Mandrel Bend Solutions

Features of Mandrel Bend Solutions

Mandrel Bend Solutions

Using a mandrel to bend pipe helps prevent wrinkles and kinks. It is a highly repeatable process that allows for a much more precise bend.

The patented design reduces machine and tooling maintenance. Dangerous pinch points are eliminated, and there is less stress on the pressure die arm and swing arms.

Precision

Mandrel bending is one of the most precise metal-forming processes available. Unlike other bending techniques, it prevents wrinkles or breaks in the tubing. It also produces a more accurate radius bend than standard bending. It eliminates the need for post-bend weld inspection, reduces fabrication hours, and saves on materials, welding costs, and labor.

Unlike other bending methods, which lose 25% of the original diameter during the bending process, mandrel bends maintain the pipe’s original diameter. It results in consistent airflow through the exhaust system and allows the engine to produce more horsepower and torque.

A custom exhaust system is more than just a way to set your vehicle apart on the street—it improves fuel efficiency by eliminating turbulence in the gas line and allowing it to flow freely. Mandrel bends keep this airflow consistent, which frees up power to the engine and increases horsepower and torque.

The type of mandrel used in the bending process is crucial in producing a quality result. There are two primary types: plug mandrels and form mandrels. A plug mandrel is a solid rod that slips inside the tube or pipe before bending. The mandrel is then placed against a wiper die, which helps to mitigate defects in the final bend, such as flattening or crinkling. Form mandrels are designed for thicker-walled tubes and are shaped to provide more support over the full arc of the bend.

Flexibility

In addition to delivering high quality, mandrel bend solutions also provide flexibility. It is essential when bending thin wall tubing with a high OD and WT. A mandrel prevents the tube from collapsing and breaking at the bending point. It also helps mitigate defects such as flattening or crinkling of the inner radius of the bent tubing.

Compared to other bending processes, the benefits of mandrel bending are significant. For instance, press bending and roll bending leave deformations on the inside diameter of bent HSS, which may reduce overall system flow or increase the risk of corrosion. On the other hand, mandrel bending creates smooth, rounded corners that maintain the interior diameter of the bent tubing/pipe.

Mandrel bending is a popular rotary draw bending technique in which a solid rod is inserted into the tube/pipe during bending. Its internal support mitigates defects such as buckling, collapse, or kinks while allowing the operator to bend precisely. It is recommended for applications requiring tight and large radius bends and multiple radii. It is also ideal for bending thin tubing as it eliminates wrinkles.

Accuracy

Using mandrels during tube bending prevents a lot of the common issues that can occur in this process. These include spring back, crinkling, and bending at high angles. A mandrel also helps to eliminate any entrapment areas on the inside diameter of the tube or pipe that could otherwise cause backpressure during operation.

There are different types of mandrels for various bending jobs. Plug mandrels are typically used for thick-walled tubes that require a deep bend with a large radius. These mandrels are solid rod that inserts into the tube/pipe during the rotary-draw bending process. A form mandrel is similar to a plug mandrel, except the tip of the mandrel is formed to match the tube’s desired radius. Ball mandrels are similar to plug mandrels but consist of multiple balls (linked or unlinked) inserted into the tube.

Regardless of the type of mandrel used, the proper setup is essential to achieve a quality result. If you’re experiencing a problem with your mandrel tubing bender, check that the correct size mandrel is used and that the lubrication is appropriate for your application and bending job specifications. It will help reduce friction between the mandrel and the bending die. It is especially critical if you’re attempting to avoid wrinkles, kinks, or tube collapse during the bending process.

Efficiency

Wrinkles occur in HSS bending for many reasons, including insufficient pressure, a slip from the clamp while under pressure, or not using a wiper die. By inserting a mandrel into the tubing and holding it in place with a rod, mandrel bending mitigates these issues and provides a smoother bend.

The inserted mandrel also preserves the pipe’s internal diameter, reducing deformation and other issues that can cause damage or decrease functionality. It’s important to note that HSS is not as strong as welding due to welding distortion, so bending it with a mandrel tool is an excellent option for companies looking to save time and money on fabrication hours, materials, and weld inspection costs.

Compared to crush bending, mandrel bending eliminates wrinkles, pinches, and collapsed diameters that slow down and restrict airflow, which increases engine horsepower and fuel efficiency.

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