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2 easy ways to assemble a machine for rolling a profile pipe with your own hands

Hello. In this review, I will talk about simple methods using which you can make a machine for rolling a profile pipe. There will be two ways, which means you can decide which one suits you best in terms of the materials used and the set of necessary tools.

Of course, in specialized stores you can buy or order ready-made equipment for the correct deformation of the metal profile. But why buy ready-made equipment if the price of what you can assemble with your own hands will be much more affordable.

Method one - assembly of equipment with a manual drive

To begin with, I propose to know how to assemble a machine for a profile pipe with manual drive supply of the workpiece.

In such a device, it is possible to manufacture not very wide ribs for building greenhouses, as well as wider parts for the manufacture of massive metal structures, for example, elements for assembling hangars.

The design of the equipment is simple, but at the same time effective. The lower guides are fixed on the movable bed, and the upper guides are fixed.

By changing the angle between the two parts of the bed, the position of the lower guides relative to the upper ones changes. As a result of rolling the pipe between the guide rollers, the bending radius changes.

The workpiece to be processed is driven by a manual drive, which spins the feed rollers. To increase the productivity of the process, the workpiece is driven not only by the winch, but is also additionally pushed or pulled by the end face.

Assembly technology

To assemble the machine, we need the following materials and components:

• Profile pipe with a cross section of 20 × 20 mm with a wall thickness of 2 mm;
• Channel 120×50 mm with a wall thickness of 8 mm;
• Corner 60×60 mm;
• Corner 40×40 mm;
• Bearings (outer diameter 47 mm, inner diameter 19 mm) — 2 pcs. for mounting the gate;
• Bearings (outer diameter 35 mm, inner diameter 17 mm) - 6 pcs. for assembly of side holders;
• Studs with a diameter of 16 mm;
• The pipe is round with an inner diameter of 17-18 mm.

The tool will require the following:

• Welding machine;
• Bulgarian with discs for cutting metal;
• Electric drill with a set of drills for metal;
• Measuring tool;
• Clamps and vise.

The installation work listed below is recommended to be performed on a flat surface relative to the horizon. When assembling most nodes, you must use a level and a plumb line. Following these simple recommendations, it will be possible to ensure that the machine will provide a given radius on both sides of the workpiece.

Installation instructions are as follows:

• From a pipe with a cross section of 40 × 40 mm, we cut the following parts: 2 pieces of 70 cm and 2 pieces of 16 cm;

• From these parts we weld a rectangular frame, which will serve as the base of the machine;
• From a pipe with a cross section of 40 × 40 mm we cut the following parts: 4 pieces of 27 cm and 4 of 35 cm;
• From the prepared parts on the already welded base, we weld vertical racks and diagonal supports;

• From the corner we cut 4 pieces 18 cm long, which we assemble into a design with a square section on the sides and with a cutout in the lower part, where the shaft will come into contact with the workpiece;

• We weld the tunnel for installing the shaft in the upper part of the vertical racks;
• From round pipes we make a gate consisting of a handle 50 cm long with a transversely welded shaft;

The greater the length of the gate handle, the greater the force that can be applied to the lever, which means that it will be easier to turn the drive of the machine. However, the length of the gate handle should be related to the diameter of the blanks from which you make it. That is, a too long handle with a small diameter of pipes and with a small thickness of their walls will most likely bend and break under heavy load.

• For ease of use, we weld horns 10 cm long along the edges of the handle;
• From two pieces of sheet steel 3 mm thick, we cut out plates with sides of 60 × 60 mm;
• In the center of the prepared plates, we drill a hole for the gate shaft;
• On one side of each plate, we weld a piece of pipe 2 cm wide into which the gate shaft will freely enter;

• In the cavity of the welded tunnel, we weld two bearings, one from each edge;

• On the sides of the tunnel, we fasten pre-prepared plates to the self-tapping screws, which will protect the assembly from contamination;
• From the channel we cut 2 pieces 35 cm long;
• We weld one of these pieces to the frame and to the vertical supports;

• The second piece of the channel is bolted to the first welded piece so that it can be moved in a vertical plane relative to the welded channel by 90°;

• In the middle of the channel pieces, rollers are welded fixed in bearings;

• For greater strength of the machine, the bearings, dressed on the rollers, are not only welded to the channel, but also reinforced with a design of pieces of a corner.
• In the lower part of the movable channel, a jumper from the corner is welded on the outside so that the jack is stuck into it;
• For more machine life metal surfaces can be painted in two layers with inexpensive PF-115 enamel.

Comments on the installation and subsequent operation of the finished device

For the convenience of work, bicycle rubber grips can be put on the ends of the gate handle. As a result, turning the gate with effort will not only be easier, but also safer.

The greatest productivity and bending accuracy will be ensured by the immobility of the installed machine. This can be achieved by welding the machine base to a metal table. As a temporary solution, the base can be attached to a stationary workbench with clamps.

The operation of the machine is most effective when used by several people, namely, one turns the gate, the other feeds a straight profile, the third takes a curved profile.

Method two - assembling a machine with a manual and auxiliary electric drive

Now that you know how to assemble a manual pipe rolling machine yourself , I suggest that you read the instructions for manufacturing a similar machine with an electric drive.

Let's take a closer look at the steps listed in the table.

To assemble the machine, you will need the following materials and parts:

• Channel 120×50 mm with a wall thickness of 8 mm
• A hardened bolt for the width of a channel with nuts;
• Timing gear from Zhiguli;
• Piston pin from KAMAZ;
• Metal round timber with a diameter of 25 mm
• Bearings
• Reducer from a grinder or a tool of similar size.

Assembly technology

The instruction for manufacturing a pipe bender with a combined drive is as follows:

• We cut the channel into 3 parts 50 cm long, 40 cm and 30 cm long;
• Channel 50 and 40 cm are welded with sidewalls;
• On a channel 40 cm long, we cut out a technological rectangular hole for the drive gear;

• We weld loops and an axis of rotation with side stoppers from nuts to the end of a long channel;

• We weld a short piece of the channel to the axis of rotation;

• We assemble two single units from a metal round timber, a gear and a piston pin, as shown in the photo;

The gears are made of cast iron and the piston pin is made of alloy steel. You can weld these two parts with an electrode for cast iron.

• Clips are made from pipe scraps for bearings that are welded to the frame;

• The bearings are welded into the cages and the previously made rollers with gears are already attached to them;
• On the upper shaft, on the opposite side of the gear, the gate handle is welded;
• On a fixed frame, along the line of the gears, we fasten the gearbox, for example, from a burnt grinder;

• As shown in the photo, we install the timing chain on the gears so that it also passes through the gearbox;

If the parts are cut to the dimensions specified in the instructions, the timing chain will have to be shortened. It is not difficult to do this - connecting pins are pressed from the joints and the links are separated. Having shortened the chain by the required number of links, the pin is installed in place and pressed.

• Now we are trying to scroll the handle of the gate and as a result we see that the rollers are rotating and the gears of the gearbox are spinning;

• Now, through a piece of hexagon, we attach a screwdriver or a more powerful drill to the gearbox;

• As a result, we obtain a device in which the rollers are driven by a handle, but when the bend radius changes, the rotation can be enhanced by a drill drive;

Using a screwdriver as an electric drive, we set a lower gear.

• To lift the movable part of the bed, a hydraulic jack is used, which is installed under the bed and stuck into a technological hole or into a welded corner.

Conclusion

Of course, an industrial cold pipe rolling mill will be an order of magnitude more powerful and productive than those machines that you have learned about assembling. But, you can certainly bend the details for the construction of a greenhouse or a polycarbonate canopy.

