Category: Metal solutions

17 Nov

Metal bending basics

From time to time, our lives change and as a result, we are forced to change our habits. Isn’t it why you are here? It really matters not if you are taking up mandrel bending as a new passion, a business opportunity or something you must do. In the world there is nothing else like working with metal, so your background won’t be much of help.

But you should have a project in mind.

Whatever you learn from this point forward, look to apply your newly gained knowledge to what you plan to do. If you have any questions, ask them in a way that it would answer a problem with your project. This way you will learn everything much faster because you immediately can apply your skills.

So, let’s move on to bending.

Pipes, materials and tools

Working with any metal tube comes down to the essentials – the material, wall thickness and the outside diameter are the most important factors. We have covered this a little in the everything you should know.

Depending on the materials and the thickness of the metal, you can use different ways to make a perfect bend for your project. You might have already seen some YouTube clips of DIY metal bending at home. But these videos mostly utilize different angles of the several basic principle methods:

Ram bending

This is a classic way to get the right curve. Is simplest terms, you use a radius block (a ram) in the middle and two blocks of pressure. This is such a popular method because you don’t need electricity as in ram bending you use hydraulic power to get the job done.

Roll bending

A common way to work with even the widest tubes is roll bending using three counter rollers, where two of the rolls are stationary and roll counter clockwise while the top roll can be moved to adjust the bend curve. It goes clockwise to allow the tube move forward.

Pressure

While this method is used with the biggest industrial projects, due to its simple application, you can also find it among your gardening pins on Pinterest and your free bonuses for new players videos on YouTube.

Here it is how it works in ‘real life’:

This is how people on the internet apply it to their own projects:

As you see above, a simple $2 clamp will heavy duty job of holding your tube, while the curve can be adjusted as you see fit with additional wood cuttings.

Rotary draw bending

Lastly, there is rotary draw bending. It has its advantages – it fits when you require precision. However, when it comes to DIY projects it’s the hardest to apply due to complex structure (it can have 10+ axes).

Here are there four main principles of tube bending that have been developed over the last 100+ years. We hope that was useful but if there is still something that is stopping you from applying this, give us a shout.

tubing bender
27 Jul

Mandrel tubing bender – can it be home built?

Mandrel bending is a slightly more costlier, pricier choice to press bending on account of the price of equipment together with the process itself being more time consuming. The mandrel is subsequently moved or bent to provide the tubing a necessary shape. The key issue to keep in mind is that you select a mandrel that is in fact about 30% smaller than the hoop you would like to create.

Engine specifications

engine

Building your own muffler is a fast and straightforward means to control the way your bike rides and the way it sounds. The exhaust guarantees that the auto engine is working very efficiently. Thus, when you’re installing exhaust or other parts in your engine, it’s quite important to think about your engine specification and elect for the best option. This heavy-duty exhaust gives a dyno-tested increase up to 32 horsepower and, additionally, 60 ft-lbs in torque. Thus, when you’re installing a customized exhaust for your car, it is extremely important to select the help of an expert and do it in the proper way.

The most frequent kind of tubing

Is it true that the exhaust system you’re installing have the above mentioned features, well then, you’re all set. The exhaust system of a vehicle is to blame for keeping the engine of the vehicle free from all sorts of disturbances. An excellent automobile exhaust system has various benefits. On the opposite hand, if you’re installing a high performance vehicle exhaust system in your auto, it is possible to find mandrel bent tubing where diameter will continue being same all around the tube. A high performance exhaust process is among the simplest and most cost effective modifications you are able to make to your vehicle. When there are lots of aftermarket exhaust systems readily available, heavily customized vehicles often need custom-built systems. Installing aftermarket exhaust process is a huge way to improve the power of your vehicle.

Im pretty sure that you can secure that specific bend from a mandrel bent pipe. A best bend doesn’t need a mandrel. It wants a little bend to straighten it. 72 degree bend is an excellent bend for producing your own DP. What angles to produce a 90, which ones to create a 45.

The most frequent kind of tubing utilized for chopper frames is DOM. Such a tubing is made with mild steel. You always wish to put money into stainless, mandrel bent steel tubing, irrespective of the size. There are two sorts of pipe bends. The other pipe demands just a little finesse. This kind of piping is far more expensive and a good deal more difficult to find.

