The rolled steel tubular profile is widely in demand in the laying of spatial utilities, in the manufacture of greenhouses and greenhouses, in various household jobs. This is facilitated by the high rigidity of the section with a low weight of a running meter.
In many situations, there is no need to purchase expensive drive devices, since you can make a simple manual pipe bender with your own hands.
Pipe bending is not a power-consuming stamping operation, so manual bending forces are low. The difficulty lies in the fact that without observing certain conditions, the section of the bent pipe is deformed, and the quality of the bending is low. This happens for the following reasons:
- When bent at an angle exceeding 10 ... 150, the inner regions of the section are under the action of compressive stresses, and the outer ones are under tension. Therefore, folds and / or cracks appear on the pipe surface;
- Pipes made of medium-carbon steel (steel grades 40 and above) have increased elasticity. This manifests itself in the springing effect of the bent profile when its dimensions do not correspond to the specified ones. When bending along a complex spatial contour, springback can reach 15 ... 20%;
- Without forced fixation of the end of the pipe, its end is distorted, and its border loses its perpendicularity relative to the axis. As a result, it becomes difficult to install adjacent parts.
With this in mind, it is necessary to choose billets from pipes made from ductile steel grades. Cold formed pipes bend less well than hot rolled pipes. In general, seamless steel pipes in accordance with GOST 8732-76 are more suitable for manual bending, as well as pipes made of plastic non-ferrous metals and alloys - aluminum, brass, copper, etc.
Bending a profile pipe without using a pipe bender at home
A square metal pipe is considered a versatile building material for arched and semicircular structures. An example is a semicircular arch for a greenhouse, a curved visor made of ...
To eliminate the negative influence of stress concentrators, all external surfaces of the material must be free of scale and rust.
General diagram of a manual pipe bender
How to make a pipe bender? Regardless of the bending method - open or semi-closed - a homemade pipe bender should include:
- Replaceable profiled roller, which will be used for compression.
- Deforming lever used to bend the pipe.
- Latch of one of the ends.
- Adjustable template or lever travel stop.
- Protective cover.
- Base.
Some do-it-yourself pipe bender designs may have a drive to deform thick-walled materials. For this, hydraulic motors are used: they are silent, autonomous and perform bending with increased accuracy.
Vertical axles with accessories are located in rolling bearings. The attachment attaches to a locksmith's bench or other supporting surface.
In simple cases (the ratio R / d> 20; here R is the outer radius of the bend, d is the outer diameter of a round pipe or the size of the side - for a square), a pipe bender is not required, since the deforming forces are insignificant. To bend them, it is enough to place the tubular blank in a composite template, the parts of which are sequentially moved in the required direction.
The springback (in degrees) when bending medium-carbon steels at angles 90 ... 1800 is taken into account using the following table:
| Outer pipe diameter, mm | Pipe wall thickness, mm | |||
| Up to 0.5 mm | Up to 1.0 mm | Up to 1.5 mm | Up to 2.0 mm | |
| Up to 10 mm | 2…3 | 3…4 | 4…5 | 5…6 |
| Up to 20 mm | 3…4 | 4…5 | 5…6 | 6…8 |
| Up to 30 mm | 4…5 | 5…6 | 6…8 | 8…10 |
| Up to 50 mm | 5…6 | 6…8 | 8…10 | 10…12 |
| Over 50 mm | 6…10 | 8…10 | 10…12 | 12…15 |
The following are designs that can be made at home. Drawings of such pipe benders are available on the Internet, so homemade products are always obtained using improvised means.
Diy template pipe bender
Manual bending according to a template is the simplest technology for any (including spatial) bending of pipes. It is often used with a workpiece heated at the bend (for example, with a flame torch or blowtorch): the ductility of the metal increases, and the deformation force decreases.
Description of the template pipe bender:
- Anchor-shaped retainer where the pipe is inserted.
- Movable / replaceable stop, along the axis of which there is a recess corresponding to the arc of the outer diameter of the pipe.
- Plate with fixing holes.
On the opposite side of the stop, a bevel is made, the angle of which corresponds to the required (after bending!) Value of the bending angle.
All parts can also be made from ordinary structural steel (for example, steel 45), however, the stop will stand longer if it is made of tool steel such as U10A steel.
The step-by-step installation is as follows. A retainer is installed on the base plate, then a stop is attached to it coaxially. The spacing between parts should be taken into account the known range of R / d ratios. It is very important to adhere to the recommended radius of curvature when transitioning to the curved section of the pipe.
In accordance with GOST 17685-71, they are accepted as follows:
- S / d< 0,03 – не менее 4d;
- S / d< 0,06 – не менее 3,6d;
- S / d< 0,11 – не менее 30d;
- S / d< 0,16 – не менее 2d.