If you have experience in assembling more productive equipment for the deformation of a profile pipe, tell us about it in the comments to what you read. By the way, finally, I recommend watching the video in this article.

If you want to express gratitude, add a clarification or objection, ask the author something - add a comment or say thanks!

The simplest option available to most novice craftsmen is to bend pipes according to a pre-made template. A similar method is used when it is necessary to obtain a large number of the same type of blanks.

Bending a pipe on a wooden template is the easiest way to solve the problem

As a template, you can use a structure made of wooden boards. The thickness of the wood is chosen based on the diameter of the pipes to be bent - the board should have a margin of 2–3 cm. So that the metal profile does not slide off the template during operation, the ends are processed with a slight slope.

The structure is fixed to the floor or other surface in any way, mounting a stop for the pipe nearby. Having inserted the profile into the gap between the template and the thrust element, gently and gently press on its other end, pressing the pipe against the template. In order to lighten the pressing force, you can use a suitable size lever or adjust the winch.

The winch can facilitate the process of bending pipes using a template

In a similar way, a metal profile of small diameter can be bent. If it is required to change the configuration of the pipe by more than 1 inch, then the template is equipped with pieces of powerful reinforcement. To do this, holes are made in the concrete slab along the required trajectory, into which guides are inserted in the form of pins from pipe sections, fittings, etc. Bending is performed by fixing the edge of the metal profile by welding.

The advantage of this method is its cheapness and simplicity, however, the accuracy of the obtained blanks and the quality of their processing leave much to be desired. In addition, the template will have to be made every time you need to get a bend of a different radius.

Factory-made snail pipe bender

For the manufacture of a large number of the same type of workpieces with a small radius of curvature, you can use a snail pipe bender. This unit consists of two pulleys (wheels) of different diameters, mounted on shafts. Having fixed the end of the pipe on the impeller, a smaller-diameter roller (driving wheel) is pressed against the workpiece, while rolling it along the workpiece.

The most versatile and practical are home-made rolling pipe benders (bending machines), in which you can set any angle of deformation of rolled metal. The simplest design of a rolling unit is a base with drive shafts fixed at a certain distance from each other.

The pressure on the pipe is carried out by a movable roller, and its broach is carried out due to the rotation of the drive shafts. As a power drive of such devices, screw devices, jacks, winches and electric motors are used. The rolling machine is the most difficult to replicate at home, as it requires turning and welding.

However, there are many variations of its design made by amateurs, which indicates the high popularity of this solution. With the help of such a device, a bend of any configuration is obtained, and the process itself is often automated. The only thing such a device cannot cope with is obtaining the minimum radius of curvature of the metal profile in a small segment.

The machine for bending a profile pipe is structurally different from the usual one. This is due, firstly, to the greater resistance of the profile to bending loads, and secondly, to the fact that the bending radius is usually required to be large. Therefore, there are three rollers in the design. Two of them are installed permanently, one remains mobile.

Two extreme rollers are fixed on the body. They are raised above the base plane. For the middle roller, a special U-shaped frame is brewed. In the middle of its jumper, a long clamping screw of large diameter is installed. A third roller is attached to the lower end of this screw (can be welded). By rotating this screw, the roller lowers and rises, changing the bending radius of the profile pipe.

A cloud is welded to one of the fixed rollers, with the help of which the pipe is rolled through the machine. In order to be able to apply less effort for rolling, two fixed rollers are connected by a chain. For efficient transmission of torque, sprockets are welded to the rollers (possible from a bicycle), a chain is selected for them. Such a simple mechanism makes bending a profile pipe much easier.

In this design, the right or left roller is made movable. It moves along with part of the base. This part is connected to the rest of the frame with the help of powerful metal hinges.

Drawing of a bending machine for a profile pipe with a lifting platform

You can change the height using a jack, as shown in the drawing. The height of the platform in this case is selected depending on the height of the jack. The bending radius is changed by lifting the movable part of the table.

Unlike the previous design, this pipe bender for a profile pipe is driven from the central roller - a handle is welded to it. To reduce the force required, it is also possible to weld the sprocket to two fixed rollers and transmit the torque using a chain.

The base of the pipe bender is made from a channel or two welded corners. The thickness of the shelves is at least 3 mm, select the width of the shelves and the back of the channel according to the available parts. One rule - the base must be massive and reliable.

Several holes can be made along the edges of the platform. Through them, you can fix the machine to some kind of heavy base using large-diameter self-tapping screws. Fixation is necessary, since when bending pipes with a thick wall, considerable effort has to be applied and it is more convenient to work if the machine is firmly fixed.

A few words about rollers. They should be made of good quality, preferably hardened steel. It is the rollers and the axles that hold them that account for most of loads.

It is necessary to say about the form of rollers. They should not be smooth - there should be rollers along the edges that will not allow the pipe to “walk” during rolling. Only under such conditions will the arc from the profile pipe be even, and not twisted. Ideally, each pipe size needs its own rollers. But then the design becomes more complicated - they must be made removable, a reliable method of fastening should be thought out. The second option is to make rollers of complex shape, such as in the photo. Carve several steps for different sizes of pipes.

The same photo shows that the upper part of the bed is uneven, but notched. With the help of such teeth, it is possible to rearrange the rollers at different distances and thus also adjust the bending radius.

In general, they assemble home-made bending machines for shaped pipes from what is at hand or what they find / buy inexpensive. Who has the opportunity - grinds rollers, inserts bearings. Those who do not have such an opportunity use what they have - up to the bushings from bicycle wheels. In general, it is necessary to understand the design and

Explanations and photos are good, but seeing the assembly process or the work of the finished unit is much more useful. The first video shows the process of assembling (welding) a manual pipe bender for a profile pipe. The option with a movable middle roller was chosen. The second video is about the operation of a simple pipe bender with a movable platform.

Profile benders come in various designs; in industrial conditions, rather large machines with an electric or hydraulic drive are used; for bending a small number of products of small diameters - more compact manual or electric devices.

Universal production bending machine

The purpose of the roll forming machine is indicated by its name. This is the bending of metal profile pipes in order to obtain a certain radius of curvature in the required area or along the entire length of the workpiece. Using a profile bender, or in other words a pipe bender, you can perform several technological operations with rolled metal of various types:

• bending metal bars or fittings, including spring steel blanks;
• bending of profile metal-roll of square or rectangular type;
• getting knees from round pipes or bending them at the right angle;
• rounding of parts of any length from long products (corners, I-beams, channels).

There are several models of bending machines. Some allow you to apply effort only on a certain section of the workpiece. Others roll the pipe between rollers, applying pressure along the entire length. For some reason, it was the latter that received the name "profile benders" from specialists, although both of them directly relate to equipment of the same type.

Roll type profile bender

Depending on the type of drive, which, in turn, directly affects the power and productivity of the machine, profile benders are divided into several types.

Profile bending machine with hydraulic drive. Powerful and very expensive

Hydraulic pipe benders are industrial equipment, therefore they have high power and are designed for stationary installation. Such units are used mainly in small-scale and mass production, when it is required to obtain a large number of the same type of workpieces. The hydraulic drive completely removes the load from the operator, giving him the ability to control the machine by pressing buttons.

What is a pipe bender used for?

Profile pipe - a hollow profile of square, rectangular, oval section with a thin wall. Profile pipes are very widely used in construction, industry, mining complex, agriculture. Square and rectangular products are also used in everyday life: during the installation of metal structures, for the manufacture of furniture, garden buildings, sheds, greenhouses, fences, arbors, sheds, pavilions, pergolas.

