IMTEX, 19/01/2012 - Bangalore

Imtex 2013 - 16th Indian metal cutting Machine Tool Exhibition with International participation. IMTEX series is the largest exhibition of metal - cutting machine tools and manufacturing solutions in South & South-East Asia.

IMTEX 2013 will showcase exhaustive range of innovations and technological refinements in the complete product segment of metal cutting machine tools and pipe bending machines.

IMTEX 2013 would spearhead a wide range of opportunities for everyone connected to metal-cutting manufacturing - manufacturers, users, technocrats, researchers, policy-makers, academia and even budding engineers & tech graduates.

Tooltech 2013 is a concurrent show with IMTEX 2013. Tooltech 2013 is 15th International Exhibition of cutting tools, tube benders, tooling systems, machine tool accessories, metrology and CAD/CAM at the same venue. Tooltech is India's premier exhibition showcasing newest trends in cutting tools and tooling industry, from all across the country as well as from various corners of the globe. An event that features recent innovations in tooling technologies for precision finish as well as for cost competitiveness in all metal working operations.

Advancements in metalworking have virtually transformed the concepts of manufacturing in many industries. Enhanced productivity, quality and superior finish are achieved through improved machining process, alternative processes, state-of-the art Automation, Tooling systems, Control equipment and so on. To highlight the evolving trends in the metal cutting industry, globally, Indian Machine Tool Manufacturers' Association (IMTMA) has scheduled an International Seminar on Machining technologies on 23rd January 2013, coinciding with IMTEX 2013 exhibition in Bangalore.

BENDING TUBE

A bend die, clamp die, and pressure die are the minimum essentials for tube bending. The bend die helps to prevent the tube from flattening and forms a given radius of bend.

The clamp die holds the tube in position while bending. The pressure die forces the tube into the bend die.

Springback is excessive when a mandrel is not used. This should be considered when selecting a bend die. Springback is the term used to describe the tendency of metal that has been formed to return to its original shape. Springback will cause the tube to unbend from two to ten degrees depending on the radius of bend, and may increase the bend radius of the tube. The smaller the radiuses of bend the smaller the springback.

The tube may kink or buckle, this may be due to hard material which will not compress on the inside radius of the bend. The material, not being able to compress, pushes in toward the centerline of the tube. This condition can be corrected (provided the tube is not too hard) by proper set up of the tooling. A plug mandrel is indicated if the tube buckles and is still within the wall factor and the diameter of the bend.

The purpose of a plug mandrel is to prevent the tube from flattening and to bend without wrinkles or kinks. The mandrel is held in a fixed position while the tube is pulled over it. The tube stretching process is localized on the outer radius of the bend and the material is work hardened to retain its shape and not flatten. The material stretching is done on the forward tip of the mandrel. This force, acting on the mandrel tip, supports the inner radius of the bend, holding it firmly into the bend die groove. CNC bender is used on CNC benders from 0.25" inch to 6" inch tube bending machines.

The pressure die should be adjusted for a light pressure against the tube. The purpose of the pressure die is to keep the tube against the bend die through the duration of bending. The pressure die also keeps the mandrel from bending and maintains a straight tube between tangent points of bends (the portion of ubing left on the mandrel after steel bending). The location of the mandrel affects the amount of springback. The mandrel in a forward position (toward tangent) will stretch the material on the outside of the bend more than is necessary. This increases the length of material on the outside beyond that which is required to make a bend. When the bent tube is removed from the bend die, it will conform to the die and there will be little or no springback.

EMO HANNOVER - 19 September 2011

On 19 September 2011 the EMO Hannover, the world's premier trade fair for the metal working technology will be opening its gates. For six days the city of Hannover will be the center of attraction for production specialists from throughout the world, the meeting point for the entire international sector.

Round about 2 000 companies from 40 countries will be showcasing the entire spectrum of products and services almost for the metalworking technology - spotlighting their performance capabilities and innovative vigour for the highly qualified experts. This year's EMO Hannover is presenting its products and events under the motto "More than machine tools".

Whether as an exhibitor or a trade visitor, a journalist, technically oriented youth or a representative of the political and academic communities, on our website you will find all the important information you need on EMO Hannover 2011.