These restrictions apply for cold bending. By heating the deformable part (no more than up to 1500C), the given values can be reduced by 12 ... 15%. This type of pipe bender does not limit the maximum angle, however, at angles exceeding 450, folds form on the workpiece, and the section of the pipe loses its original shape.
Homemade roller pipe bender
The advantages of roller pipe benders are advanced technological capabilities and increased bending accuracy. The design of the fixture is simple:
- Profiled replaceable roller, freely rotating on a vertical (less often horizontal) axis.
- Swivel arm with handle.
- A bending exchangeable roller mounted on the opposite arm of the arm.
- Stop-wiring.
- Stanina.
To reduce the force, both rollers must rotate freely, for which they are installed in rolling bearings. Since each pair of rollers is adapted to bend pipes with a certain outer diameter, they must be quick-changeable.
The material of the parts is chosen for the same reasons as for the previous version. In order to increase the rigidity, the stop-wiring can be welded to the body. The bending radius (selected according to the above ratios) will be equal to the profile radius of the bending roller.
To ensure the proper quality of deformation, the radial runout of the roller axes should be minimal, and their axes should be strictly parallel to each other.
Making a winding pipe bender
The principle of operation of such a pipe bender is similar to the previous one, but instead of a swivel roller, the bend of the workpiece produces a moving stop that slides along horizontal guides.
The winding pipe bender contains:
- Profiled sector, the angle of which defines the maximum permissible bending angle.
- A short vertical axis that can rotate freely in a ball bearing assembly.
- Two adjacent rollers forming a movable stop.
- One-sided guides.
- Stop travel stop, which prevents its spontaneous displacement during operation.
- A safety fork that covers the profiled sector, increasing the positioning accuracy of the workpiece.
Structurally, the device is more complex, however, it allows deformation in a limited space, and changing the angle not by changing the rollers, but by simply adjusting the initial position of the clamping device. Such a pipe bender is available with a hydraulic or electric drive option.
Making a crossbow pipe bender
The crossbow pipe bender is the most compact, although it is characterized by increased labor intensity of manufacture. The sequence of operation of the device is that the tubular workpiece to be bent is pressed against two steel rollers rigidly fixed to the frame, the distance between which is determined by the radius. A manual hydraulic cylinder is mounted in the pipe bender body (often used with a brake cylinder, from a car). By pulling the trigger, a high-pressure fluid is injected into one of the cylinder cavities, under the influence of which the piston rod begins to move towards the deformable workpiece. Since the rollers and the cylinder are installed on the same base plate, the accuracy of the crossbow pipe bender will depend only on the quality of manufacture and assembly.
The advantage of the device is the elimination of physical exertion applied by the user (a conventional jack can be used as a source of pressure). The disadvantage is the increased complexity of work in the house when assembling and setting up the device: it is necessary to make a supporting frame, carefully adjust it to the existing jack dimensions, ensure the alignment of the rollers and the perpendicular movement of the rod to the axis of the original workpiece.
The hydraulic drive, providing the required force, can be assembled in another way. A conventional car jack is installed on a frame made of channels and is supplied with two symmetrically located stops (they can be provided with adjustable ones).
A removable nozzle is attached to the screw of the jack, the profile of which corresponds to the diameter of the arc of the outer section of the pipe. The distance between the frame ribs depends on the bending angle. To implement the process, the jack is placed on top of the deformable workpiece, pre-fixing it on the stops.
Homemade hydraulic pipe bender is ready to use. Extra large pipes are additionally secured with bolts for safety. Next, the screw is rotated, and deformation is performed to the desired value.
DIY hydraulic pipe bender
A jack hydraulic pipe bender is a good solution that allows you to use an automobile jack available in the arsenal of a home craftsman. Disadvantages - low productivity and restrictions on the length of the workpiece (for long pipes, the dimensions of the frame will increase significantly).
Cochlear pipe bender
In such a pipe bender, the movement of the pressure roller is provided by a fork sliding in the guides, which are equipped with stops. Holes are drilled in the fork for installing two rollers - a small one, which will perform deformation, and a large one, for fixing the tubular workpiece. A working handle is provided to move the fork from its opposite side.
Work order:
- Make a clamping fork.
- Carve pressure rollers (it is possible with replaceable inserts that will determine the outer diameter of the pipe).
- Insert and fix the rollers on the fork (you can also use cotter pins, but it is better to provide a threaded connection).
- Make a base from sheet metal with a thickness of at least 8 mm, providing holes for fasteners in it.
- Fasten the fork travel stops on the base.