At the same time, steel has a certain plasticity - thin-walled pipes can be bent. But when bent, the pipe can bend, form creases and folds - these defects reduce the strength of the pipes and do not look too aesthetically pleasing. Therefore, special devices are used for bending - pipe benders.

When laying pipelines and manufacturing bent structures bending allows you to minimize the number of welds and connecting fittings, which saves a lot of money.

Making a rolling structure with your own hands

The use of a special tool that allows you to easily and simply bend pipes, including profile pipes, can already be considered a plumbing tradition. Meanwhile, for all the time of locksmith practice, a number of the simplest methods for obtaining folds without using a special tool have been invented.

Device drawings

Profile bending classification

Pipe benders are classified according to the bending method and type of drive. In addition, pipe benders are universal and specialized: for round or shaped pipes.

The bending process itself is hot and cold, with or without filling the inside of the pipe with filler (sand or salt).

Bending devices are manual, hydraulic, electric, hybrid - combining molding elements with hydraulic and electric drive. There are industrial units for bending thick-walled pipes, in which the bending point is heated by induction.

Hydraulic devices are manual and stationary, on which workpieces with a diameter of up to 75 mm can be bent. Electrically driven (electromechanical) machines can bend pipes of various diameters. Electromechanical units can also bend thin-walled tubes with good quality bending, without folds and creases (see photo - this should not be so).

Hybrid units are stationary, they have a hydraulic drive on part of the shafts, and an electric drive on the other part of the shafts.

Manual devices are used either as portable (they are used near the place of assembly of metal structures), or for bending small diameters or soft workpieces (copper, stainless steel, plastic). In home gardens or when working in an apartment, pipes of small diameters and in limited quantities are used, so at home it is enough to get a manual pipe bender.

According to the method of bending pipes, the profile bender happens:

• Roller - the workpiece is formed when passing between three rollers.
• Crossbow - the workpiece is bent when laid in a special shape, according to appearance the design resembles a crossbow - hence the name. One device is usually accompanied by a set of molds for blanks of various sizes and for various angles and bending diameters.
• Segment - the workpiece is bent by a special segment, while stretching around the segment.

• Lever - designed for manual bending of thin-walled pipes.
• Spring - used for copper or plastic pipes, a spring conductor made of thick wire is inserted into the workpiece (sometimes put on top) and manual bending.

• Mandrel - with a filler (sand, salt) or a mandrel installed inside the workpiece. The pipe is wound on a winding roller, the mandrel or filler protects the bend from the formation of wrinkles.
• Mandrelless - the workpiece is wound on a bending roller.

How to make a pipe bender for a professional pipe yourself

1st way

To make and use a bending machine for a profile pipe, it is necessary to prepare two pieces of a channel, two trimming fingers that are part of the tractor tracks, and four corners.

To bend the workpiece, you will need a jack capable of developing a force of 5 tons or more. At the same time, it will be required to modernize it by installing a steel platform on the retractable rod, for the manufacture of which it is possible to use a worn-out pulley with a “stream” width comparable to the pipe profile.

The bed of the future machine is assembled from corners fixed on a steel plate by welding. In total, four corners are used, having a shelf from 60 to 80 mm, at the upper ends of which two channels are fixed by welding. To adjust the bending angle, it is necessary to have symmetrical holes in the walls of the channels that need to be drilled.

To bring the finished machine to its original position for work, it is enough:

• insert the axles (fingers) into the holes obtained in the channels and fix the rollers on them as stops for the workpiece;
• raise the jack platform to such a level that the workpiece can pass into the gap formed;
• install the workpiece in the machine for the profile pipe and create the required bend using the jack, using its functionality.

2nd way

A home-made pipe bender for a profile pipe based on rolled products implies that the workpiece will be laid on the side rollers, and pressed on top by the third. After fixing the pipe in this position, it remains only to set the shafts in motion by means of a chain drive to achieve the desired bend.

To make a machine for rolling a profile pipe, you will need:

Attention! It is problematic to manufacture a functional rolling pipe bender without appropriate calculations and drawings. At the same time, not everyone has the knowledge necessary for this, so it is best to use ready-made documentation.

Independent production of a pipe bender for a profile is a completely feasible task that must be correlated with certain goals. If you plan to carry out such work only as a one-time event, then you can collect wooden structure, which is quite capable of withstanding a short service life.

To assemble a stationary device required for bending pipes, you must do the following:

• mount metal carcass by connecting its elements with bolts and welding;
• install the axles and shafts on them in accordance with the existing drawing, observing the placement levels: two are higher than the third;
• collect chain drive used to power the machine, which will require not only a chain that can be borrowed, for example, from an old motorcycle, but also three gears;
• attach a handle to one of the shafts.

You can make the simplest profile bending machine yourself. This work is quite on the shoulder of the home master. The quality of homemade products is practically not inferior to industrial designs. Performance, of course, differs from models with an electric drive, but after all, a house and an estate do not require a huge amount of bent products.

Drawings and diagrams

Regardless of how you decide to make a pipe bender, you should first consider the scope of its application - decide what size and shape products you will bend, with what bending radius. For garden structures and furniture, the bending radius can be 2.5 sides of the section (for round blanks - 5 radii), and can be 10-15-20 sides (for gazebos, greenhouses and other large structures). Then draw a drawing or diagram with exact dimensions. Without a drawing, it is impossible to assemble a high-quality pipe bender.

The simplest pipe bender is a template cut out of boards, stuffed on a base - thick plywood or OSB. Bent rolled manually. The thickness of the boards should be greater than the diameter or size of the side of the workpiece - then the bending is better. You can make a template from steel pegs or hooks driven into a solid base (preferably concrete).

It is enough just to assemble a manual Volnov machine for a profile workpiece. On a solid metal plate, a roller with a radius equal to the bending radius is fixed, and two metal plates with a second roller fixed. The end of the pipe is clamped with a clamp, the roller on the plates turns and bends the workpiece.

There is another version of the profile bending machine, which you can make yourself - with three rollers.

For the manufacture of pipe bending rolls, or a rolling pipe bender, you will need:

• Metal frame (frame) from a rectangular channel.
• A sturdy stand welded from square profiles, channels, angles, or a stable steel workbench.
• Three rollers with shafts; the rollers must be turned in such a way that a groove with dimensions equal to the dimensions of the bent profile is formed in them; shafts and rollers are ordered from a turner.
• Shaft bearings.
• Chain.
• Winch.
• Clamp.
• Corners for guides.

Tools:

• Bulgarian with cutting discs.
• Welding machine, electrodes.
• Dye.
• Electric drill.
• Shaft mounts.

A frame is fixed on a stand or workbench - they are welded to the stand, fastened to the workbench with clamps. Weld guides. Bearings are fixed on the frame, two lower shafts are in the bearings, rollers are on the shafts. Shafts and rollers are ordered from a turner.

A double-row chain is put on the shafts, a winch is fixed in the middle, and the chain is fixed. Fix the pressure movable shaft. The upper pinch roller and shaft are moved along the guide by means of a screw.

Purpose and types

The pipe bender is an indispensable device when you need to delicately and accurately bend a round or shaped metal pipe.

The bending of metal profile pipes is directly related to their diameter, wall thickness and material of manufacture, therefore, metal-roll manufacturers always indicate the minimum deformation radius in special tables.

Table for calculating the bending radii of steel pipes depending on the diameter and wall thickness

To obtain a bend of the required curvature and not damage the part, special devices - pipe benders - allow. Depending on the length of the fragment to be bent, two types of devices are used:

• lever pipe benders;
• rental units.

