Tube Bending

Custom Tube Bending Services

JIAHUI is your ultimate destination for exceptional custom tube bending services. With a reputation that precedes us, we are renowned for our unparalleled expertise in bending round, square, and rectangular tubing of all sizes and materials. Backed by years of experience, our team possesses an in-depth understanding of the art and science of tube bending.

From intricate angles to precise radii, we masterfully craft tubes to your exact specifications, ensuring a seamless fit and optimal performance within your applications. Our state-of-the-art equipment and skilled artisans guarantee the highest quality bends that meet even the most demanding standards.

  • Microscopic Accuracy
  • Customization Expertise
  • Streamlined Workflows
Tube Bending - https://jiahuicustom.com/

What’s Tube Bending Process?

The tube bending process is a manufacturing technique that involves reshaping tubes into specific angles, curves, and configurations to suit various applications. This intricate process demands both advanced machinery and skilled operators. Initially, the tube is precisely positioned and securely clamped. A mandrel, a rod-like tool, might be inserted inside the tube to prevent it from collapsing or wrinkling during bending. The bending machine then exerts a force at the precise point while the tube gradually takes on the desired shape.

Critical factors such as the tube’s material, diameter, wall thickness, and the intended bend angle must be considered to achieve accurate results. Complex calculations and precise adjustments are necessary for successful tube bending. This process finds utility across industries, from automotive to construction, where customized tube shapes ensure optimal functionality and fit within intricate systems, underscoring its significance in modern manufacturing.

Our Qualification For Tube Bending Service

Our tube-bending qualifications exemplify our commitment to excellence. Count on us for precision tube bending services that flawlessly align with your project requisites. Our manufacturing boasts a remarkable 99% error-free rate, a testament to our unwavering dedication to quality.

This stringent standard ensures components that impeccably fit your unique specifications, eliminating unnecessary disruptions. Our expertise extends beyond bending; we offer comprehensive solutions encompassing various materials and bend complexities. With cutting-edge technology and meticulous planning, we anticipate challenges, ensuring a seamless production process.

When you partner with us, you’re assured of receiving exceptional products and a collaborative approach that values your project’s success. Experience the pinnacle of tube bending prowess, designed to elevate your endeavors to unmatched levels of precision and perfection.

Manufacturing Process

Beginning with meticulous planning and material selection, we proceed to secure clamping and mandrel insertion. Advanced bending equipment then applies gradual force, resulting in accurate angles and curves. Rigorous quality checks at each step ensure the final product aligns seamlessly with your specifications.

Material Diameter Wall thickness Bending angle Bending Radius Tolerance
Stainless Steel 6~50mm 1~10mm 1º~180º 1.5D~3D ±1.5mm/m
Carbon Steel 6~100mm 1~10mm 1º~180º 1D~6D ±1.5mm/m
Aluminum 6~60mm 1~10mm 1º~180º 2D~3D ±1.5mm/m
Copper 6~80mm 1~10mm 1º~180º 3D~6D ±1.5mm/m
Titanium 6~50mm 1~5mm 1º~180º 1.5D~3D ±1.5mm/m

Our Tube Bending Production Capabilities

At JIAHUI, our tube-bending production capabilities redefine possibilities. Our multi-axis bending equipment ensures accurate repeatability, while our in-house tooling expertise allows customization for unique projects. From large-diameter tubes for structural applications to intricate shapes for specialized sectors, our ISO-certified processes guarantee exceptional quality and compliance.

Materials for Tube Bending Parts

Our proficiency encompasses a wide range of alloys and grades, including stainless steel, aluminum, copper, and brass. This versatility ensures that your project benefits from materials with specific properties, be it corrosion resistance, durability, or conductivity. Our team’s deep understanding of material behaviors during bending guarantees optimal results, maintaining structural integrity and performance.

