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Tube Bending Seminar

Tube Bending Seminar
April 2008 April 2008
Viet My Trading Services Construction Co., Ltd
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Course Objectives Course Objectives
Course Objectives
Identify the components of the Swagelok hand tube
bender.
Explain the purpose of
the three types of marks used in bend layout.
the straight tube length mark.
adjustment (gain), as well as describe how each method of bend
layout compensates
for it.
minimum length of last leg, as well as describe one way this
length can be used
Calculate the length of tubing used in an offset.
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Course Objectives Course Objectives
Course Objectives
Bend tubing into a shape as specified by a template using
the Pre-Measure method of bend layout.
Identify five potential bend defects.
Bending Exercise.
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Straight Tube
Length Mark
Long Handle
Short Handle
Roll Support
Nameplate
Clevis
Bender Die
Roll Die
Link
Tube Latch
Vise Clamp
Block
Hand Tube Bender Components Hand Tube Bender Components
Hand Tube Bender Components
Grip
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Hand Tube Bender Models Hand Tube Bender Models
Hand Tube Bender Models
MS-HTB-10M 25 24 10
MS-HTB-12M 31 38 12
MS-HTB-4T 13/16 9/16 1/4
MS-HTB-8M 23 24 8
MS-HTB-6M 21 15 6
Part Number Minimum Length
of Fitting (mm)
Bender Bend
Radius (mm)
Tube OD (mm)
Metric
MS-HTB-8 1 3/16 1 1/2 1/2
MS-HTB-6T 15/16 15/16 3/8
MS-HTB-5 7/8 15/16 5/16
MS-HTB-4 13/16 3/4 1/4
Part Number Minimum Length
of Fitting (in.)
Bender Bend
Radius (in.)
Tube OD (in.)
Fractional
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Tube Bending Variables Tube Bending Variables
Tube Bending Variables
The minimum length of tubing required from the
end of the tube to the beginning of the bend
The adjustment (gain) of the tubing when a bend
is made
Springback and tubing stretch
Minimum length of tubing required from the last
bend to the end of the tube
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Tube Bending Variables Tube Bending Variables
Tube Bending Variables
Changes in direction
Bend offsets
Tubing material
The limitation of the tubing as determined by the
manufacturer
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When installing fittings near tube bends, you must
leave a sufficient length of straight tube
to allow it to be bottomed in the Swagelok
tube fitting.
R
Bend Radius of Tube Bender
Minimum Length of Straight Tube
Tube OD
R
L
T
L
T
C
L
Minimum Length of Straight Tube Minimum Length of Straight Tube
Minimum Length of Straight Tube
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The Straight Tube Length Mark The Straight Tube Length Mark
The Straight Tube Length Mark
The straight tube length mark indicates the
minimum length of tubing required from the end of
the tube to the beginning of the bend.
L
Straight Tube
Length Mark
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Pre-Measure Method of Bend Layout Pre
Pre
-
-
Measure Method of Bend Layout
Measure Method of Bend Layout
Adjustment (Gain) Calculations
Radius of the Tube Bender
Degree of Bend
0
45
90
13
5
180
M S
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Adjustment (Gain) Adjustment (Gain)
Adjustment (Gain)
Vertex (P1)
P2
2 in.
2 in.
Adjustment (Gain)
Vertex (P1)
P2
2 in.
2 in.
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C
L
Adjustment (Gain) Adjustment (Gain)
Adjustment (Gain)
The larger the bend angle, the larger the
amount of adjustment (gain).
Vertex
2 in.
Reference Mark
Gain
2 in.
Radius
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1/4 0.24 90
3/16 0.20 85
5/32 0.16 80
1/8 0.13 75
3/32 0.10 70
3/32 0.08 65
1/16 0.06 60
1/16 0.05 55
1/32 0.03 50
1/32 0.02 45
negligible 0.01 30
Fraction Decimal
Adjustment (Gain) Bend Angle
9/16 in. Bend Radius
Decimal Equivalent = 0.56 in.
Adjustment (Gain) Charts Fractional Adjustment (Gain) Charts
Adjustment (Gain) Charts

Fractional
Fractional
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5/16 0.32 90
1/4 0.26 85
7/32 0.21 80
5/32 0.17 75
1/8 0.13 70
3/32 0.10 65
3/32 0.08 60
1/16 0.06 55
1/32 0.04 50
1/32 0.03 45
negligible 0.01 30
Fraction Decimal
Adjustment (Gain) Bend Angle
3/4 in. Bend Radius
Decimal Equivalent =0.75 in.
Adjustment (Gain) Charts Fractional Adjustment (Gain) Charts
Adjustment (Gain) Charts

Fractional
Fractional
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13/32 0.40 90
11/32 0.33 85
9/32 0.27 80
7/32 0.21 75
5/32 0.17 70
1/8 0.13 65
3/32 0.10 60
3/32 0.08 55
1/16 0.06 50
1/32 0.04 45
negligible 0.01 30
Fraction Decimal
Adjustment (Gain) Bend Angle
15/16 in. Bend Radius
Decimal Equivalent = 0.94 in.
Adjustment (Gain) Charts Fractional Adjustment (Gain) Charts
Adjustment (Gain) Charts