The most common products are lever-type pipe benders. In such devices, the force is applied in the right place, and the bend itself repeats the shape of the segment (template), which in some devices can be removable. As a rule, the package of such units includes several segments for pipes of various diameters.

In addition to segment devices, the industry produces mandrel and crossbow pipe benders, the bending shape in which is set by two guide rollers and a pressure template (mandrel). This design allows cold working of round steel pipes in short sections. By the way, compact crossbow pipe benders are the most popular tool among utility installers.

Simple, fast and high quality - these are the advantages of crossbow pipe benders that attract professional installers

Depending on the design of the lever bending device, it can have any type of drive:

• hydraulic;
• pneumatic;
• electric.

IN household a machine for bending a profile pipe is not used so often as to buy expensive factory-made equipment.

If such a need arises, a simple pipe bender can be made privately, having previously decided which type of this design is suitable for the task.

This article details the types of pipe bending machines, describes the principles of their operation and methods of construction.

There are many equipment modifications to change the configuration of profile pipes. This is due to the minimum bend radius. If this important parameter is neglected, the strength characteristics of the material will change for the worse at the bending point. You also need to know some technological subtleties and take them into account during work.

When choosing a design, the workpiece material, diameter, wall thickness are taken into account.

Classification of bending machines by drive type

Depending on the type of drive, machines designed for bending any pipes are manual, electromechanical and hydraulic.

Manual. These are extremely simple mechanisms, available for self-production even to a person who is not privy to the intricacies of working with metal.

A hand-made, self-made machine for bending a profile pipe is an indispensable assistant in the manufacture of frames, decorative elements, self-installation of a ventilation system

Electromechanical. Such a machine has a drive in the form of an electric motor - stepping or conventional, connected through the lower gearbox. The latter solution provides high quality bending due to proper stress distribution.

The device of the mechanism is not easy to make, you need special knowledge and at least a little professionalism.

The electrically driven roll forming machine in most cases has the appearance of a 3-shaft structure. The profile pipe is passed between the rollers. An element located in the center can change its vertical coordinates. When the central shaft rotates, the profiled pipe changes its geometry

Hydraulic. The drive in this model is manual. Unlike simple handmade design, here a hydraulic cylinder is included in the circuit, which significantly reduces the muscular efforts applied during bending.

Rollers make it possible to bend the profile pipe in any desired direction. A manual profile bender with hydraulics, with its low weight, can bend a pipe assortment up to 10 cm wide.

The hydraulic cylinder of the roll forming machine exerts pressure on the surface of the pipe by mechanical action. This causes the cylinder rod to move. As a result of the resulting load, the product is deformed. The pressure in the piston can be increased in two ways - manually and with the help of an electric pump.

Types of pipe benders by installation method

There is a division of profile benders and depending on the installation method. Distinguish between stationary, portable and wearable equipment. Stationary machines can look like a simple concrete slab with rods, or solid equipment.

The compact portable benders have a support stand, while the portable model does not have a support, which is picked up every time the equipment is used.

Classification of machine tools by bending method

The design of the profile bender and its performance will depend on the bending method. There are 3 main bending methods. The first is extrusion, when the geometry of the profile pipe is changed using a deforming roller that acts as a punch. There is no matrix in this case.

To perform the operation, 2 strong supports are required on opposite sides of the bend, which act as a matrix. Swivel shoes or rollers are used as such supports.

Since the force builds up gradually and is always perpendicular to the pipe, the method makes it possible to obtain a good end result. We apply the method only for work in a small amount.

The second is pressing. To obtain a bend, the principle of a bench vise is used - a pipe segment is placed between the matrix and the punch.

The profiles of the latter, in order to obtain a high-quality bend, must exactly repeat the geometry of the part. And also in the calculation it is necessary to take into account the residual deformation of the metal. At home, this method is applicable when high accuracy is not required.

The machine for changing the shape of a profile pipe by rolling consists of three cylindrical rollers, a chain, a drive and a base. The diameter of the rollers must correspond to the parameters of the deformable profile pipe

The third - rolling - a universal method used for bending both thin-walled and thick-walled pipes. The bend is obtained by pulling the workpiece between the rollers - one rotating and two supporting.

In addition to those mentioned above, pipe bending can also be carried out by the following methods:

Image gallery

Bending of a pipe is carried out by means of three rotating rollers. In this case, the bending radius determines their location in relation to each other.

When bending the pipe with a crossbow pipe bender, it rests against two rollers, and the template that is located on the rod of the device bends it between the supports

The principle of operation of this pipe bender is to bend the pipe in a cold state by rolling it with a roller around the bending block

The guide platform is connected to the main frame by means of door hinges. On the extended limiters and the edges of both platforms, bearings are mounted by welding and the structure is reinforced with corners. The shafts are inserted into the bearings, and a handle is attached to the middle one.

A jack is installed under the edge of the guide platform and fixed to the base with a bolted connection.

The pipe bender with a turntable is assembled in the following sequence:

Image gallery

For the manufacture of a pipe bender, you will need the following materials: pipe, channel - 2.5m, bearings, jack, hinges, rollers

It is necessary to cut the channel into two parts - one of them will be the main platform, and the second - the guide. They are connected with metal loops.

The next step is to cut 6 pieces of pipe 2 cm wide and bend them to mount the bearings

Having cut the rollers of the required length, they must be connected to the bearings and the structure welded to the working platform

The central roller must be welded at a height of 8-9 cm above the platform. This is necessary so that a profile pipe can pass under it.

Using welding, we connect the working platform to the base and check the reliability of all connections

The unit for bending a metal profile, pipes, rolling products of various sections is called a profile bender. Depending on the complexity of the cross-section of the profile, rollers with a simple side surface are used, or it is bored under a corner, an I-beam, a channel, a Taurus. This is done so that it repeats the view of the section at the end face of the processed shaped steel.

The principle of the machine

With the help of hydraulics, a general clamping force is provided, this is how the deformation of metal profiles of large thickness occurs. Pipe benders in the factory give a force of more than 8 tons, this indicator affects the choice of machine control: manual or electric. Devices with forced and manual clamping bend the rolled metal, providing cold deformation of the metal. Bending action in various machines different direction:

• The pressure roller moves in a downward direction. The scheme with the top arrangement of a shaft is demanded during the work of the roll-forming equipment with electric control. In machines with a jack, this direction of movement of the working shaft is rarely used.
• The working shaft moves from the bottom up, and the side rollers are fixed in static immobility. Such a scheme is used in units with hydraulic jacks, a change in position occurs when the central roll is moved.

These two working schemes are equally effective, although they differ in the location of the working and auxiliary shafts, as well as the type of pressing device.

Homemade bending unit

In the workshop, most often they design and assemble a roll forming machine with their own hands. The drawings are made for a unit designed for a metal profile, which in cross section has a diameter of 6 cm or less, since the bending of powerful rolled products requires a professional electric hydraulic drive.

The choice of constructs and materials

Materials are selected based on performance. For the base, take beams that are not curved, rust on them can occupy an area of ​​\u200b\u200bno more than 10%. So that work does not have to be interrupted in search of missing materials, prepare the elements in advance:

• bearing units with pressed rolling rollers;
• channel, you need to take it No. 100 or 80;
• monolithic shafts made of steel, the diameter of which is not less than 80 mm;
• a metal rod with a diameter of 12 mm;
• steel strip with a thickness of 5 mm or more;
• bicycle chain or timing chain from the "Zhiguli" gear;
• engraving and simple nuts, washers, M20 bolts, the length of the last 60 mm.

