Discussion with the fabricator can establish what materials, tooling and capabilities they have to help you with your project. It is a two-stack machine and can accomplish both types of forming on the same part, in a multiple step process.Ī good step to minimize the tooling costs associated with tube bending is to at the beginning of your design process reach out to fabricators that potentially can do your work. K-zell Metals has a Horn Metric 65TBRE CNC tube bending machine with both rotary draw bending and push roll capabilities. There are specialized tooling and CNC bending machines that can greatly reduce this distortion (such as our Horn 65TBRE Machine) but there needs to be enough production quantity to justify the initial programing, set up, and scrap rate costs to justify the process selection. The closer to the 8D value the greater degree of distortion that will be present and the more time and money a part will cost. The degree of this distortion is relative to the material alloy, the section wall thickness, and how close to the 8D value you are rolling to. That distortion can manifest in ripples produced on the surface of the tube, change of dimension of the tube profile, flatness issues after forming, ect. Centerline radius bends from 8D up to 16D can be difficult to nearly impossible to accomplish without significant distortion. Like the Rotary Draw Bending there is a zone that presents unique challenges to the Push Roll / Roll Bending process. One you have determined the process by which to accomplish the bending of the part there are other design consideration as it pertains to each process: If the centerline bend radius of the part is less than 8 times the material cross section then Rotary Draw Bending is the required process if the radius is greater than 8 times the cross section (also known as an 8D bend) then push rolling is the correct process.ġ” OD Round tube with a centerline bend radius of 3” requires Rotary Draw Bending (3” Centerline Radius / 1” OD Tube = 3 or 3D Bend)ġ” OD Round tube with a centerline bend radius of 12” requires Push Roll Bending (12” Centerline Radius / 1” OD Tube = 12 or 12D Bend) The general rule to determine which type of bending process is required is based on the bend radius divided by the tube/angle/channel cross section dimension. The differences between the two pertain exclusively to the requirement of the centerline bend radius of the tube (this can also be applied to other structural shapes like, angles, channels, I- Beams, T’s, etc). A couple of the most common methods are Rotary Draw Bending and Push Roll Bending. There are several different processes for bending tube, and those process vary with machines and tooling. Part Design Best Practices when Tube Bending is Required: We also offer services for tube rolling, round tube, square tube, bar and pipe. We are here for your custom metal bending needs, so request a quote today to begin your project. We'll take on any project, large or small.K-zell Metals offers tube bending and mandrel tube & pipe bending services. For more information on the custom metal forming services we provide, contact us today. As a customer, you can pick and choose the services you need for your specific application. We create custom formed parts, manufactured to your exact specifications whether you provide us with a cardboard cutout or a digital 3D design and prototype.Īlongside our metal forming services, we also provide laser and plasma cutting, tube bending, leveling and blanking services in order to be a one-stop shop when you need one. Our state-of-the-art, Los Angeles area Southern California facility is fully stocked and we have many materials on hand which shortens metal forming lead times and lowers costs for the customer. We manufacture frame channels, stair pans, trailer components, kick plates, and many other products servicing the automotive, construction, ornamental, and industrial markets. Stainless, mild steel, high strength, aluminum, and numerous other types of processed steel are all used in our metal forming services. Our California facility contains numerous press brakes with capacities including: We become an extension of your team when it comes to your metal forming needs, doing everything in our power to make sure you get exactly what you want and need. We provide a range of metal processing services including tube and steel bending for Los Angeles, California and surrounding areas. Hansen Steel is an expert in metal forming, tube bending, cutting, and fabrication for various markets throughout California. 1200 ton 40'-0" Tandem Press Brake Click to enlarge
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