Anyone who loves independently tinkering various products and designs, often faces the need to bend the profile pipe into an arc. It is impossible to make this without special devices evenly and accurately, so there is a need to make a pipe bender for a profile pipe with your own hands. Craftsmen invented a lot of designs of this device. Many of them can be done independently. However, they do not require large funds and are easy to manufacture and use.
Basic information about pipe benders
Before you begin the story about the options and methods for the manufacture of pipe benders, you need to decide what it is and what it is used for. So the pipe bender is a manual device or a stationary machine that allows you to bend a pipe from any material at an arbitrary angle.
The pipe can be steel, copper, aluminum or plastic with a diameter of from 5 to 1220 mm or profile with any section. Bend angle from 0 to 180 degrees. This article brings to your attention the technology of manufacturing several types of this uncomplicated device, having studied that, in a few hours you can make any piece you like.
Helpful advice! Before proceeding to the manufacture of pipe benders, it is necessary to understand their types. You should choose the one that best suits you in terms of functionality and is available for independent production by you.
If we are talking about industrial devices, they are divided into several types according to the method of the drive, as well as the type of bending.
Machines are: hydraulic, electromechanical and manual. Machines based on hydraulic actuators are manual and stationary. Their power is enough to quietly bend pipes even 3-inch diameter. Hydraulic pipe benders are used in professional activities at specialized industries and are capable of performing a very large amount of work.
Electromechanical devices can be used to bend virtually any pipe, even with very thin walls, which is beyond the power of hydraulics. After all, electronics allows you to very accurately calculate the force and angle of bending, which does not allow the material to burst. The pipes bent by such devices have no signs of deformation.
Manual pipe benders are used only for bending small diameter pipes made of polymers, stainless steel or non-ferrous metals. They work mainly from the mains. They are easy to use and do not require much physical strength to work. It is quite possible to make such pipe benders for a profile pipe with your own hands.
Bend the pipe using the device in various ways. Depending on this, the following types of pipe benders can be distinguished: crossbow, spring, segment, mandrel.
Crossbows are equipped with a special form, which is the bending element. It is designed for one diameter or section of pipe. To bend a pipe of a different diameter, the shape should be replaced. Spring devices are equipped with elastic springs, allowing plastic pipes to be bent without deformation. Segmental units are equipped with a special segment, which around itself stretches the pipe, bending it at the desired angle.
It should be understood that the method and magnitude of the bending angle of a pipe depends on its characteristics. There is even such a value as the minimum bending radius, with a further decrease in which the pipe is deformed or simply breaks. This indicator depends on the wall thickness, material and section of the pipe.
Helpful advice! Regardless of whether or not the pipe can be bent more than prescribed, this should not be done. Even if you can bend the product without damage, the quality of this fold will be poor, and this will sooner or later manifest. Therefore, the minimum radius must be adhered to.
Now consider some homemade versions of pipe benders. The simplest option provides for the possibility of bending the pipe by means of a template for a given radius. This technology is quite suitable for bending steel pipes, and not just aluminum. The template is simply cut from boards, the thickness of which is somewhat larger than the diameter or section of the pipe that is required to bend.
These boards are securely fastened to each other so that the pipe during the folding process cannot jump out of them. To form a gutter, the fastened boards are simply cut down with a slope for a round pipe. Then, the finished wooden template is attached to a table or other similar base. Next to the template is fixed stop for fixing the pipe.
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A self-made pipe bender for a profile pipe of this type is capable of bending even fairly thick-walled pipes if you use a winch. If the pipe is profiled, then bevels do not make when sawing boards. Instead, the pipe is fixed with a few stops.
Using wood, you can even build a rolled tube bender, if you carve wooden rollers. They can also be made from bearings or polyurethane. In general, the complexity of making improvised pipe benders depends in a certain way on the flexibility of the pipe. Pliable options can be bent on wooden fixtures without much difficulty just with your hands, but for hard pipes you will need more complex devices with metal parts.
If you decide to make a real hydraulic pipe bender, you need to get a jack with a hydraulic drive, a channel, two rollers and a shoe. In addition, you will need several metal plates of steel more than 3 mm thick.
From the channel with the help of the welding machine they create a rectangular structure, the height of which coincides with the height of the fully extended jack. It is installed on a rigid base and securely fastened with metal plates.
The jack needs to be chosen with a loading capacity of at least 5 tons. It is designed to perform the role of a pusher. The main task here is to find the most suitable clips. The difficulty is that only with the most accurate girth of the pipe with rollers can a really high-quality bend be obtained. If you find different rollers and make them removable, it will be possible to bend pipes of various sections and diameters.
The advantages of a hydraulic pipe-bending machine built for the profile pipe are: ease of manufacture, affordability and low cost of the jack and parts. Such a device allows with high quality to bend any shaped and round pipes in a cold state.
The process of bending the pipe in a rolling machine is as follows. The pipe is laid on the side rollers, and the third is placed on top of it, fixing the product in a predetermined position. When we begin to rotate the handle, the chain drives the shafts into rotation, and the profile or round tube bends at the required angle.
For the manufacture of such a device is necessary:
- grind out rollers and bearing cases. This task can be entrusted to the turner, who according to the drawings will do the work in the best possible way. The device will have three shafts, one of which is suspended on springs, and the other two are fixed in the sides of the frame;
- prepare a shelf of a 50 mm channel. It has the form of a rectangle with sides of 100×30 cm. Holes are made in it for fastening the shafts and threading is made to adjust the position of the pressure shaft;
- fasten all the parts together with a welding machine;
- the shelf with the clamping shaft is suspended on springs, and the side shafts are connected via sprockets with a chain. On one of the shafts weld handle for rotation;
- mount the jack so that it can be used to easily adjust the clamping force.
Helpful advice! To make a rolling pipe bender without the presence of drawings and calculations you are unlikely to succeed. If you do not have engineering knowledge, it is better to find ready-made documentation on which to make the machine.
A pipe bender for a profile pipe can be done with your own hands. Its complexity depends on the purpose for which you need it. If these are only one-time actions, then wooden structures are enough. If you are constantly engaged in the manufacture of products from the pipe, then you need a more complex unit.