Display Categories:

· Machine tools for cutting, splitting and milling

· Sheet metal, wire and tube working machines, metal forming machine tools

· Machine tools for thermal, electro-chemical and other processes

· Surface finishing technology, thin-film processes

· Software for entire manufacturing technology area

· Control systems

· Components for flexible automation

· CAD/CAM

· CNC bending machines

· Quality management systems

· Robotics and automation

· Material flow and storage technology

· Industrial electronics, sensor and diagnostic technology

· Precision tools, diamond tools, measuring tools

· Metal forming machine tools

· Tube benders

· Machines and systems for tool and mould construction, rapid prototyping, model construction

· Instrumentation and control technology

· Coolants, lubricants

· Welding, cutting, hardening, heating

· Mechanical, hydraulic, electrical and electronic accessories for manufacturing technology

At EMO Hannover 2011 we again will offer trade visitors a series of events, supplying them with additional information. Also Tauringroup, leader in metal bending machines, will show its new products in this exhibition.

One of the theme of the conferences is new manufacturing production technologies for the aerospace sector. The aerospace industry has become a significant technological and economic motor for the manufacturing location Germany over the past years. High market requirements with regard to minimal fuel consumption, high cargo capacities and extended range of airplanes lead to a growing demand for light and high-strength structures at the same time. For the first time, the Institute of Production Engineering and Machine Tools (IFW) at Leibniz Hannover University will be hosting its prestigious conference entitled "New Production Technologies in the Aerospace Industry" at the EMO Hannover. The event is co-organised by the nationwide Machining Innovations Network (MIN). EMO visitors from the aerospace industry will be offered a top-class forum for acquiring new information and exchanging news and views about the status of research work on an international level.

Further insights:

http://www.emo-hannover.de/homepage_e

TUBE BENDING

The most common processes for bending pipe and tube are: ram, roll, rotary-draw, heat-induction, and sand-packing and hot-slab forming. Ram pipe bending was probably the first pipe bending method used to cold-form materials.
This pipe bending method pushes a die against the tube or pipe by a mechanical force, forcing the pipe to conform to the contours of the die. Lacking internal support in the pipe, this pipe bending process creates some cross section ovality. The thinner the wall the more deformation of the pipe is seen.
Maximum pipe bending angle is normally 90 degrees. This is a commonly used pipe bending process where high levels of cross section ovality are acceptable such as furniture tubing, conduit and handrails.
During roll pipe bending, a series of spool-like rollers apply pressure to the pipe as it passes through them. Pipe bending operators change the location of the rollers to produce pipe of the desired radius. This pipe bending process is ideal for forming helical pipe coils for heat transfer applications as well as long sweeping sections such as those used in steel construction-curved trusses and roof components for structures requiring large open spaces. It deforms the pipe cross section very little for such sweeping sections.
The specialization of the company is providing tube manipulation services to clients. There is a range of specialist tube bending and forming services for compressor tubing, square or round tubing and mild steel, stainless steel or aluminium tubing.

The tube bending machines cater for round tubing from 6mm to 60mm with a maximum of 4mm wall thickness and square tubes up to 50mm with a 3mm wall thickness. The machinery works with ferrous and non-ferrous materials particularly mild steel, stainless steel and aluminium.

Square or round tubing can be supplied self coloured or finished, wet or powdercoated painted tubes, or they can be zinc plated for a clear or yellow finish. The company services a wide and diverse range of markets like the pneumatic and compressor markets, automotive, industrial, laboratory, aerospace and retail markets.
The benefit of using square tube bending versus round tubing is that you can attach braces and covering material to it so easily.
Then you can manufacture the rack for the four wheeler or tractor all by yourself to haul that old ice chest that no one makes a carrier that will fit it.
You could manufacture the rack to hold the garbage cans up high enough so that the dogs don't scatter it all over the street. You could make that bracket to hold some of that stuff on the floor of the garage up on the wall. That way you'd have room for more stuff on the floor of the garage.
A neat project would be to make a green house without one weld. It can be done.
The bender can be made without a welder. It can be used to fabricate all kinds of neat things and all without a welder.