  • Stainless Steel
  • Alloy Steel
  • Carbon Steel
  • Aluminum
  • Copper
  • Titanium

Stainless Steel

Stainless Steel

Stainless steel is metal-enriched with chromium elements (11%) and a small amount of carbon. Chromium offers corrosion resistance to stainless steel. Due to this, the tube bending parts are less likely to be affected by rust or corrosion. It can be easily molded into several forms. Thus, manufacturers prefer it for the die-casting process.

Characteristics

  • Extremely durable
  • High tensile strength
  • Corrosion resistant
  • Easy fabrication and formability
  • Low maintenance cost

Alloy Steel

Alloy Steel

Alloy steel is a type of steel that incorporates additional elements, such as chromium, nickel, or molybdenum, to enhance its mechanical properties. These alloys impart improved strength, hardness, and resistance to wear, corrosion, and heat, making alloy steel suitable for various applications in industries like automotive, construction, and aerospace.

Characteristics

  • High strength
  • Improved hardness
  • Enhanced corrosion resistance
  • Heat resistance
  • Versatility for various applications

 

Carbon Steel

Carbon Steel

Carbon steel is famous for its low cost and versatile nature. Typically, carbon steel is divided into three categories, i.e., low-carbon, medium-carbon, and high-carbon steel. The properties of these types differ according to the carbon content present in the material. Low-carbon steel is known for its good machinability and weldability, whereas high-carbon steel is used in high-strength applications.

Characteristics

  • Very hard
  • Ductile and malleable
  • Relatively low tensile strength
  • Good machinability
  • Low cost

 

AluminumAluminum

The distinctive characteristics of aluminum make it one of the best materials for tube bending. The major aluminum alloys are A360, A380, A390, A413, ADC12, and ADC1. Among all, the A380 is the most worthwhile aluminum alloy.

Characteristics

  • Excellent corrosion resistance
  • Lightweight
  • High strength and hardness
  • Outstanding thermal conductivity
  • High electrical conductivity
  • Remarkable EMI and RFI shielding properties

CopperCopper

Copper is a reddish-orange metal with a face-centered cubic structure that is highly valued for its aesthetics. It exhibits remarkable properties, yet, it can be alloyed with different elements, such as aluminum, tin, zinc, nickel, etc., to improve its characteristics further. The following are some fundamental properties of copper that make it ideal for producing die-casting parts.

Characteristics

  • Very soft
  • An excellent conductor of heat and electricity
  • Good corrosion resistance
  • High ductility
  • Fine malleability

 

Titanium - https://jiahuicustom.com/

Titanium

Titanium is a silver-grey transition metal often used for manufacturing high-strength parts. It is relatively soft when present in its pure form. However, adding certain elements like iron, aluminum, and vanadium makes titanium harder. The properties of titanium make it a perfect choice for manufacturers to use for die-casting parts.

Characteristics

  • Extremely high tensile strength
  • Lightweight
  • High corrosion resistance
  • Able to withstand extreme temperatures
  • High melting point
  • Excellent oxidation capabilities

 

Surface Treatment For Tube Bending Parts

By choosing the appropriate surface treatment for tube bending at JIAHUI, you ensure that your tube bending parts perform optimally and maintain their quality and visual appeal over time.

Name
Product
Description
Materials
Color
Texture

Anodizing

Anodizing_Tube Bending Part - https://jiahuicustom.com/

Anodizing improves corrosion resistance, enhancing wear and hardness and protecting the metal surface. This surface finish is widely used in mechanical parts, aircraft, automobile parts, and precision instruments.

Aluminum, Titanium

Clear, Black, Grey, Red, Blue, Gold, White, Silver, purple

Smooth, Matte finish

Powder Coating

Powder Coating_Tube Bending Part - https://jiahuicustom.com/

Powder coating in surface treatment is a dry finishing process where a fine powder is electrostatically applied to a surface. The coated object is then cured under heat, melting the powder particles and forming a durable, smooth, uniform coating.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Vertical stripe

Smooth, Matte finish

Passivation

Passivation_Tube Bending Part - https://jiahuicustom.com/

Passivation is a surface treatment process involving chemical solutions to remove contaminants from the surface of metal objects. This process enhances corrosion resistance by forming a protective oxide layer, thereby increasing the life and performance of the metal.