The disadvantage of the cochlear pipe bender is its low productivity, since the fork travel is determined by the dimensions of the deformed part of the pipe, as well as the maximum deformation force. On the other hand, cochlear benders take up little space and are easy to change: just move the large roller to a new position.
Roller pipe bender on car hubs
A limitation of homemade roll benders is the difficulty of producing replaceable profiled rolls. You can get around this difficulty by using car hubs as sectors. The dimensions of the device will increase, but in return its reliability and stability will increase, which is important when bending long and thick-walled pipes. For manufacturing you will need:
- Three automobile hubs: two - movable, cantilevered, and one - fixed, which is located longitudinally to the axis of the device.
- Two short axles that are assembled on a rigid welded bracket.
- Swivel mechanism of cam or eccentric types, with which you can change the distance between the hubs.
- Axial longitudinal guide, which can be taken as a cold-rolled channel.
- Flat travel stops.
- Internal channel channel with bolt holes for stops.
- Rotary handle.
This design will pay off in the manufacture of spatial tubular elements of complex shapes. The presence of two hubs, the discs of which are spaced apart on opposite parts of the base, makes it possible to apply force locally, only to that part of the pipe that is being bent at the moment. This compensates for such design flaws as the complexity of installation and commissioning, as well as increased overall dimensions.
Features of a pipe bender for a profile
How to make a profile pipe bender with your own hands? The distortion of the profile of such pipes in the process of normal deformation affects not only their appearance, but also causes difficulties in the subsequent one. We do not consider the option of cutting the profile at bending points with subsequent welding of the notch, due to a significant weakening of the section strength.
The simplest profile pipe bender consists of the following elements:
- The frames are in the form of a rectangular channel, the cross-section of which makes it easy to place the pipe there along the axis.
- Pairs of flat feed rollers that are mounted on the ends of the frame.
- A screw feeder, which includes a power screw with a handle, a bending punch and two supports installed in the center of the frame.
- The feed handle, which is connected to the rollers.
All parts are fastened with bolts, the frame itself is fixed to the workbench. The pipe is placed on top of the rollers, and by rotating the feed handle it is set against the axis of symmetry of the punch. Then the screw is rotated, and bending is performed, visually controlling the required angle.
To eliminate deformation of the section, use one of the techniques described in the next paragraph.
Technology of work on homemade pipe benders
The main failures of using hand-made pipe benders are significant deformation of the pipe cross-section, which is observed with any deformation pattern. Loss of cross-sectional stability can be minimized or eliminated by creating back pressure from the inside of the pipe.
There are several ways to do this:
- The pipe is filled with fine-grained sand, and sealed plugs are inserted into the holes. Since the sand is not compressed, the internal pressure will balance the external one, and the section will not deform;
- Use ordinary water for similar purposes, which should be completely frozen before use. The method is inconvenient, but quite acceptable in the cold season;
- Using a tension spring with a suitable diameter as a source of back pressure. The spring is inserted into the pipe, then the workpiece is deformed;
- Filling the pipe with metal washers 1 ... 2 mm in diameter smaller than the inner diameter. The parts are strung on a steel cable, which is passed through the pipe and fixed somewhere outside the pipe bender. When bending, the washers are able to move freely along the pipe axis. Possessing high rigidity, they prevent wall deformation.
When bending at small angles (up to 12 ... 150), there is no need for the described techniques.
Conclusion
In this article, the most common designs of pipe benders are systematized and considered, mainly with a manual drive. All of them can be made using non-scarce materials, assemblies and tools available to home craftsmen. Without pretending to fully cover the issue, we expect new effective designs of these devices from users.
The construction of greenhouses and sheds, the laying of utilities - all this requires a bent metal profile. But buying pipes bent to order is expensive, purchasing a ready-made pipe bender is also not a cheap pleasure. So modern craftsmen use to create metal arcs of the required radius of the device and mechanisms of their own manufacture.
In this article, we will cover the following issues:
- Varieties of homemade pipe benders and their features.
- The design of the simplest device for bending square pipes.
- Design of three-roll bending machine for round and square pipes.
- Pipe bending technology on a three-roll homemade pipe bender.
Varieties of pipe bending devices and mechanisms
Nowadays, you can find examples of pipe bending equipment of various designs: from relatively simple devices for manual bending to self-made machines with a manual or electric drive.
By design, pipe benders are divided into two types.
The first type is angular (allow you to give the desired radius to a specific section of the workpiece).
The second type - three-roll pipe benders - machines and devices that allow you to form a given bend radius along the entire length of the workpiece.
According to the method of adjusting the radius, pipe benders are mechanical.
And hydraulic.
The drive of the support shafts can be either manual or electric.
