Table of Contents

1. Introduction
2. Mechanics of Mandrel Bending
3. Applications of Mandrel Benders
4. Hongli Pipe Machinery Solutions
5. Numerical Analysis and Parameters
6. Conclusion
7. References

Introduction

Mandrel bending is a precise technique employed in shaping pipes and tubes. The process integrates a mandrel, a supportive tool, to prevent wrinkling and collapse. This results in smooth, consistent bends that are integral in numerous industrial applications.

Mechanics of Mandrel Bending

The mandrel bender functions by inserting a mandrel into the pipe before bending begins. This ensures the inner diameter maintains its roundness during the bend. Typically equipped with a wiper die, pressure die, and bending die, mandrel benders can achieve bends as tight as 1D (diameter of the pipe). The process involves:

• Inserting the mandrel into the tube.
• Rotating the bending arm around the bending die.
• Applying pressure with the pressure die to shape the tube.

Applications of Mandrel Benders

Mandrel benders are essential in industries that require precise tube bending. Key applications include:

• Automotive: Manufacturing exhaust systems, roll cages, and chassis components.
• Aerospace: Crafting hydraulic systems and structural elements.
• Furniture: Creating frames and other metal components with aesthetic bends.
• HVAC Systems: Developing ductwork and piping systems.

Hongli Pipe Machinery Solutions

Hongli Pipe Machinery offers advanced mandrel benders tailored for various industrial needs. Their solutions include:

• HLQ-68 Model: Capable of bending pipe diameters from 10 mm to 68 mm with a precision of 0.5°.
• HLQ-100 Model: Designed for larger pipes, supporting diameters up to 100 mm, ensuring less than 1% distortion on tight bends.
• Customization Services: Providing tailored solutions to meet specific curvature and diameter requirements of clients.

Numerical Analysis and Parameters

When designing with mandrel benders, several parameters must be considered:

• Bend Radius: Commonly set at 1-3 times the tube diameter. For a 50 mm tube, a 50-150 mm radius is standard.
• Wall Thickness: Minimum wall thickness helps prevent collapse. For mild steel, a thickness of 1.5 mm is typical.
• Tolerance Levels: Ensures precision within ±0.1° for critical applications.

Finite Element Analysis (FEA) simulation can predict stress distribution and potential failure points, optimizing the mandrel bending process.

Conclusion

Mandrel bending is a vital process in modern manufacturing, providing precision and efficiency in producing bent tubes. With advancements from companies like Hongli Pipe Machinery, industries continue to benefit from innovative solutions that meet exacting standards and specific requirements.

References

1. Technical Guide on Mandrel Bending, Industrial Manufacturing Journal, 2022.
2. Hongli Pipe Machinery Product Catalog, 2023 Edition.
3. Finite Element Analysis in Tube Bending Processes, Engineering Review, 2021.