Tube Bending. Objectives At the end of this training you will be able to: 1.Explain the key features...

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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

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

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

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

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

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.

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

Layout Calculations

3.5 in.

Reference Mark

1/4 in. OD Tubing

Adjustment (Gain)Calculations

Original Calculation11 1/2 in.

Layout Calculations

Reference Mark

6 3/16 in.

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°

Bend until 0 meets 180, then a little more for spring back

Right Reference Bends

3 in.3 in.

Reference Mark

9 in. Tubing

Align Vertex Markwith R

Reference Right Bends

90° Bends – Reference Right

Changing Planes

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°

Bend Direction

Multi-Plane Bends

Bend Direction

15°30°

Multi-Plane Bends

15°30°

Multi-Plane Bends

15°30°

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

• 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

Stagger Connections

Avoid straight line connections whenever possible

Bend up staggers for easier access and maintenance

Expansion

Installing Tubing Runs

Final Exercise

Tube Bender Training

150° 150°

15°/90°15°/90°

30° 30°

15°2 3/42 1/2

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.

1 1/4 1 1/4

Quantity 500

Thanks

Tube Bending. Objectives At the end of this training you will be able to: 1.Explain the key features...

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