For the manufacture of the bed, two pieces are cut from a channel 20 cm long (for transverse guides) and two blanks of 70 cm each (for longitudinal racks). At the ends of the last two blanks, an angle of 70˚ is formed using a grinder.

initial stage

To install bearing assemblies, at the top of the longitudinal struts, holes are marked for their fastening. To do this, use a core and mark where the bolts will be located. After that, the bearings are removed to the side, and holes are drilled in the marked places using electric drill using a metal drill.

The dimensions and location of the side fasteners are not marked on the drawing, but are selected at the place of manufacture, these parameters depend on the dimensions of the shafts that are prepared for installation in the structure. Through holes are drilled in the mounts, they are designed for setting the shaft. The edges of the holes are reinforced with additional overlays made of a metal strip so that the thickness of the passage (wall) is 10 mm.

A piece equal to the width of the shaft is separated from the channel with a grinder, its ends are formed at 45˚. It is needed in order to make a clamping unit. A skeleton is assembled for attaching the shaft from the upper crossbar and two side racks in the form of the letter P. The remaining channel is used to cut two 50 cm segments to make a guide structure.

Main production cycle

To prepare the elements connected with bolts, two pieces are cut from the steel strip. They are calculated so that they fit freely into the cavity of the channel. For M12 bolts, holes of the appropriate diameter are drilled in pieces of plates, retreating from the edges by a distance of 10 mm. Finished parts are placed inside the channel and welded.

The prepared longitudinal and transverse parts are connected by welding, the frame of the profile bending machine is obtained. During the assembly process, a shaft is inserted into the structure of the top and two sidewalls. Guide vertical sections of the channel are welded to the frame, which were prepared on initial stage assembly, the clamping mechanism will move along them.

A 22 mm hole is drilled in the upper part of the clamping device for the M20 bolt. The end of the bolt freely enters the hole, but does not fall out of it; for this, soldering is done at the end by welding. The guides for moving the carriage make them from two sections of the channel, the length of the blanks is equal to the distance between the skids. The holes in the crossbars are made exactly so that they coincide with those previously drilled in the guide parts of the runs. A hole in the center is drilled according to the diameter of the nut, then it is welded on top.

For fixing the crossbar of the top, a bolted connection is provided, the hardware is inserted into it. Tighten the bolts using engraved nuts. Bearing assemblies are mounted on top of the frame base, and stationary shafts are placed on them. Bearing assemblies are bolted through holes using engraving nuts.

To connect the hub to the gears, it is welded under the chain. The hub diameter must match that of the spindle shaft. A protrusion in the form of a groove is boiled on it, and a passage in the form of a groove is machined on the surface of the shaft; during installation, they must match. Sometimes, in order to simplify, the hubs are welded onto the shaft. Then the gears are put on the spindles and secured with two nuts: a lock nut and a main one.

Final works

In the middle part of the guide beam, placed vertically, an axle for the gear and a gate are welded under the collar. Work is performed from the side of the installed gears. The axis is located in relation to the guides so that the chain can be removed if necessary, and in the working position it was stretched.

A bar is welded to a steel strip about 50 cm in size, which will serve as a handle. It turns out a gate to which a hub is welded from the second end. For its manufacture, the rest of the pipe is taken, and it turns out that the diameter of the hub is equal to the internal size of the gears.

The gear is pressed onto the hub handle, it serves to wind the chain, a vice is used for this work. To speed up the pressing process, the gear is heated to 120˚, from which the mounting hole will expand, and after putting it on, it will decrease, and the gear will get a tight fit.

The assembly of the clamping assembly is completed by making a kind of handle; for this, a hole is drilled at the end of the bolt, where a piece of metal bar is inserted. Before throwing the chain on all three gears, the hub is attached to the axle prepared in advance and tightened with a lock nut. It turns out a gearbox in order to transmit the torque from the handle.

After completion of work, the machine is painted with oil compounds to prevent rust and corrosion from the surrounding atmosphere. Those parts of the unit that interact with each other with surfaces or rub during operation are not painted.

Drawing Features

Before you make a profile bender with your own hands, drawings, dimensions are calculated independently or taken from the Internet or printed publications. In this case, you need to thoroughly understand the design, since unsuccessful schemes will lead to loosening of the frame over time and a violation of the specified profile bending parameters. Sometimes inaccurately installed shafts contribute to the twisting of the profile or obtaining an angular radius.

According to the finished drawings, you can make a frame, position the shafts, attach the guide skids for the carriage and prepare the gearbox on the shaft. For the choice of the surface of the rollers, such information schemes are only suitable if they are intended for bending exactly the same profile as the master. But in addition to the configuration, the rolled beams differ in the size of the section, the thickness of the flange and other parameters (just refer to the assortment). Drawing unchanged can only be used if:

• does not contain technical errors, for this you need to contact an experienced mechanic, he will determine the performance of the selected circuit;
• the technical side of the description is developed in detail, the assembly is understandable, the drawing is provided with an extensive dimensional grid, all fastening methods are indicated, assembly units with cuts are drawn, and the interaction of adjacent elements is provided;
• the design of the machine does not require the use of little-known materials and components that cannot be bought or ordered.

Based on the finished drawings, the master can correct some provisions by adjusting the diagrams to fit individual conditions. When performing assembly diagrams pay attention to such questions:

• the configuration of the surface of the supporting and counter rollers is determined taking into account the shape of the shaped section of the rolled product, and not only with the size at the end;
• some types of rolled products, for example, a corner or a channel, bend successfully if the direction of bending is taken into account when installed in the unit (the shelf is located up or down).

A feature of the choice of the side surface of the roller disk is that it is required to minimize the possibility of tearing out the profile, its twisting, as a result there should be no crumpled shelves. This is important not only for a small section, but also large profiles with thick shelves cannot withstand the load. Therefore, the design of the roller sides is given attention during development.

A profile of a relatively simple section, for example, square or round (pipes), does not require the complication of side planes. In this case, the appearance is flat and even, and if complex sections are bent, then choose the following solutions:

• The round or oval shape of the rod dictates the formation of a groove or a kind of groove with a section of the corresponding type on the side plane of the roller.
• To bend a profile of a rectangular or square section without protruding shelves, the lateral appearance of the disks is made in the correct rectangular shape with sides. At the same time, the thickness of the disc is selected taking into account the fact that the outer dimensions of the rolled products fit exactly into the inner space between the sides, which firmly hold the product.
• If you need to bend the corner so that the resulting arch has the inner side of the profile outside (bending along the outer side), then the surface of the working disk is flat, but a board is placed to hold it. The supporting disk is made with a flat appearance, and the disks are shifted from one another by a distance of the thickness of the corner shelf.
• In case of bending the corner inside, the working roller is made flat, and the sides are provided on the disks of stationary shafts.
• When bending the channel, the situation is almost the same as with the corner. Bending on the outer side requires the implementation of the board on the plane of the working roller, while the stationary disks are made flat. Reverse bending requires retaining flanges on the backing plates, and the worker is performed with a flat appearance.
• To work with an I-beam, the cross-sectional side section of the working and stationary disks is made in size such that it corresponds to the internal size between the profile shelves. The ends of the disks must fit snugly inside the I-profile and prevent its deformation.
• To make an arch from an I-beam, in which there will be shelves at the bottom and at the top (bending across the shelves), you need to perform a complex configuration on the side planes of the roller, while two sides are made on the support and moving roller.

A roll forming unit that is universal for all types of profiles cannot be made. An option for a workshop that offers bending services would be to make separate sets of three discs bolted to the shafts and replaced with others as needed.