Simple device for bending metal pipes
The design of a homemade pipe bender depends on the volume and complexity of the work that is planned to be performed with its help. If the device is needed for one-time use (for example, for building a home greenhouse), then there is no need to create a complex three-roll mechanism with a hydraulic bend radius adjustment.
belor44 FORUMHOUSE user
We urgently need to put up a greenhouse. I want an arched one, but neither metal-based, nor my friends have a pipe bender. Build a pipe bender on shafts and rollers? There is neither time nor need for this. I believe that a manual bending device is suitable for one building.
Yes, indeed, the simpler the pipe bender, the less hassle with its manufacture. The main thing is to correctly determine the size of the device, which will directly depend on the bending radius.
Introducing a user-made device moning... It is designed to work exclusively with thin-walled pipes, because manual bending of pipes is a hard physical labor.
Moning FORUMHOUSE user
I made this piece for a square tube 30 * 30. The radius that we managed to get was about 1 meter. On the sides of the device, you can weld something like spacers or legs so that it does not throw from side to side when you press on the pipe. Regarding the lintels at the bottom of the bender: first, the pipe is placed under the upper lintel (for the initial bend), then the pipe is shifted under the next lintel (for further advancement).
Sequential bending is necessary so that the pipe does not break with a sharp bend.
It is very simple to calculate the dimensions of the fixture: for this it is enough to know the bend radius that you want to get on the finished part. The strip (40 mm wide), which serves as a mandrel for the workpiece to be bent, initially has a curvature that provides a given bending radius (R).
Given the presence of elastic deformations, the radius of the mandrel should be slightly less than the required bend radius of the workpiece.
Knowing how to use welding, grinder and auxiliary tools, this device can be made in less than 1 day.
Each metal pipe has its own elastic limit, therefore, the bending radius cannot be reduced below certain values. The admissible minimum radii can be taken from the corresponding tables.
Here is an example of a table of permissible radii for circular pipes.
| Outer pipe diameter, mm | Bend radius, min | |||
|---|---|---|---|---|
| 45 | 35 | 20 | 10 | |
| R bend, min | ||||
| 18 | 74 | 62 | 56 | 43 |
| 24 | 95 | 79 | 65 | 55 |
| 32 | 115 | 96 | 79 | 67 |
| 38 | 156 | 131 | 107 | 91 |
| 50 | 197 | 165 | 136 | 115 |
| 60 | 238 | 199 | 165 | 139 |
| 75 | 280 | 260 | 194 | 173 |
| 80 | 324 | 270 | 224 | 190 |
| 90 | 362 | 302 | 250 | 213 |
Electromechanical pipe bender manufacturing
In the design of an electromechanical pipe bender, three main working bodies can be distinguished: one push and two supporting (driving) shafts. Hence the name of the machine - three-roll rolling pipe bender.
Such a device has a rather complex design, therefore, if you were unable to get hold of the drawings of a homemade pipe bender, we recommend that you first draw each of its elements on paper (at least in the form of a sketch). And we will consistently tell you what dimensions and characteristics the main units of the future product should have.
So, the main function of a pipe bender is to bend parts to a given bend radius. The bending radius depends on the distance between the track rollers (shafts) and is adjusted by the press roller. The distance between the support rollers is a constant value. It is this that should be taken into account when starting the design of the machine.
Alli58ru FORUMHOUSE user
The distance between the bottom rollers depends on the minimum bending radius. When determining it, keep in mind that the smaller the distance between the rollers, the harder it is to lower the pressure roller and the harder it is to pass the workpiece between the shafts. Conversely, the greater the distance, the easier it is to twist. For me, if memory serves, the distance is about 35-40 cm. The shafts scroll quite easily: I bent the minimum radius of about 50 cm, but less is possible.
The bend radius (arc radius) is calculated using a simple geometric formula.
Guided by it in relation to your equipment, you can quickly adjust the machine to the specified parameters.
Roll making
For the manufacture of rollers, you should look for reliable materials that have already passed the strength test. Someone uses rotors from electric motors of old washing machines or pivots from a KamAZ car, someone uses carbon steel circles. In fact, there are many options, the main thing is not to forget that the selected material must be strong enough. User Dva11, for example, used wheel hubs from an old sprinkler.
Dva11 FORUMHOUSE user
The diameter of the hub is 75 mm, the length is 110 mm, the bearings are selected according to the hub (205 fit). I had to buy 5 bearings and 1 pulley, the rest of the parts were made of scrap metal.
Smooth cylindrical shafts - a universal option. With their help, pipes of various sections are bent. If the profile of the shafts is brought in line with the profile of the bent pipes, the quality of the bending will improve markedly.
You can also use blanks designed for different profiles of bendable workpieces.
