Multi-radius tube bending is used to create parts with two or more center line radii in one complete cycle. This allows complex shapes to be completely formed without removing or resetting the tube or involving any other machines. Here's a video of multi-radius tube bending:
https://youtu.be/XFZjaiwVx5s
Additionally, with this technique changeovers between right-hand and left-hand bending heads may be repeated multiple times as needed.
A wide range of industrial metals, wall thicknesses and lengths can be accommodated with multi-radius tube bending.
Applications
There are a wide variety of applications for multi-radius tube bending, including heavy equipment and structural frames. It is also common for parts and assemblies used in exhaust and emissions control as well as oil and gas, or other process applications.
Benefits
Using dual head equipment, bending and setup is customized to successfully deliver both small and large radii on the same part. What makes multi-radius tube bending ideal for both high-volume orders as well as complex, highly engineered, parts is its ability to achieve several different bends on a part in one cycle.
Set-Up
Creating a multi-radius bend involves setting up the machine according to the tube geometry listed in the bend data sheet or production print. The coordinates in the data sheet in addition to the LRA data (length, rotation and angle) can either be entered manually or uploaded for each specific part.
After this step is completed, a simulation is performed to ensure that the tube will successfully clear the machine and tooling as it is bent. During this check, it is important to identify any sign of potential collision or interference.
Adjustments can be made to the software, clamps, head or other parts on the bending machine, if necessary, before the start of the process.
Inserts for the tube or pipe, called mandrels, are sometimes used to ensure that the tube maintains its shape and integrity during bending.
When the machine is set, the tube or pipe can be inserted into the machine’s collet. This clamps onto the part to guide its movement. The machine then runs through the program, making the entire part in one complete cycle.
Find out more information about the types of tube bending in our blog on tube bending processes and techniques.