Aluminum, Copper, Stainless Steel, Stainless, Iron

Clear

Smooth, Matte finish

Electroplating

Electroplating_Tube Bending Part - https://jiahuicustom.com/

Electroplating in surface treatment is when a metal coating is applied to a conductive surface through an electrochemical reaction. It involves immersing the object to be plated in a solution containing metal ions and using an electric current to deposit a metal layer onto the surface.

Aluminum, Titanium, Copper, Stainless Steel, Steel

White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze

Smooth, Semi-matte, Matte finish

Polishing

Polishing_Tube Bending Part - https://jiahuicustom.com/

Polishing is the process of creating a shiny and smooth surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection but can reduce diffuse reflection in some materials.

Aluminum, Titanium, Copper, Stainless Steel, Steel

Clear

Smooth, Mirror finish

Painting

Painting_Tube Bending Part - https://jiahuicustom.com/

Painting is especially suitable for the surface of the primary material of metal. It will strengthen the material's moistureproof& rust prevention functions and enhance its compression resistance and internal structural stability.

Aluminum, Magnesium, Zinc, Titanium, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte or Gloss finish

Plastic Coating

Plastic Coating_Tube Bending Part - https://jiahuicustom.com/

Plastic coating refers to the process of applying a layer of plastic material onto a substrate surface to enhance its aesthetics, protection, or functionality. The plastic coating can provide a smooth, durable, and protective layer that can resist corrosion, abrasion, impact, and other environmental factors.

Aluminum, Titanium, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green

Smooth, Matte finish

Excellent Tube Bending Services

Trust us for exceptional quality, reliable performance, and a commitment to exceeding your expectations in every project.

Typical Tube Bending Products

Tube Bending - https://jiahuicustom.com/

FAQs Related To Tube Bending

A: The minimum bending radius of an elbow in the tube bending process is determined by several factors, including:

  1. Tube Diameter: The diameter of the bent tube is crucial in determining the minimum bending radius. Generally, smaller-diameter tubes can be bent to tighter radii than larger tubes.
  2. Material Type: Different materials have varying degrees of flexibility and ductility, influencing their ability to be bent to tight radii. Softer and more malleable materials can typically be bent to smaller radii compared to harder or more brittle materials.
  3. Wall Thickness: The thickness of the tube wall affects its ability to withstand the bending process. Thicker walls tend to require larger bending radii to avoid deformation, wrinkling, or cracking during bending.
  4. Material Properties: The material properties, such as yield strength and elongation, play a role in determining the minimum bending radius. Materials with higher yield strength or lower elongation may have limitations on the tightness of the bend radius.
  5. Bending Machine and Tooling: The capabilities of the bending machine and the specific tooling used also affect the minimum bending radius. Different machines and tooling have different limitations and capabilities, which need to be considered when determining the minimum bending radius.
  6. Desired Bend Quality: The desired quality of the bend, such as smoothness, roundness, and absence of defects, may influence the minimum bending radius. Tighter radii can sometimes result in compromised bend quality.

Considering these factors and their interactions is essential to determine the appropriate minimum bending radius for a specific tube bending application. Consulting with experienced professionals and conducting trials or simulations can help find the optimal bending parameters.