Fractional
Fractional
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5/8 0.64 90
17/32 0.52 85
13/32 0.42 80
11/32 0.34 75
9/32 0.27 70
7/32 0.21 65
5/32 0.16 60
1/8 0.12 55
3/32 0.09 50
1/16 0.06 45
1/32 0.02 30
Fraction Decimal
Adjustment (Gain) Bend Angle
1 1/2 in. Bend Radius
Decimal Equivalent = 1.50 in.
Adjustment (Gain) Charts Fractional Adjustment (Gain) Charts
Adjustment (Gain) Charts

Fractional
Fractional
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Compensating for Springback Compensating for Springback
Compensating for Springback
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Minimum Length of Last Leg Minimum Length of Last Leg
Minimum Length of Last Leg
Correct Incorrect
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Minimum Length of Last Leg Fractional Minimum Length of Last Leg
Minimum Length of Last Leg

Fractional
Fractional
3 2 1/16 2 1 11/16 1 1/2 90
2 7/8 2 1 7/8 1 5/8 1 1/2 85
2 3/4 1 15/16 1 13/16 1 9/16 1 7/16 80
2 5/8 1 7/8 1 3/4 1 1/2 1 3/8 75
2 9/16 1 13/16 1 11/16 1 7/16 1 3/8 70
2 7/16 1 3/4 1 5/8 1 7/16 1 5/16 65
2 3/8 1 11/16 1 9/16 1 3/8 1 5/16 60
2 1/4 1 5/8 1 1/2 1 5/16 1 1/4 55
2 3/16 1 9/16 1 7/16 1 5/16 1 3/16 50
2 1/16 1 1/2 1 7/16 1 1/4 1 3/16 45
1 7/8 1 3/8 1 5/16 1 1/8 1 1/8 30
1 1/2 (in.) 15/16 (in.) 15/16 (in.) 3/4 (in.) 9/16 (in.)
Bend
Radius
1/2 (in.) 3/8 (in.) 5/16 (in.) 1/4 (in.) 1/4 (in.) Tube OD
Bend
Angle
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75 55 51 39 90
72 52 49 38 85
69 51 47 37 80
66 49 45 36 75
64 47 44 35 70
61 46 42 34 65
59 44 41 33 60
57 43 39 32 55
55 41 38 31 50
53 40 37 30 45
47 37 33 28 30
38 (mm) 24 (mm) 24 (mm) 15 (mm) Bend Radius
12 (mm) 10 (mm) 8 (mm) 6 (mm) Tube OD
Minimum Length of Last Leg Metric Minimum Length of Last Leg
Minimum Length of Last Leg