Ideally, removable nozzles or ring clamps (limiters) are installed on the shafts, with the help of which the profile of the rollers is adjusted to the width of the pipe.
rusi45 FORUMHOUSE user
I made some improvements to the design of the rollers: on the outer shafts, where the limiters are, I made nozzles for the pipe. The tests were carried out on a 1 "pipe. The attachments are easy to replace. For this, I made one side of the bearings sliding. The nozzle is made of 65G steel (plus hardening). There is practically no wear, and the hardness - the file does not take.
The inner radius of the roller or nozzle for a round pipe should be made with a margin: pipe radius plus 1-2 mm. For example, if the pipe diameter is 24 mm, then the inner radius of the roller will be 13-14 mm. Only in this case, the pipe will not jam during rolling.
We are talking about this size.
If the pressure roller designed for bending rectangular pipes has a slight bulge in the middle, this will help preserve the geometry of the bending profile. The roller will press the top wall of the pipe inward, preventing the workpiece from expanding to the sides.
Frame design
Having decided on the center distance and the design of the rollers, you can mark the blanks of parts for the frame. Based on the experience of FORUMHOUSE users, it should be concluded that the strongest frames are obtained from a steel channel (at least 80 mm wide). This material is easy to get, so you can safely take note of it.
The photo shows the machine at the manufacturing stage. And here is the drawing, which is taken as a basis.
Human FORUMHOUSE user
During the execution of the work, some changes were made to the original drawings.
The presented drawing is not a mandatory guide to action, but gives an objective understanding of how a rolling tube bending machine works.
Clamping mechanism
Many craftsmen make a clamp from a conventional car jack (mechanical or hydraulic). The efforts that he is able to create are quite enough to give the metal blank the desired configuration.
The desire to equip a country house and a plot dictates the need for a maximum of tools. When carrying out a water supply system, building a greenhouse, installing arched structures, you cannot do without a good pipe bender. Its cost in stores is measured in hundreds of dollars, so it is better to make this tool with your own hands.
We will tell you how to make a pipe bender with your own hands. The article presented by us describes in detail the constructions tested in practice, and provides step-by-step instructions for assembly. With our advice, you can build a great tool for your own household.
Pipe benders are mechanical or hydraulic structures that help to bend metal pipes, angles, rods, profiled steel without disturbing the internal structure of the product. Hand tools are mainly used to form a bend in one place, and large machines can change the shape of pipes along the entire length at once.
By the principle of operation, pipe benders of the following types can be distinguished:
- Mechanical with direct hand force. They are used when working with pipes of small diameters, when deformed, the strength of one person is sufficient.
- Hydraulically driven. Mostly such tools are made according to the crossbow type, and they are designed to form a local bend.
- With ratchet mechanism. Pipe benders of this type use manual force, but allow after each press of the tool handle to record the level of deformation achieved.
- Machine tools with an electric drive. The electric motor greatly facilitates the process of pipe deformation, but also significantly increases the cost of the tool.
Features of working with some types are discussed below:
Image gallery
Your attention is invited to an article with step-by-step instructions and drawings for the manufacture of a swivel pipe bender for a profile and round pipes. We will tell you about the basic rules for assembling a lever and a home machine bed with your own hands and provide video instructions with comments.
At different stages of construction, installation of a water supply system and other work, one often has to face the need to evenly bend the pipe along a large or small radius. It is impossible to do this without a special device - the pipe is deformed and the quality of the product will come to naught.
A little about radii
A circular bend implies the definition of the value of the radius, which can be divided into three categories:
- Small radius - from 50 to 250 mm. A bend under such a radius can be called a knee. It is carried out on water pipes with a circular cross-section Ø 15-75 mm, or on pipes with a square profile of 15-25 mm (decorative forging).
- The average radius is from 250 to 500 mm. It is often used for the manufacture of ring molds from a 40x3 strip, pipes Ø 15-75 mm, square (15-25 mm) or rectangular (up to 20x40 mm) profile - the rim of barrels, tanks.
- Large radius - over 500 mm. It is used for the manufacture of arched elements - frames of greenhouses, canopies, ribs of welded structures. Usually it is a square (15x15, 20x20) or rectangular profile 20x40, 40x60 mm. Arches from a round pipe are usually not made - it is inconvenient to attach a distribution crate to them, but it is possible to bend a round pipe of a large radius with a diameter of no more than 75 mm.
The radius on thicker pipes is not performed by bending, but by segmentation - when the elbow is cut into segments and welded.
Small radius bends are generally required for water pipes Ø 15-38 mm. The fact of bending at the right angle is often more important than its quality. In the everyday life of craftsmen, there are two types of pipe benders for this task - three-point and rotary.
