Discussion with the fabricator can establish what materials, tooling and capabilities they have to help you with your project. It is a two-stack machine and can accomplish both types of forming on the same part, in a multiple step process.Р”Р„ good step to minimize the tooling costs associated with tube bending is to at the beginning of your design process reach out to fabricators that potentially can do your work. K-zell Metals has a Horn Metric 65TBRE CNC tube bending machine with both rotary draw bending and push roll capabilities. There are specialized tooling and CNC bending machines that can greatly reduce this distortion (such as our Horn 65TBRE Machine) but there needs to be enough production quantity to justify the initial programing, set up, and scrap rate costs to justify the process selection.

The closer to the 8D value the greater degree of distortion that will be present and the more time and money a part will cost. The degree of this distortion is relative to the material alloy, the section wall thickness, and how close to the 8D value you are rolling to. That distortion can manifest in ripples produced on the surface of the tube, change of dimension of the tube profile, flatness issues after forming, ect. Centerline radius bends from 8D up to 16D can be difficult to nearly impossible to accomplish without significant distortion. Like the Rotary Draw Bending there is a zone that presents unique challenges to the Push Roll / Roll Bending process. One you have determined the process by which to accomplish the bending of the part there are other design consideration as it pertains to each process: If the centerline bend radius of the part is less than 8 times the material cross section then Rotary Draw Bending is the required process if the radius is greater than 8 times the cross section (also known as an 8D bend) then push rolling is the correct process.Р”РЋРІР‚Сњ OD Round tube with a centerline bend radius of 3РІР‚Сњ requires Rotary Draw Bending (3РІР‚Сњ Centerline Radius / 1РІР‚Сњ OD Tube = 3 or 3D Bend)Р”РЋРІР‚Сњ OD Round tube with a centerline bend radius of 12РІР‚Сњ requires Push Roll Bending (12РІР‚Сњ Centerline Radius / 1РІР‚Сњ OD Tube = 12 or 12D Bend)

The general rule to determine which type of bending process is required is based on the bend radius divided by the tube/angle/channel cross section dimension. The differences between the two pertain exclusively to the requirement of the centerline bend radius of the tube (this can also be applied to other structural shapes like, angles, channels, I- Beams, TРІР‚в„ўs, etc). A couple of the most common methods are Rotary Draw Bending and Push Roll Bending. There are several different processes for bending tube, and those process vary with machines and tooling. Part Design Best Practices when Tube Bending is Required: We also offer services for tube rolling, round tube, square tube,Р’В bar and pipe.Р’В We are here for your custom metal bending needs, so request a quote today to begin your project.

K-zell Metals offers tube bending and mandrel tube & pipe bending services.

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