BENDING MACHINES AND ANGLE ROLLS

Bending machine is versatile, it is easy to operate and is well suited for bending pipe, tube, aluminum extrusions and other sections.

Standard features include double pinch hydraulic forming rolls, hardened precision threaded shafts, and dual adjustable lateral guides.

The design is the result of years of experience and is aimed at providing the highest level of performance, accuracy and consistency throughout the life of the bending machine with the additional advantage of being virtually maintenance free.

The lateral guide rolls are hydraulically powered and can be adjusted to work very closely to the bending rolls, minimizing the distortion of non-symmetrical profiles. Moreover, the guide rolls are equipped with the tooling to bend angle leg-in.

Angle rolls machines are used for bending tube, angle, or shapes into coils, circles or large arcs using a wide variety of materials. By simply adjusting the third roll you change the size of the arc or circle. Tube bending sizes require specific rolls. There are rolls for any application including CNC bender controlled.

Profile rolls often called angle rolls. We used the same technology as our 3 and 4 roll plate bending rolls which results in a stronger and higher quality machine than most other manufacturers but still at a very competitive price.

The rolls can bend almost every profile and section in steel, stainless and aluminum and are virtually maintenance-free.

The components are:

• Heavy steel manufactured frame, machined on CNC machining centers for the best accuracy
• 3 direct driven rolls, with hydraulic planetary motor to eliminate gear boxes, connecting arms synchro devices and clutches
• 2 forming rolls for reduction of flat ends
• double roll spherical bearings SFK or equal = maintenance-free and maximum rigidity
• hydraulic motors attached directly to each planetary drive, eliminating the loss of torque
• Modular tooling which can be configured to roll most standard sections. Special tooling can be ordered for rolling pipe, tubing or channels the hard way.

Bending a spiral

Hi, i recently found this nice article about how to make a spiral staircase using a tube bending machine.

For stair handrails it is advised to use a box section, for instance a semi-circular profile.

Start by setting up the machine measuring the radius of your staircase: the machine uses a series of drive rollers that are set out to achieve a degree of pipe bend required.

The pipe is pulled through these angle rolls and then made into an arc.

Here you can find more about his article:
http://www.mustknowhow.com/index.php/mustknowhow/how-to-bend-handrails-for-spiral-staircase

Comparing bending machines prices

I found this interesting site were you can see a wide selection of products and can easily compare prices and features, which is a good way of evaluating the right choice before making a purchase.
Obviously, we focused on bending machines value, as you can see in this page: See bending equipment prices.

Useful instructions for copper pipe bending

Here is another interesting article we found, about how to use a copper pipe bender; there are many commonly used applications which require bending the copper pipe, such as heating, plumbing, air conditioning, etc.

These kind of bending machine allow the user to manually bend pipe to the required angle to connect to the system fixtures.

Copper pipe will straighten slightly after being removed from the copper tube bender. It is advised to bend the pipe about 2 to 5 degrees more than the desired angle. It wikk take some practice to get familiar with this process and correctly judge the extra bend angle to use.

Source: How to Use a Copper Pipe Bender | eHow.com http://www.ehow.com/how_5592467_use-copper-pipe-bender.html#ixzz18r1S2H2s

Bending Machines Operator

A bending machine operator sets up and operates machinery constructed to bend metal structural shapes, such as pipes, tubes, bars, rods, angles, to angle or contour according to speficic requirements such as drawings, templates, or layouts: the operator selects and bolts holding clamp, die block, and guide clamp to machine.
Following, are some of the activities due during the daily operations:

• Positioning and clamping end stops on machine to set specified location of bend.


• Screwing or insterting or plug stops into guide wheel to set specified degree of bend.


• Positioning workpiece against end stop. Locking and holding clamp and guide clamp onto workpiece.


• Lubricating workpiece with oil.


• Starting turntable to draw workpiece through guide clamp around die block until stopped by plug stops or until dial indicator points to specified degree of bend.
• Sliding mandrel into tubing instead of using guide clamp.