How to make a rotary pipe bender with your own hands
This type of tool can often be found in the "hand" version. The force is applied by the operator through the lever. The fixture is easy to make, with the skill of a locksmith and a welder. To do this, you will need the main elements - a lever, two wheels from blocks (with grooves) of different diameters, a steel plate and other metal parts.
First you need to make a powerful fork (metal at least 5 mm) for the thickness of the wheels. This requires a calculation. Suppose we need to bend a pipe with an outer diameter of 25 mm. We have at our disposal wheels (bearings) of two diameters: r 1 = 250 and r 2 = 100 mm (radii 125 and 50 mm, respectively). The radius of the larger wheel will be the inside radius of the knee.
The fork design will be like this:
Pipe bender fork design
The main dimension of the lever fork is the distance between the wheels ( d = 25) - the seat of the pipe and should be equal to its diameter plus 1-2 mm. In our case, this is 25 mm.
Note. If the wheels have a groove, the inner point of the groove is taken into account.
The next step is to determine the distance between the wheel axles ( a) according to the formula:
- a = d + r 1 + r 2 = 25 + 125 + 50 = 200 mm
Next, you should determine the sufficient size of the fork, based on the distance between the axles of the wheels ( with). Here you need to adhere only to the approximate gap between the small wheel and the rear wall of the fork (take 10 mm), as well as the stock of metal for fastening the stationary axle of the large wheel (take 30 mm):
- c = a + r 1 + 10 + 30 = 280 mm
The size of the gap between the shelves of the fork ( v) will be equal to the thickness of the wheel plus 1-2 mm (take h = 30 mm).
The small wheel will be mounted on an axle fixed to the fork shelves. Try to use a bearing on this axis - this will make the work much easier compared to a simple ("dry") mount.
If the task is to make a pipe bender for several pipe diameters (from 15 to 38 mm), the distance between the shelves of the fork should be sufficient to install the thickest pipe. Make the fork flange longer and drill holes for the stationary axle for each diameter.
Node 1 - fastening the lever to the fork - if possible, make a reliable threaded connection with welding. Simply weld the lever handle "to the butt end" will be unreliable, since it is through this point that the entire load is transferred.
A steel plate 350x200 mm or more with a thickness of 8 mm or more is suitable as a basis for a pipe bender platform. Think right away what the purpose of the machine will be - stationary or portable. Provide mounting holes in the plate Ø 12-20 mm.
Site design: 1 - stop; 2 - mounting holes; 3 - lever; 4 - direction of force at the moment of bending; 5 - axle fixed to the fork; 6 - pipe; 7 - stationary axis
The stationary axle can be made from a regular pin by welding it in the center of the plate, but it is better to use a bearing or bearing sleeve. The stop is fixed in place after the swivel mechanism is assembled. If the machine is designed for one diameter, the stop (corner 50x50 mm) can be simply welded to the platform. If there are several diameters, empirically establish the location of the stop under each of them, make holes in the appropriate places and pick up the rods (fastening "on the finger").
How the pipe bender works, video
The precision-made machine is complemented by clamps for bending thin-walled pipes. This approach is relevant in production, where work is carried out mainly with one or two types of pipes.
Video: pipe bender in production
This basic model can be improved by making the wheels move along the mounting axis, thereby expanding the range of radii. This will require more ingenious solutions and precise execution of details.
Improved do-it-yourself manual pipe bender, video
Factory machines and tools for setting small radii have the same unchanged principle, but are arranged in a different way. More convenient and perfect fasteners that can be rearranged easily and quickly, mechanized labor, precise execution and a careful attitude to the workpiece are what a professional who is used to working hard and efficiently needs.
Manual electric pipe bender
High-quality production of the main parts of complete machine tools - a system of stops and levers - is possible only in the factory.
Observing the basic rules and the principle of pipe bending itself, you can use any available parts to improve the machine.
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Application of bent pipes
You can bend it using a special device -. When performing such a procedure, you can get good quality products that are used in many areas of our lives.
Bent shaped pipes are used for the manufacture of building structures, arches, greenhouses, fences, gates. They are the decoration of elegant outdoor furniture: benches, chairs, tables. Curved profile and used for the production of school desks, chairs, furniture for medicine, offices and other institutions.
Features of hydraulic pipe benders
A do-it-yourself hydraulic pipe bender according to your sketches or drawings, or taken from the Internet, is a special device using which you can bend pipes or rolled products at different bending angles, ranging from 0 to 180⁰.
You can buy a good hydraulic pipe bender in stores, or you can try to do it yourself, which, in terms of the quality of its functioning, will be in no way inferior to factory products.