Purchase of a private house or suburban area rarely associated with the desire to spend the weekend passively. Very little time will pass and a greenhouse covered with polycarbonate will appear on the site, and a fancy visor will be installed above the veranda of the house, capable of protecting from raindrops and the scorching sun.

The basis for such important and necessary structures is a frame made of bent profile pipes. Well, in order to get a bend of a given radius and shape, a pipe bender is needed. In this article, we will talk about how to make a similar pipe rolling machine, which a home craftsman cannot do without.

Profile deformation

What is a pipe bender and why is it needed

Industrial production

A machine for rolling a profile pipe or a pipe bender is a technical device that belongs to the tools and mechanisms used to work with rolled metal products. With it, you can easily bend the profile of ordinary pipe materials according to a given radius. Its main advantage is the ability to bend any number of products with the same radius.

Note! Bent pipes can be used to install pipelines for transporting hot or cold water, as well as to create frames of various types and shapes, which are often used in construction.

Many people wonder why a hard worker is needed ?. It would seem, strengthen one end of the pipe and pull the other. But in fact, not everything is so simple.

Such a method will lead to the following consequences:

1. Lack of ability to control the radius;
2. By bending the product in this way, you will create a zone of stress concentration, thereby reducing the strength of the structure;
3. Reduced service life of the structure.

A pipe bender is simply necessary for a home master, so for many there is an acute question of what is the price of such a machine, or is it more reasonable to make it yourself.

How to choose?

When purchasing any tool for their own use, each master should be guided by the principle of its reasonable need.

Advice. The tool with which pipes are rolled must perform its functions properly, without requiring additional expenses from its owner.

Criteria for choosing a mechanism of this kind:

1. Type of drive. The choice is made depending on the overall dimensions of the pipes, the expected scope of work and the intensity of use of the tool;
2. Maximum geometric parameters of processed profile products;
3. The principle of operation of the machine, depending on the specifics of the operations performed.

Another important factor is the size of the machine itself. Based on the location on the desktop or in a separate corner, you can choose a stationary multi-tool.

Pipe bender device

Pipe Bending Methods

The main purpose of this type of tool is the rolling of a profile pipe, i.e., giving the workpiece the required shape.

The most common among home craftsmen is precisely the three-roller version of the machine with manual type drive. Such a unit is a triangular structure of three rollers, equal in width to the section of the workpiece.

The rollers located at the base of the structure are interconnected by means of a chain drive. The top roller is part of a screw mechanism with a screw-type clamp or press.

This top roller is able to reciprocate in the vertical direction.

1. The pipe is placed on the lower rollers and pressed against the upper one connected to the screw mechanism;
2. Turning the handle, the master produces a broach;
3. Further, without removing the workpiece from the mill, we increase the pressure by turning the clamping screw several turns;
4. The workpiece is stretched again.

The described cycle must be repeated until the pipe acquires the desired shape.

Types of pipe benders

Despite the fact that the device seems quite simple, there are a huge number of designs of this kind. According to some basic features, they are divided into the following categories.

According to the type of drive, the machine for a profile pipe can be:

• Electromechanical. The drive for such a device is a conventional or stepper motor. Moreover, the usual one is connected through the lower gearbox, which allows you to evenly stretch the applied efforts over time in order to achieve a high quality bend;

Note! The electric motor can drive the roller of the rolling tool or the arm system of the mandrel type machine.

• Hydraulic. A more powerful version of the hand-operated design. The use of a hydraulic cylinder as a clamping mechanism will reduce the effort required for bending;
• Manual. The most common type of mechanism, which is usually present in the workshop of every master and good owner.

Note! The workpiece is rolled and the clamping force is generated only by the force applied by the operator.

According to the bending method, rolling mills can be classified as follows:

• Dornovy - as a rule, industrial production. Most often you can find electromechanical or hydraulic. The advantages of this design include high-quality deformation with a small specified bending radius;

mandrel tool

• Segment - for working with thin-walled pipes made of soft types of metal. Commonly used by plumbers and heating system builders. It consists of two levers with holders for bending products. A mandrel with the required radius is installed in the place of the hinged connection of the levers. Bending in this case is made after installing the pipe by bringing the handles together;
• Spring - is a dense spring of a certain diameter, inside which a pipe is threaded. To obtain a high-quality bend, you need to have considerable experience. Commonly used by air conditioners;
• Crossbow - used for deformation of copper, aluminum and steel thin-walled pipes. It is a T-shaped structure, on top of which pipe holders are fixed, and in the center a movable lever with replaceable mandrels. When you press the handle, the lever extends, and the ratchet mechanism allows you to gradually increase the bending force.

crossbow assembly

Do it yourself

For example, the instructions for creating a three-roller manual type unit will be considered:

In the photo - a homemade design

1. As a body, you can use steel sheets 3 mm thick, on which we mark with a simple pencil;
2. The rollers can be made from rope pulleys endowed with bearings;
3. The seat for the roller is drilled using a conventional electric drill;
4. Opposite the roller, at the very top, a sufficiently high nut is welded, which will be part of the clamping mechanism;
5. A U-shaped part is welded, equipped with mounting holes for the roller mounting screw. A welded washer will be responsible for lifting the pressure roller.

Finally

Manual pipe bender

The cold rolling mill of pipes will allow you to effectively bend products different type and size. Having built it yourself or buying such a unit and installing it in your own workshop, you can be sure that the construction of frames of even the most bizarre shapes will no longer be a problem for you.

With the help of such a tool, you will make a greenhouse frame, an original canopy, and any other design you need.

And the video in this article will reveal to you even more nuances of building your own instrument.

Hydroguru.com

We make a homemade pipe bender and profile bender with our own hands

There are many models of industrial pipe benders on the construction markets, but it hardly makes sense to buy a professional tool in order to bend two or three pipes. But to make this simple tool with your own hands and use it in the household is quite within the power of every person who has certain technical skills.

The use of pipe benders

Pipes have been and are one of the most popular building materials that are used both in the household and in industry and construction. In addition to being used in the installation of water and gas pipelines, pipes are also used for the manufacture of fences, greenhouse structures, arbors, sheds, garden furniture etc. Thus, the presence of a pipe bender in the household will never be redundant.

Often, for the manufacture of various structures from pipes, it is necessary to bend the profile pipes along the radius. For these purposes, a pipe bender is used, which allows bending pipes up to an angle of 180 degrees. Pipe benders allow you to easily and accurately change the configuration of pipes made of various materials - aluminum, metal-plastic, stainless steel. The bend is made according to the required shape and size.

Types and models of pipe benders

The industry produces various types of professional pipe benders. Small-diameter pipes are usually bent using hand-operated tools, but pipes up to three inches in diameter are bent using hydraulically driven pipe benders.

Such a tool is designed to perform large-scale work. Industrial pipe benders can be made both in stationary and mobile versions. The most convenient tool that connects to the mains.

Electromechanical pipe benders provide the most accurate bending angle and radius. At the same time, changing the shape of the pipes does not entail any deformations of the internal profile.

Pipe benders are also subdivided according to the method of bending:

• in crossbow pipe benders, a shape of a certain diameter is used as a bending element;
• manual spring tool is designed for bending metal-plastic pipes using special springs;
• in segment pipe benders, bending is carried out by stretching the pipe around the segment; mandrel tools carry out bending of thin-walled pipes to a small radius using steel, plastic and brass mandrels.

When bending a pipe, allowable bending radii for pipes of various diameters and different wall thickness parameters should be taken into account. Permissible bending radii for products of various characteristics are presented in special reference books. If the radius is violated, the quality of the bend can be significantly reduced.