• Etc

Being the bending industry quite big, it can be easy to find several open positions for this kind, despite this industry has been challenged as many others by the struggling faced this year by western countries economies.
For instance, it is whorth looking at sites such as:
http://ca.indeed.com/Bending-Machine-Operator-jobs

Bending Performance Evaluation

I found this interesting document and I would like to share it with you:
square tube bending performances of aluminum beams reinforced by aluminum plates under three point bending loads have been evaluated using experimental tests combined with theoretical and finite element analyses.
Basic properties of aluminum materials used for initial input data of the finite element simulation were obtained from the true stress-true strain curves of specimens which had bean extracted from the Al tube beams.
True stresses were determined from applied loads and cross-sectional area records of a tensile specimen with a rectangular cross-section by real-time photographing. True strains were obtained from in-situ local elongation measurements of the specimen gage portion by the multi-point scanning laser extensometer. Four kinds of aluminum tube beam specimens adhered by aluminum plates were employed. The bending deformation behaviors up to the maximum load described by the numerical simulation were in good agreement with experimental ones. An aluminum tube beam strengthened by aluminum plate on the upper web showed an excellent bending capability

(source:http://www.scientific.net/KEM.297-300.2290)

How to Work on Bending Machines & Press Brakes

I found this interesting article on eHow.com with some step by step instructions on how to operate press brake bending machines risk-free, since they are designed to bend metal using tremendous amounts of pressure.

Here is a summary of the instructions to take care of your bending machines:

• Ensure that the machine is not in repair and is in ready working order.
• Clear the machine of any foreign objects before applying power. Adjust the machine to best fit your ergonomics.
• Wear all required protective gear and use all required safety equipment. If safety equipment is required and is not available, do not use the machine.
• Operate the machine according to use and not for ease.

Read more: (http://www.ehow.com/how_4703000_work-press-brakes-bending-machines.html)

A Guide to Cnc Tube Bending Machines

Do you know about CNC tube bending machines? These are designed in a fashion to minimize the time of set up and to maximize production. The CNC tube bending machines are available with many companies. Some of the companies have also launched CNC tube bending machines that feature electrical servo-drives on all axes and these are available in single as well as multi stack versions.

CNC pipe bending machines with multistack benders facilitate complicated bending without the requirement of tool change. In case, you cannot apply a multistack tool for stability reasons, try to switch over to an automatic clamp die changing system that will easily accommodate up to eight clamp dies.

The tube CNC bending machines feature excellent bending procedures that are programmable and boosting via the transport carriage in conjunction with the boosting in the area of pressure die. The boosting tends to minimize wall thinning towards the outer bend that further facilitates narrow bending. You can easily achieve a radius of less than 1 x OD. Other important features of CNC tube bending machines include the following:

An MMI multicontrol 2020 system
TFT monitor
Touchscreen
Plausibility verification
XYZ coordinate recalculation into bending parameters
Flexible programming
Multitasking
3-D displays
Integrated modem
Access to the world wide web

The integrated modem and access to the internet works towards providing the best of remote maintenance and technology support.

The CNC tube bending machines has a bending template. This helps in bending the pipe as desired. The unbent portion of the pipe is supported on a pipe that supports rail carries. It is also adjustable in height. The adjustment of height can be easily done by a drive and it is best suited for step-less positioning. This easily sets the pipe-supporting rail to a height that is already specified by the CNC control unit. Before bending the pipe, the height to which the pipe has been moved, is determines via a functioning program that is dependent on a full set comprising of tool data that has been input into the control unit.

Here are the features specifications of a CNC tube bending machines:

Industrial PC control
I/O card machine control
Input of all program to industrial PC via touch screen
Input data of Y.B.C.
Input data according to Descartes X.Y.Z coordination to build bending parameter.
The profile of tube will display on the PC as per the built parameter or input data.
Servo-motor control that feeds axis-X as well as rotates Axis-B, and then bends Axis-C that’s derived via hydraulic pressure
Program transmits via flash disc, floppy disc or the World Wide Web.
Adopt windows XP Embed operation system.
Process of the function auto and manually
Operation via Pedal
Single step change via the operator

Automatic bending rebound numerical compensation data s per accurate measured data.

(http://www.cncinformation.com/CNCBlog/a-guide-to-cnc-tube-bending-machines/)