And since improvised means and materials are used for self-production, the cost of such a bending structure will be much cheaper than serial devices. And the financial side in the manufacture of such a device, you see, for most of us, is of great importance. Considering this, many craftsmen make universal structures with their own hands, with the help of which profile and round pipes with any bending radius are easily and efficiently bent. And the Internet helps them, where you can choose not only the hydraulic pipe bender you like for making with your own hands, but also see ready-made drawings, videos, listen to or read the advice of experienced craftsmen.
Among the factory counterparts, the stalex hydraulic manual pipe bender is very popular, with which it is easy to bend as well. It is convenient for professionals to work with such a tool, since pipes can be bent directly on the construction site, and very smoothly and accurately. The design of the serial production manual pipe bender is such that when using it, flattening or kinking is completely excluded.
Peculiarities:
- creates an effort that is equal to 12 tons;
- equipped with a hydraulic drive;
- equipped with a set of interchangeable shoes;
- can function horizontally or vertically;
- provided with automatic return of the slider;
- during operation, the entire working stroke of the cylinder is involved;
- the bending radius is adjustable with vertical or horizontal supports (depending on the model).
Advantages
Among the many manual pipe benders, hydraulic machines are considered the most popular and demanded. There are good reasons for this.
Hydraulic devices are able to bend even a 3-inch round pipe with high quality. They are successfully used both by professionals - for performing large volumes of work, and by novice amateurs who want to bend one or two shaped or round pipes.
In addition to such advantages as:
- ease of manufacture;
- reliability;
- strength;
- low cost,
they are also appreciated for the force of impact, thanks to which it is possible to process not only thick-walled, but also to work with rather large products made of other metals: aluminum, brass, bronze.
In addition, a special installation (jack) greatly facilitates the work of the operator, who makes a minimum of effort to obtain a large force of pressure on steel, or other materials, pipes.
Important! It is impossible to bend the pipe more than is foreseen by the design of such a device, although there may be opportunities for this. This is due to possible invisible damage to the finished part, which will certainly appear a little later, during operation.
Preparation for manufacturing
Before making a manual pipe bender, you need to decide on the type of device. To do this, you need to familiarize yourself with the drawings and photos, as well as diagrams of possible designs made by yourself, watch a video, remember what materials and improvised means you have available, and only then start the manufacturing process. And most importantly: for what purpose and for what work do you need a structure with which you can bend the risers. Plus, it would be nice to consult with a more experienced neighbor or friend who has already dealt with the manufacture of such or a similar device. And if you're ready, you can start making the profile bending device.
Manufacturing process
Before you start making a machine for bending a round pipe, you need to stock up on everything you need:
- a hydraulic jack from a machine or tractor (you can use more powerful ones, if possible);
- channel (about 3 meters);
- 3 rollers with axles;
- metal plates.
When making a manual pipe bender, a simple algorithm should be followed:
- Using a tape measure, measure the required length of the channel for the base and cut off 2 equal pieces with a grinder, thanks to which the base of the future hydraulic pipe bender, and with it the frame (1), will be more stable.
- Place the cut pieces of the channel close to each other, weld from below and from above along the joint line. This platform will be the basis of the pipe bending machine.
- Weld the side channels on both sides of the base at an angle of 110⁰.
- Weld longer pieces to the upper part of the side channels, in which several (from 2 to 8) holes must first be drilled, placed symmetrically on both sides of the future pipe bending machine. They are designed to install axles with pressure rollers in them, by rearranging which it will be possible to adjust the bending radius of the risers.
- Fasten with plates with holes for bolts (2) with a diameter of 10-12 mm, the jack (3) on the base so that it does not move when working with steel or other pipes. To do this, you need to drill the base in certain places and fix the hydraulic device with bolt strips.
- Securely fasten the shoe (4) to the jack rod so that, if necessary, it can be easily removed and replaced with another.
Scheme for the manufacture of a manual pipe bender
Everything, the structure is ready for work, and the required dimensions are indicated on the drawing of the pipe bender made by hand, although in the photo, holes are not drilled in the upper channels (there are 2 of them, one on each side of the side channels). Therefore, the handheld hydraulic tube bender shown is designed to bend parts with only one bend radius.
The height of the bending machine is determined by the parameters of the jack and the distance "a". This means that to bend a half-inch steel pipe, this length must be approximately 2 cm (if the jack is inoperative).
It should be noted that all the force from the punch is directed to the top of the hand tube bender. Therefore, there are cases when the outer part of the bendable part is subjected to too much tension, which will contribute to a significant thinning of the wall of the circular pipe. There are even tears in the riser. Therefore, it is not always possible to use the unit to bend thin-walled pipes.