Let's start manufacturing

Despite the apparent simplicity of the process, pipe bending requires a rather serious approach, since with an incorrectly selected tool, various defects and deformations are possible, leading to a decrease in the throughput of pipes and a decrease in their strength characteristics.

Therefore, the selection of the tool is carried out taking into account the compatibility of the characteristics of the pipe and the principle of operation of the tool.

Pipes made from different material, having different diameters and different wall thicknesses, have a certain minimum bending radius. The following table is used to determine it:

Of course, pipes can be bent with a smaller radius, but it should be borne in mind that this will reduce the quality of their bending.

Now let's talk about the independent manufacture of pipe benders and consider several designs of such tools.

It is easiest to bend the pipe using a special template. It should be noted that similar way allows you to bend not only aluminum, but also steel pipes.

To make a template, we need wooden boards with a thickness slightly exceeding the diameter of the bent pipe. In order to prevent the pipe from slipping out of the template during operation, the boards are cut with a certain slope.

The boards fastened together must be fixed on a table or on another convenient base. In addition to the template, it is also necessary to fix the stop holding the bent pipe at a certain distance. The simplest model pipe bender is ready.

The end of the bendable pipe is inserted into the space between the fixed template and the stop. Taking the pipe by the opposite end, it is necessary to bend the product with smooth movements. To facilitate the process, you can use a lever by inserting a strong reinforcing rod into the pipe or putting a pipe on the product to be bent larger diameter.

Attempts to bend the pipe along the center of the template should be avoided, as this not only requires considerable effort, but can also lead to breakage of the pipe.

A similar template can also be made from metal hooks attached to a sheet of plywood along the corresponding bend line. The advantage of this design is the ability to adjust the bending line by rearranging the hooks.

The simplest pipe benders allow you to bend not only thin-walled flexible pipes, but also thick-walled products. To do this, use a hand winch.

With the use of such a design, even powerful profile pipes can be bent. However, for these purposes, when sawing out a wooden template, a bevel should not be made, and the pipe must be fixed with several stops at once.

In various workshops, you can often find pipe benders with a similar design:

You can make it yourself. In the process of manufacturing such a pipe bender, the most problematic is the selection or manufacture of the necessary templates and rollers, since the quality of the bend depends on the girth of the pipe.

If the tool is designed to work with flexible pipes, steel rollers and templates can be replaced with similar parts made of hard rock wood.

Rollers can be machined on a lathe. Also, the roller can be cut with a jigsaw. To do this, circles of different diameters are cut out of solid plywood with an inclination in the required direction, which are then fastened into a single piece. Finally, the roller should be processed with sandpaper. To give greater strength to the product, it should be strengthened with metal plates.

To obtain a large bending radius, the use of rolling pipe benders is optimal. These tools, like the ones described above, do not differ in the complexity of the design. In general, the level of complexity of the design of rolling pipe benders largely depends on the material of the pipes being bent.

If the tool is needed to work with flexible pipes, its working surfaces can be made of wood. Since wooden parts are quite easy to manufacture and do not require large expenditures, they can be easily replaced when worn.

If the wooden parts are inefficient in operation, they can be replaced with metal ones. Consider several designs of home-made rolling pipe benders.

As you can see, this tool is made mainly of wooden parts. The rollers in this model are made of polyurethane, however, they can also be made of wood. T

Bearings can also be used as rollers. However, in this case, it will be necessary to jam the pressure bearing so that it does not scroll.

The technical characteristics of the pipe bender depend on the distance between the rollers of the pipe bender. The greater the distance between the rollers, the less effort will be required to bend and run the pipe. However, in this case, a minimum bending radius is ensured, and a significant section of the pipe is not subjected to bending at all.

In order to make a more versatile tool, it should be possible at the design stage to install side rollers in various positions. On the sides it is necessary to fix steel clamps holding the pipe in a certain position perpendicular to the axes of the rollers. Otherwise, the pipe will begin to bend in a spiral.

The pressure roller of the pipe bender should be tightened from below with a metal strip with a thread of the required diameter cut in the center.

By gently tightening the pressure roller of the device, the bent pipe is rolled through the pipe bender. When rolling, for every half-turn of the fixing metal strip, a pipe run is made.

When bending a small radius, 50 to 100 runs will be required. In order for the bending circle not to be deformed, it is necessary to roll the pipe at the same speed. If there is a welded seam on the surface of the pipe, it is necessary to check that the seam is always on one side during rolling.

Homemade pipe bender for a profile pipe

Spring is coming, soon rooks and an unfinished greenhouse for many years now). From the very beginning, I decided to make a normal greenhouse from a normal profile. To do this, you need to bend the frame. You can, of course, look for where it is bent or even buy a finished one, but we are not looking for easy ways. We will bend ourselves, and for this we need to make a pipe bender. It will come in handy more than once in the household ...

So, rummaging through the search for drawings or diagrams for making a pipe bender with my own hands, I collected a small collection of photos. So let's start this manufacturing process with drawings and photographs.

The pipe bender himself:

A bit of the manufacturing process:

Well, when we already have an idea about the design, the drawings themselves:

The most important thing is to machine the rollers and bearing races. The dimensions of the shafts are selected based on our bearings and sprockets. Asterisks can be completely abandoned by making a drive from one roller, but according to reviews, the design can slip this way.

Another clamping screw can be replaced with a jack. In any case, the main shafts.

Well, let's start the selection of materials and correction of drawings? In the meantime, you can look at an even more advanced version. The shafts are machined to fit a pair of round tube diameters and a regular shaped tube.

I bought bearings first. I didn’t take simple ones, but bought self-centering ones with supports for a ruble more. Since the “premium class” profile bender will be made, the gears with the chain for it should also be premium). In my case, Mercedes.

The task for the turner was formulated on a piece of wallpaper and he successfully completed the task

Well, the first example

The gears will be fixed through the key. In the rings, you still need to drill holes and cut the threads to fix them.

I drill holes and make grooves for the key, for fastening the gear.

I drill holes in the restrictive rings and cut the threads for the clamp bolts. I sawed off a piece of the channel for fastening the pressure shaft. One shelf was cut off so as not to interfere with the installation of the jack. Holes drilled and threaded for mounting bearings.

Now you can move on to welding. I lay out the parts on the "welding table". I assemble the structure, weld the legs.

Screw on the pinch shaft. We control it and weld the nuts for the springs.

I hang the platform on the springs. By the way, the upper stop is bolted, just in case, you suddenly have to remove the pressure roller.

I'm making a chain tensioner. As a holder - a magnetic corner. Excellent thing!

I fasten the stars, not forgetting to insert the dowels. The dowels were made by cutting the engraver. I tighten the tensioner.

The next detail is a handle for rotation. Do not forget to make a handle with a rotating tube, so as not to rub corns. And we install the jack, weld a couple of bolts and fix it on the site.

Result

It's time for bench tests! What can I say about the quality of the bend… the bend itself turned out just wonderful. There is a slight wrinkle at the extreme points. There is no way without it. But thanks to the shoulder on the central shaft, there is no such jamming along the arc.

In principle, the result is more than satisfied. The machine turned out to be what you need. Spins easily, bends well. It remains a little to give a presentation ... paint is used.

gredx.ru

Homemade pipe bender for a profile pipe: device and manufacturing nuances

The need for reliable and simple device for bending profile pipes occurs when the home master begins to seriously deal with metal. Pergola frame, carport, garden bench, workbench…

These and many other designs turn out to be strong and beautiful if the profile metal for them is carefully bent on a special profile bender.

Purchase finished machine there is always an economical alternative, since you can make a pipe bender for a profile pipe with your own hands in your home workshop. Before the first workpiece is clamped in a vice, we suggest that you familiarize yourself with the principle of operation and existing varieties homemade pipe benders.