Metric
Metric
Bend
Angle
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Changes in Direction and Plane Changes in Direction and Plane
Changes in Direction and Plane
Directional Mark
Outside Surface of the Bend
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Offset Bends Offset Bends
Offset Bends
L = Length of tubing used in the offset (Travel)
O = Offset Dimension (Set)
E = Offset Angle
2.613 22 1/2
1.154 60
1.414 45
2.000 30
Offset Bend
Allowance
(Cosecant)
Offset Angle
(E)
L
E
O
L
C
L
C
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Operator Variables Operator Variables
Operator Variables
The degree of precision achieved using the
Swagelok hand bender depends, to a large
extend, on a persons ability to:
accurately make required measurements, calculations,
and measurement marks.
consistently make bends to the angles required by the
application
inspect the quality of the bend
provide adequate care for the bender
As with anything, proficiency is achieved through
practice.
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Marks Used in Bend Layout Marks Used in Bend Layout
Marks Used in Bend Layout
0 on Roll
Support
0 on
Bender Die
Measurement Mark
Reference Mark
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Marks Used in Bend Layout Marks Used in Bend Layout
Marks Used in Bend Layout
Directional Mark
Directional Mark
Outside Surface of the Bend
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Vertex
Distance from end of
tube to the Vertex
Distance from Vertex to Vertex
Vertex
Vertex
Bend Dimensioning Bend Dimensioning
Bend Dimensioning
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How to Use the Hand Tube Bender How to Use the Hand Tube Bender
How to Use the Hand Tube Bender
Loading the Bender
Short Handle
Tube Latch
Bender Die
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How to Use the Hand Tube Bender How to Use the Hand Tube Bender
How to Use the Hand Tube Bender
Loading the Bender
Reference Mark
Tube Latch
Short Handle
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Correct
(Viewed from Back of Bender)
Incorrect
(Viewed from Back of Bender)
How to Use the Hand Tube Bender How to Use the Hand Tube Bender
How to Use the Hand Tube Bender
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Aligning the Tubing Aligning the Tubing
Aligning the Tubing
There are several marks used for alignment with
the measurement mark.
0
45
R
L
0 on Roll
Support
0 on
Bender Die
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Aligning the Tubing Aligning the Tubing
Aligning the Tubing
Some angles are not on the bender faceplate.
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Aligning the Tubing Aligning the Tubing
Aligning the Tubing
Keep the tubing in the intended plane.
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Springback Springback
Springback
Remember that the material
will demonstrate
Springback,
which will affect the degree
of the bend.
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Making Bends 90 or Less Making Bends 90 or Less
Making Bends 90 or Less
Push the short handle down
until the 0 on the roll support
reaches the desired degree
mark on the nameplate.
Short Handle
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Making Bends 90 or Less Making Bends 90 or Less
Making Bends 90 or Less
Swing the short handle
up and away from the
bender die.
Unlatch the tubing and
carefully remove it from
the bender groove.
Short Handle
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Making Bends Greater than 90 Making Bends Greater than 90
Making Bends Greater than 90
Push the short handle down
until the 0 on the roll support
reaches the desired degree
mark on the nameplate.
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Making Bends Greater than 90 Making Bends Greater than 90
Making Bends Greater than 90
When the roll support reaches
approximately 90, loosen the
short handle from the
clevis (four turns).
Short Handle
Clevis
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Making Bends Greater than 90 Making Bends Greater than 90
Making Bends Greater than 90
Swing the short handle up
until it is slightly above the
perpendicular position in
relation to the long handle
and then retighten.
Short Handle
Long Handle
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Making Bends Greater than 90 Making Bends Greater than 90
Making Bends Greater than 90
Continue the bend until
the 0 on the roll support
reaches the desired degree
mark on the bender die.
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Practical Demo 1
Making 90 bend
Practical Demo Practical Demo 1 1
Making Making 90 bend 90 bend
3 in.
P2
2 in.
Reference Mark
Reference Mark
Measurement Mark
P1
X
Y
P2
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Practical Demo 2
Making Bends Greater than 90
Practical Demo Practical Demo 2 2
Making Bends Greater than 90 Making Bends Greater than 90
75mm
180
100 mm
P1
P2
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Bend Layout Bend Layout
Bend Layout
180 bends
The first measurement is the distance from the
reference mark on the tubing to P1, the vertex of
the bend.
Place a measurement mark
75 mm from the
reference mark.
Reference Mark
X
75 mm
P1
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Bend Layout Bend Layout
Bend Layout
180 bends
The second measurement is the distance from P1 to the
desired end of the tubing (P2), minus the adjustment
(gain) of the bend, plus the diameter of the bender.
Reference Mark
X
P1
117 mm
75 mm
P2
Adjustment (Gain) =
15 mm 0,86 = 12,9
Diameter of bender =
15 mm 2 = 30
Measurement from P1 to
P2 =
100 mm 13 mm + 30 mm
= 117 mm
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Bend Layout Bend Layout
Bend Layout
180 bends
The total length of tubing needed for this example =
75 mm + 117 mm = 192 mm
Cut the tubing to 192 mm.
192 mm
P1
117 mm
75 mm
Reference Mark
P2
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Solutions
Causes
Defect
Align bender die
and bend shoe.
Reduce latch
pressure.
Correct bender
size.
Replace or repair
bender.
Clean bender.
Replace damaged
roller.
Correct bender
size.
Correct bender
size.
Make sure link
is vertical.
Correct bender
size.
Increase wall
thickness.
Improper alignment
Excessive pressure
on the tube latch
Undersized bender
Damaged bender
die
Dirt or foreign
matter in bender
die
Frozen roller
Oversized
bender
Undersized
bender
Positioning link
in incorrect
vertical
alignment
Undersized
bender
Thin wall
thickness
Excessive
Deformation Scored Kinked Flattened Wrinkled
Characteristics of Defective Bends Characteristics of Defective Bends
Characteristics of Defective Bends
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Bending Exercise Bending Exercise
Bending Exercise
Offset
30 Deg 2.000 X Offset
45 Deg 1.414 X Offset
60 Deg 1.154 X Offset
90 Deg Adjustment 0.25 =
60 Deg Adjustment 0.065 = 1/16
45 Deg Adjustment 0.03125 = 1/32
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Bending Exercise Bending Exercise
Bending Exercise
P1 = 2.25
P2 = 2.25 + (2.25 0.25) = 4
P3 = 4.25 + (1.414 X 2.125) = 7
P4 = 7.2547 + (2.0625 0.03125) = 9
P5 = 9.2859 + (2.25 0.25) =11
P6 = 11.2859 + (1.25 0.25) = 12
P7 = 12.2859 + (2.25 0.25) = 14
Offset
30 Deg 2.000 X Offset
45 Deg 1.414 X Offset
60 Deg 1.154 X Offset
90 Deg Adjustment 0.25 =
60 Deg Adjustment 0.065 = 1/16
90 Deg Adjustment 0.03125 = 1/32
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