A: There are several mold design schemes commonly used in the tube bending process. The choice of the design scheme depends on factors such as the desired bend angle, bend radius, material properties, and the application's specific requirements. Here are some of the commonly used mold design schemes:

  1. Single-Stacked Tooling: In this scheme, a single set of tooling, consisting of a bending die and a clamp die, is used to achieve the desired bend. It is suitable for simple bends with a single radius.
  2. Mandrel Bending: This scheme involves using a mandrel inserted inside the tube during bending. The mandrel supports and prevents the tube from collapsing or wrinkling, especially for tight radius bends or thin-walled tubes.
  3. Wiper Die Bending: Wiper die bending uses a wiper die that contacts the outside surface of the tube during bending. It helps maintain the bend's roundness and smoothness, especially for large radius bends or when aesthetics are critical.
  4. Rotary Draw Bending: Rotary draw bending involves using a bending machine with a rotating bend die, and a fixed clamp die. The tube is drawn around the bend die, resulting in precise and controlled bends suitable for complex shapes and tight radii.
  5. Compression Bending: Compression bending is used for bending thin-walled tubes without the use of mandrels or wiper dies. The tube is compressed and deformed to achieve the desired bend radius. It is commonly used for larger radius bends and applications where mandrels or wiper dies are impractical.
  6. Roll Bending: Roll bending utilizes a series of rollers to bend the tube to the desired shape gradually. It is suitable for large radius bends or when precise control over the bend radius is not required.

These are just a few examples of the mold design schemes used in tube bending. The selection of the appropriate scheme depends on the application's specific requirements, the tube material, and the desired bend characteristics.

 

A: The quality standards for tube bending process inspection can vary depending on the industry, application, and specific requirements. However, several common quality standards and criteria are often considered during the inspection of tube bending processes. Here are some key aspects that are typically assessed:

  1. Bend Angle: The actual bend angle of the tube is compared to the desired bend angle specified in the design or customer requirements. This is usually measured using angle measurement tools such as protractors or angle gauges.
  2. Bend Radius: The radius of the bend is measured to ensure it falls within the specified tolerance range. This can be done using radius gauges or other measuring devices.
  3. Wall Thinning: The thickness of the tube wall at the bend area is checked to ensure it remains within acceptable limits. This is important to avoid structural weakness or failure.
  4. Surface Quality: The surface quality of the bent tube is inspected for any defects, such as cracks, scratches, or dents. Smoothness and uniformity of the bend are also assessed.
  5. Ovality: The ovality or roundness of the bent tube cross-section is checked to ensure it meets the specified requirements. Special measurement tools are used to assess this parameter.
  6. Straightness: The straightness of the tube sections before and after bending is evaluated to verify that the bending process did not introduce excessive distortion or misalignment.
  7. Dimensional Accuracy: The overall dimensions of the bent tube, such as length, width, and height, are measured to ensure they meet the specified tolerances.
  8. Material Integrity: The material integrity of the tube, including its composition and mechanical properties, may be assessed through destructive or non-destructive testing methods to ensure it meets the required standards.

In addition to these specific quality criteria, industry-specific standards and customer requirements may also apply. Industries such as automotive, aerospace, and medical devices often have their own particular quality standards and inspection protocols. It is essential to consult the relevant standards and specifications applicable to the specific application to ensure compliance with the required quality standards for tube bending processes.

A: Several common tube bending processes are used in the industry, each with advantages and applications. Here are some of the most commonly used tube bending processes:

  1. Rotary Draw Bending: This process involves using a bending machine with a rotating bend die, and a fixed clamp die. The tube is drawn around the bend die, resulting in precise and controlled bends. It is suitable for complex shapes and tight radii.
  2. Mandrel Bending: Mandrel bending is a process where a mandrel, or a solid rod, is inserted into the tube during bending to provide internal support. This helps to prevent the tube from collapsing or wrinkling, especially for tight radius bends or thin-walled tubes.
  3. Compression Bending: Compression bending is used for bending thin-walled tubes without the use of mandrels or wiper dies. The tube is compressed and deformed to achieve the desired bend radius. It is commonly used for larger radius bends and applications where mandrels or wiper dies are impractical.
  4. Roll Bending: Roll bending utilizes a series of rollers to bend the tube to the desired shape gradually. It is suitable for large radius bends or when precise control over the bend radius is not required.
  5. Ram Bending: Ram bending, also known as press bending, involves using a hydraulic or mechanical ram to apply force and bend the tube around a fixed bend die. It is commonly used for larger-diameter tubes or heavy-duty applications.
  6. Heat-Induction Bending: Heat-induction bending involves heating the tube to a specific temperature using an induction coil or a furnace. Once heated, the tube is bent using external force or a bending machine. This process is often used for bending thick-walled or heat-resistant materials.