Mandrel bending is the remedy to this issue. With a mandrel produced from the appropriate material for the tubing is very important to prevent galling within the tube and to prolong the life span of the mandrel. On the exhaust pieces the turbulence brought on by the welded and joints aren’t going to make a great deal of difference. It isn’t simple, and TIG welders are very costly. The preferred method is TIG since it is an incredibly smooth and robust weld.

metal kit
20 Jul

Understanding the Variations in Metal Building Kits

There are two different kinds of metal building kits, pre-engineered and pre-fabricated. Pre-engineered sets will often fit together in a number of different ways whereas pre-fabricated is a basic one design kit. Both will arrive at a construction site ready to erect with the minimum of effort for construction workers.

Metal is better

Metal building systems are the best you can get and are so much better than other materials in terms of durability and weather resistance. There are also other factors at play which makes metal the best choice.

Time is often a constraint that the building industry is up against. Pre-engineered or pre-fabricated buildings arrive ready to assemble immediately and can be put up fast, much faster than when using other materials.

Metal also keeps the cost down. Because it is easier to assemble the amount spent on labour is less and also because it is self assembly lower skilled workers can be used who will be paid less per hour than their more skilled counterparts.

Quick and cheap, but without compromising on quality is the kind of construction that brings smiles to the faces of bosses and in fact this kind of construction can be up to 60% cheaper than other methods.

Versatility

Metal building systems allow expansion where necessary. If a building needs to be increased in size it can be as simple as removing an end or side wall and attaching a new frame to the existing model. And it can all be completed quickly.

It can withstand weather like no other material, even hurricanes or earthquakes pose little problem for the structure.

And due to its fire retardant nature, metal buildings can be up to 40% cheaper to insure.

Environmental advantages

metal roof

Environmental concerns are growing and more sustainable materials need to be used. Many metal building systems are made from at least in part recycled steel. A 2000 square foot building needs the equivalent amount of steel that could come from six scrapped cars. The same size structure in wood would use 50 trees, so it is definitely an advantage.

Metal also has a longer lifespan and will not need replacing with new material as quickly as a wooden building which means using fewer resources still.

Steel is also much more energy efficient when it comes to heating or cooling of a building.

Whether pre-engineered or pre-fabricated, steel building kits are the way forward in construction.

mandrel
20 Jul

Everything you should know about mandrel bending

Quite often when bending metal, mandrels are used to provide a smoother bend. The mandrel assists particularly in more complex bends by hindering collapsing of the tube or wrinkling or kinking for a much smoother finish.

Ideally a mandrel wouldn’t be required for a bend, but the radius of a bend, thickness of tubes and differing tube materials make the use of a mandrel the best way forward.

Different mandrels

mandrels

There are many different kinds of mandrel made from different types of material and choosing the best one for each bending job is critical. It is most common to find mandrels constructed from an aluminium and bronze alloy or steel with chrome plating.

The aluminium and bronze mandrel can be used for bending stainless steel, titanium or other harder materials. Steel and chrome mandrels are best used with aluminium, copper, steel or softer materials.

Ball mandrels are the most commonly used as they are able to flex in all kinds of plane. Plug mandrels are also used in international pipe size applications, and even single plane mandrels are used in some situations.

There are also mandrels containing a pre-cut radius to match the bend that will be made. These are formed tip mandrels.

There are inserted ball mandrels for higher volume tasks and these have a nosepiece to them which can be replaced.

Thinner materials can be bent using a close pitch or thin wall mandrel. There are also ultrathin and ultraclose mandrels for the absolute thinnest of materials and for the tightest radii which are typically used in situations involving applications for aircraft.

Precision is key

precision

Where the mandrel is placed is the most important part of the operation. Get this wrong and the bend will be wrong. The very front end of the shank of the mandrel should be situated just past the tangent and it should be done with great care. Obviously it is critical to check all tangent settings before beginning.

Sometimes the bend might not work out properly and there may be mandrel problems. The size or placement of the mandrel could be wrong. It can all be resolved with some troubleshooting.

By choosing a mandrel of the correct material and size and correctly maintaining bending machines, this technique is by far the best and easiest way to bend a whole host of materials accurately and leave a good finish.