As you can see, there is nothing complicated, and the design for bending a round pipe is reliable, durable and will last for more than a dozen years. And most importantly, only improvised materials were used for its manufacture, which greatly reduced the cost of such a device.
Rolled version of the pipe bender with a turntable
The device is used for shaped pipes. The principle of operation of such a structure is as follows: a turntable, driven by a jack and through which the bending angle is set, is connected to the main bed by means of a hinge. The profile is pulled as a result of the rotation of the handle, which is connected to the intermediate shaft of the bending machine.
Bending machine
The base for the manual pipe bender and the stands are made of channels with a wall height of 125-200 mm. Cages for bearings, the base of the rollers, can be made of steel pipe, moreover, its diameter must match the diameter of the bearings.
The bending parameters can be adjusted in two ways: using the turntable and using the rollers located at the edge.
To this end, it is necessary to drill the support plates and the channel, which will ensure the mobility of the elements of the bending machine.
Both platforms of such a device are also made of channels. To raise the extreme platform of the manual pipe bender, a conventional automobile or tractor hydraulic jack is used.
To weld a vertical post from a channel, it is necessary to retreat from the edge of one side of the base of the hydraulic pipe bender approximately 45-50 cm. To strengthen it, it is advisable to pair two pieces.
Using the building level, it is necessary to achieve strict horizontality of the stationary platform of the homemade bending machine, and then weld the stand to it from behind. With the help of the profile pieces, build up the limiters to a height at least equal to or greater than the thickness of the shaped or round pipes, which will be flexible.
Using the door hinges, connect the main frame of the hand tube bender to the guide platform. Mount the bearings on the edges of the moving and stationary platforms, as well as on the stops of such a device, using welding for this.
To strengthen the entire structure of the hydraulic pipe bender, it is necessary to use the corners, which are welded in separate places. Attach a handle to the middle shaft of the bending machine, and install bearings on the outer ones.
Place the jack underneath the guide platform, use the bolts to securely fasten it to the base and the homemade pipe bender is ready to go.
By the way, the repair of a hand-made hydraulic pipe bender can also be done independently, and here's why: no one except you knows the features of its structure and the principle of operation. Therefore, only you yourself can make a high-quality repair of the pipe bender at home.
Bending technology
The bending process looks like this: first you need to install the steel pipe in the shoe and fix it on both sides. After that, you need to use a jack, thanks to which, such a device (the rod together with the shoe) will rise up. The force created by the hydraulic drive will instantly be transferred to the rollers, after which the riser will begin to bend under the previously set bend radius. After the end of the folding process, the device must be lowered and pulled out the finished product. The main thing is that such a bending machine can be stopped at any time, which eliminates the possibility of injury.
Important! If it is necessary to bend a very short profile pipe, and the distance between the rollers does not allow this, then it is necessary to build up both ends of the riser with pipe cuttings of the corresponding diameter.
Hydraulic bending pipe methods
Before bending a profile or round pipe, it is advisable to heed the advice of people experienced in this matter.
Firstly, home-made hydraulic pipe benders bend pipes made from any materials with sufficient quality. It is very important that with the help of the device, thick-walled products are bent, without any kind of marriage, which is beyond the strength of pipe benders of other structures made on their own at home.
Secondly, the procedure can be carried out using hot and cold methods, which also makes such devices more popular and in demand.
The highlight of cold bending is that a steel or pipe made of other metals must be filled with something before performing the operation. Sand, salt, oil or oil processing, water are well suited for this. Thanks to such fillers, the quality of the bending of steel pipes or is significantly increased, and the appearance of all kinds of unnecessary deformations is excluded.
With the hot method, you need to preheat a certain section of the steel pipe, and then bend it in the same way as a cold workpiece, but without filler.
Thirdly, in order to obtain a quality product, thick-walled structures are bent using a homemade hydraulic pipe bender using the hot bending method.
Inexperienced operators think that the bending process with a DIY metal bending machine is a fairly simple operation. But it is not so.
If you improperly handle the manual pipe bender, then unwanted defects may appear:
- a change in the diameter of a round pipe, which is caused by the so-called crushing;
- the appearance of thinning of the original samples at the place of bending of a round pipe or a profile analogue, which can lead to a deterioration in the strength characteristics of the part.
In order to minimize possible defects, it is necessary to be able to choose the right device and become familiar with the principle of its operation.
If you need to bend identically to the template, then in order to prevent the profile or round pipe from slipping, which means that there is no difference between the template and the bent part in terms of size and configuration, the stops must be replaced with metal hooks.
Usually, a homemade pipe bender with two rollers is used when bending structures with small radii, and with three large ones.
In order to improve the design, it is necessary to make a pipe bender with your own hands so that the thrust rollers can move, which will allow you to instantly change the bending radii.