These are just a few examples of the tube-bending processes commonly used in various industries. The choice of the appropriate process depends on factors such as the desired bend characteristics, tube material, wall thickness, and the application's specific requirements.

A: Several methods are commonly used in the industry for bending and forming elbows. Here are some of the primary bending and forming methods for elbows:

  1. Cold Bending: Cold bending is a common method for forming elbows, particularly for smaller diameter tubes. It involves using a bending machine or tooling to bend the tube to the desired angle. Cold bending is typically performed at room temperature and does not require the use of heat.
  2. Hot Bending: Hot bending is used for larger diameter or thicker-walled tubes that are difficult to bend using cold bending. In this method, the tube is heated to a specific temperature, typically using a furnace or induction heating, to make it more malleable. The heated tube is bent to the desired angle using a bending machine or other equipment.
  3. Mandrel Bending: Mandrel bending is a method commonly used to form elbows with a smooth and uniform curvature. It involves inserting a mandrel, or a solid rod, into the tube during the bending process to provide internal support. The mandrel prevents the tube from collapsing or wrinkling, resulting in a high-quality bend.
  4. Roll Bending: Roll bending is often employed for large-diameter elbows or when a wide-radius bend is required. This method utilizes a series of rollers to bend the tube to the desired curvature gradually. It is commonly used for applications where precise control over the bend radius is not critical.
  5. Hydraulic Press Bending: Hydraulic press bending, also known as ram bending, involves using hydraulic pressure to bend the tube around a fixed bend die. This method is often used for larger-diameter tubes or when heavy-duty bending is required.
  6. Forming by Welding: In some cases, elbows can also be formed by welding together straight tube sections at an angle to create the desired bend. This method is commonly used for custom or non-standard elbows where other bending methods may not be feasible.

The choice of the bending and forming method depends on various factors such as the tube diameter, wall thickness, Material, desired bend radius, and specific application requirements. It is essential to select the appropriate method carefully to ensure the desired bend characteristics and elbow quality.

 

A: The mandrel used in cored bending, or mandrel bending, comes in different shapes to suit various bending requirements. Here are some of the basic shapes of mandrels commonly used in cored bending:

  1. Ball Mandrel: A ball mandrel has a spherical shape at the end, resembling a ball. It is used for bending tubes with a small bend radius and complex shapes. The mandrel's spherical shape helps maintain the integrity of the tube's inner surface during the bending process.
  2. Plug Mandrel: A plug mandrel is cylindrical and inserted into the tube during bending. It supports and helps prevent the tube from collapsing or wrinkling, especially for tight-radius bends or thin-walled tubes.
  3. Wiper Die Mandrel: A wiper die mandrel has a tapered shape and is used to create a smooth transition between the straight and bent sections of the tube. It helps eliminate wrinkles or buckling that may occur during bending.
  4. Forming Mandrel: A forming mandrel is a custom-shaped mandrel designed to match the specific shape or contour of the desired bend. It is used for complex or non-standard bends where a standard mandrel shape may not be suitable.

These are some of the basic shapes of mandrels used in cored bending. The choice of mandrel shape depends on factors such as the desired bend radius, tube diameter, wall thickness, Material, and specific application requirements. The shape of the mandrel plays a crucial role in achieving accurate and high-quality bends in cored bending processes.

