle on their own, but also be interfaced with other equipment. These models are often integrated into full-fledged production lines, in which folding is only one of the operations in the overall manufacturing process.

Features of CNC Models

These are the same automated lines, but supplemented with numerical control. What does this mean in practice? The role of the operator in semi- and automated machines is usually kept to a minimum, but still there. In this case, it lies 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, the CNC mandrel bender can be programmed with parameters such as clamping pressure, mandrel location, bending unit rotation speed, etc. At the same time, the memory of machines can store various data on the characteristics of already finished pipes, which in the futurefacilitates the method of assessing product quality. Thus, for example, defects, deviations from standard indicators and other features of the product are recorded.

Positive feedback about working with the tool

Experienced users of equipment that is used in working with rolled metal note several advantages of drone units. First of all, this is the exclusion of the characteristic waviness or corrugation, which is formed when using other bending devices - as a rule, not specialized ones. The second positive point is that the deformation is not accompanied by 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 pipe bender with the same CNC has are also highlighted. Such equipment makes it possible to obtain not just an accurate bend, but a relatively high-speed qualitative deformation in the serial production mode.

Negative reviews

Mandrel bending machines require careful maintenance. The mechanics in this case is represented by difficult mating elements that need constant maintenance. In addition, many operators of such installations note their limitations in terms of their ability to work with multi-format pipes. As a rule, one machine in the basic configuration can serve workpieces in a narrow dimensional range - this applies to both wall thickness and overall diameter. Together withthis is also indicated by users to the fact that the mandrel pipe bender takes up a lot of space on the job site, not to mention its significant mass. Accordingly, transportation and installation costs increase.

Question of price

The simplest manual models from the budget segment can cost about 50-70 thousand rubles. As a rule, they work with small-sized pipes, realizing the bending moment through physical effort. The middle segment is represented by units with automation elements. It 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 the rest of the functional units and components are attached. The shaft of the body is supplied with bending multi-stranded rollers, clamping blocks and eccentric elements. The last components of the equipment will act as workpiece clamps. Also, to perform the operation, you will need an emphasis from which the direction of the pipe will be set. This system is most often made up of pressure pads, staples and wedges. In order to be able to effectively control the mandrel pipe bender with your own hands, ina guide assembly is introduced into the structure, formed by a screw and a special steering wheel.

Conclusion

Metal pipes rarely deform already at the workplace. Usually the same fold is made in the factory according to a given project or in a standard format. Nevertheless, there are situations when during the installation operations it may be necessary to quickly perform this procedure. For this case, a manual mandrel pipe bender is designed. In some modifications, it allows you to work even in the field, which often saves time on installation activities. More solid automated installations do not involve 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.