How does a pipe bender work?

The principle of operation of this device is simple: a profile pipe is placed between three support shafts. The central shaft creates pressure that bends the metal at the desired angle.

To bend the pipe in one local area, a point machine is used.

Profile pipe bent on a point device

If you need to get an arched profile, then a rolling bending machine is used that combines the bending of the metal with the broach.

Varieties of pipe bending machines

Depending on the drive that transmits force to the profile metal, there are three types of pipe benders:

• mechanical (pressure is created manually using a central screw or lever);
• hydraulic (a hydraulic jack is used);
• electrical (bending force creates an electric motor);
• electro-hydraulic (hydraulic cylinder is driven by an electric motor).

Point mechanical pipe bender
Mechanical rolling profile bender (the screw creates pressure on the profile, broaching is performed using the central shaft and the handle)

It should be noted that a rolling pipe bender with a manual profile drawing is designed for a pipe with a small section (maximum 40x40 mm). It is impossible to stretch a large profile manually. For its bending, powerful machines with an electric broaching mechanism are used.

Manual rolling bending machine (pulling is carried out by the outer rollers driven by the handle and chain, and the pressure is created by the screw and the central shaft)

Video about the device of the machine with an electric motor:

How to make a bending machine with your own hands?

The basic principle that should be followed when developing a drawing of a home-made pipe bender is the maximum simplicity of design and reliability.

Option 1

The spot bending machine can be assembled from two pieces of channel, four corners and two scraps of pins from tractor tracks.

The bending of the pipe in it is performed by a standard hydraulic jack with a force of at least 5 tons. A steel "shoe" is installed on its working rod. It can be ordered from a turner or made yourself from an old pulley, the width of the “stream” of which is equal to the width of the profile pipe. By cutting off a half from the pulley and drilling a seat for the jack rod in it, a hydraulic drive mechanism is obtained.

The frame of the homemade device consists of four corners (shelf 60-80 mm) welded to a steel plate. Two channels are welded parallel to the upper ends of the corners. Holes are symmetrically drilled in their walls to control the angle of bending of the workpiece.

The manual pipe bending machine is brought into working position very simply:

• Two steel fingers are inserted into the holes on the channel and the stop rollers are mounted on them.
• The jack with the shoe is raised so that a profile pipe passes between it and the stops.
• Having installed the pipe, they work with the jack handle, creating a bending force.

Video of assembly and operation of a point pipe bender:

Option 2

It is also quite possible to build a rolling manual pipe bender for a profile pipe on your own. For its manufacture, 2 linear meters of a channel will be required (wall height 15-20 cm), from which the base and racks are cut.

For the manufacture of rollers take six short cuts steel pipe. It will act as a holder for the bearings. Therefore, its inner diameter must be equal to the outer diameter of the bearing. Having ordered three shafts from the turner for mounting the bending rollers, they begin to weld the bed.

For the machine under consideration, the extreme right support plays the role of a guide that sets the profile bending angle. It is mounted on a channel hinged to the main frame using conventional door hinges. The jack rests against the turntable with its working rod and raises it.

By rotating the handle, mounted on the shaft of the intermediate stop, the profile is pulled through the machine.

You can adjust the bending radius of the profile not only by tilting the rotary channel, but also by the outer rollers. To do this, they are not welded tightly to the frame, but are made movable (holes are drilled in the channel and base plates).

Instead of hydraulic jack to lift the outer roller, you can use a screw car.

Video on the manufacture of a rolling pipe bender:

remstroysam.ru

How profile pipe is rolled - equipment, technology

The rolling of a profile pipe is called a technological procedure, as a result of which the longitudinal profile of the product changes. This will require the presence of a special machine for rolling pipes, with its characteristic high productivity, which is necessary for the manufacture of curved elements of metal structures.

Material Description

The profile pipe belongs to a special grade of rolled metal, with the help of which metal structures are assembled different sizes and functions. Such rolled metal is distinguished by the presence of a multifaceted or oval profile in the cross section. Most often, its shape is a square or rectangle. It goes without saying that pipelines and other transport communications are not made from such pipes.

This limitation is explained by weak resistance to internal pressure and insufficient throughput characteristics. The fact is that profile pipes are made from a strip strip, which basically does not provide for the reliable formation of reliable connecting sections. As a result, when this material is used for the manufacture of pipelines, there is a high probability of ruptures.

What are profile pipes

When it comes to profile pipes, they mainly mean square, oval or rectangular products. As for the method of production, they are suture or seamless, with or without tempering. Vacation is a special procedure, as a result of which internal stresses are removed after the profile is formed.

In general, we can say that the assortment of profile pipes is so diverse that it took several GOSTs to normalize it. For example, square-type profile pipes are determined by GOST 8639-82.

These regulatory documents contain indications of the parameters by which profile pipes of thin-walled and thick-walled types are manufactured. The upper overall feature for them is the size of 180x180 mm, with a wall thickness of 8-14 mm. The smallest profile pipe is a square product of millimeter thickness, with a face size of 10 mm. From these values, the technology was determined, according to which this rolled product is subjected to longitudinal deformation.

A hollow beam with dimensions of 18x18 cm, where the wall thickness reaches 1.5 cm, can only be bent using a special technique.

Features of rolling

Longitudinal rolling of a profile pipe is built on rolling, which very much resembles a rolling mill. As a result, the shaped pipe rolling machine was given a pyramidal appearance.

Here there are two lower and one upper cylinder: with the help of the lower elements, transportation is carried out, and the upper roller is used for deformation of the rolled product. The rolling machine for a profile pipe has a very clear scheme of operation: the pipe lies on top of the lower pair of rollers, followed by pressing it to the upper cylinder.

Due to this clamping effect, transmitted to the upper cylinder, a deflection of the pipe is achieved, with further deformation of the longitudinal profile. After turning on the “feed” (bottom drive), the deformation area spreads over the surface of the entire pipe being processed.

As a rule, with the help of one arrival, a long profile is not particularly deformed. However, this operation can be repeated as many times as desired. This allows you to form both arcuate and looped profiles.

What are rolling mills for rolling

When assembling metal structures, you have to use a variety of blanks. For their production, a wide variety of rolling units are used.

The most popular rolling machines today are:

1. Roller sheet benders. With their help, sheet metal is deformed. Pipes in such machines cannot be processed due to the very small gap between the transporting and deforming elements. Roller sheet benders are used where it is required to produce thin-walled shaped parts - ebbs, gutters, etc.
2. Three-roller machines. With the help of such a device, both pipes and sheets can be deformed. In addition, machines of this type make it possible to process profiled rolled products (corners, etc.). The downforce generator determines the level of power and performance of this equipment. On machines with a conventional clamp, to which the pressure roller is connected, productivity is below average: any locksmith can make a similar rolling machine for a profile pipe with his own hands. When used instead of a clamp with a hydraulic drive, this type of machine can even bend T-beams.
3. Machines with four rollers. This equipment is considered the most powerful of all devices of this type. With the help of these pipe benders, it is possible to produce not only arc, but also ring profiles. On four-roll machines, an exclusively mechanical drive is used: in this respect they differ from three-roll equipment, which can be either partially or completely manual. This involves the implementation of rolling a profile pipe with your own hands, with the help of the physical efforts of the worker. To increase the power of the machine, it is necessary to complicate its design and increase the level of energy consumption. This explains why at enterprises where a profile pipe is manufactured on a mass scale, a four-roll pipe bender is mainly used: it is unlikely that you can make a profile bender of this type with your own hands.