A: Common defects that can occur in tube bends include:

  1. Wrinkling: Wrinkling happens when the tube's outer surface collapses or buckles during bending. It is usually caused by excessive compression or insufficient support. Wrinkling can result in a compromised appearance and structural integrity of the bend.
  2. Ovality: Ovality refers to distorting the tube's cross-sectional shape, causing it to become elliptical instead of circular. Ovality can occur when the tube is not correctly supported or when excessive force is applied during bending. It can lead to fitment issues and compromised functionality of the bent tube.
  3. Rippling: Rippling manifests as a series of small waves or ripples on the outer surface of the bent tube. It occurs when there is a mismatch between the tube's wall thickness and the bending radius. Rippling is more common in thin-walled tubes and can affect the aesthetics and functionality of the bend.
  4. Springback: Springback is the tendency of the tube to return to its original shape after bending. It happens when the elastic properties of the Material cause it to rebound slightly. Springback can result in dimensional inaccuracies and affect the accuracy of the final bend.
  5. Surface Cracks: Cracks on the surface of the tube can occur during bending due to excessive stress or strain. Surface cracks can compromise the strength and integrity of the bend and may lead to failure under load.
  6. Flattening: Flattening refers to the deformation of the tube's cross-sectional shape, causing it to become more flat or squashed. Flattening can occur when excessive compressive force is applied during bending or when the tube is not adequately supported. It can impact the structural integrity and dimensional accuracy of the bend.

To minimize these defects, it is essential to use proper bending techniques, select appropriate mandrels, ensure adequate support, and choose the right equipment for the specific tube and bend requirements. Additionally, conducting thorough inspections and quality checks during and after the bending process can help identify and address any defects early on.

A: Various factors can cause elbow defects in tubes. Some common causes include:

  1. Improper Bending Technique: Incorrect bending techniques, such as excessive force or uneven pressure, can lead to elbow defects. Following proper bending procedures and using appropriate equipment and tooling is essential to ensure a smooth and consistent bend.
  2. Inadequate Support: Insufficient support during bending can result in elbow defects. When a tube is not adequately supported, it can collapse or deform unevenly, leading to irregular or distorted elbows.
  3. Material Properties: The properties of the tube material can influence the occurrence of elbow defects. Materials with low ductility or brittleness are more prone to developing defects during bending. Selecting materials with suitable ductility and strength for the specific bending requirements is crucial.
  4. Inadequate Material Preparation: Poor Material preparation, such as improper annealing or heat treatment, can contribute to elbow defects. If the Material is not adequately softened or annealed before bending, it may be more susceptible to cracking, wrinkling, or other defects.
  5. Mandrel Selection: Using an incorrect mandrel, whether it is the wrong size, shape, or Material, can cause elbow defects. The mandrel provides support and prevents collapse during bending. Choosing the right mandrel is essential to ensure proper support and minimize the risk of defects.
  6. Surface Defects: Tubes with surface defects, such as scratches, pits, or dents, can be more prone to developing elbow defects. These defects can act as stress concentration points, increasing the likelihood of wrinkling, cracking, or other deformations during bending.

To minimize elbow defects, it is essential to use appropriate bending techniques, provide adequate support, select suitable materials, properly prepare the Material, choose the right mandrel, and ensure the tube's surface is free from defects. Regular inspection and quality control during the bending process can help identify and address any potential defects early on.

Benefits of Working With Us

Request For A Quote

Anything we could do for your project? Contact us now by phone, email or through our contact form.

Hear from our clients

Our Key Clients

logo NEXTER
logo MERITOR
logo KTM
logo GIMAEX
logo BOMBARDIER
logo BERTRAND PUMA
logo TEXELIS
logo POK

Related Blogs

Precision is key in advanced manufacturing. Honing is an intricate machining process that has
Read more

Case hardening, an essential metallurgical process, transforms metal components and their functionality across industries
Read more

Screen printing stands out for its wide-ranging application across industries - fashion and advertising.
Read more

Sign Up For Our Newsletters

You cannot copy content of this page