Bending your ideas into reality

Tube and
Pipe Benders

Forming Tomorrow. Today !

 Electropneumatics has been designing and manufacturing the highest quality,
technologically advanced metal forming machines since 1972. We have more than 4000
installations worldwide of a wide variety of machines for sheet forming, moulding,
spotting and tryout, compacting, honing, assembly and testing, transmission line tower
manufacturing, tube/section bending and other applications. Our indigenous capabilities
in all areas (mechanical, hydraulic, electrical, electronics and pneumatics) give our
products an edge over the rest.

2
An Introduction

In tube and wire bending, Electropneumatics

has been the pioneer in India since 1982
when we developed our first CNC tube bender.
We offer the most exhaustive range of
benders and continue to innovate to bring
better bending solutions to our customers.

Electropneumatics has many

India's first tube benders to its credit.

n 3-Axes CNC Tube Bender in 1982

n Largest Draw-type Pipe Bender in 1985

n 3-Axes CNC Wire Bender in 1997

n Boost Bender for R=1D bends in 2000

n Multi-Radius, Bi-Directional CNC Tube

Bender in 2001

n 10-Axes All-Electric CNC Tube Bender

in 2006

n 3-Axes CNC Rotary-Head Type Wire

Bender in 2006

n Multi-stack, Electric Tube Bender

complete range in 2008, 2009

n Orbital Electric Tube Bender in 2009

….. and many more.

Assembly Line for Tube and Pipe Benders 3 Forming Tomorrow. Today !
 Index
NCX/NCXR
NC Tube Benders 5

CNC3W
CNC Wire Benders 8

CNC3X
CNC Three-Axes Tube Benders 9

CNC Multi-Axes Tube Benders 12

CNC2X-B/CNC2XR-B
CNC Boost Benders 14

Special Tube Benders 16

Tube Processing Machines 18

4
 NCX/NCXR
NC Tube Benders

30NCX

65NCX

5
 These hydraulic semi-automatic NC Tube Benders
can handle tubes from OD 6 to 419 mm in round,
rectangular, square and other sections. The NCX
models can produce parts with multiple bends in a
single plane. The additional pre-settable linear and
rotary indexing arrangement in NCXR models allow
multi-plane bending. With the exception of plane of
bend (POB) and distance between bend (DBB) being
manual against pre-set stops, the bending cycle is
automatic. In bigger machines, tube orientation is
also powered.

100NCXR

Specifications
30NCX 65NCX 80NCX 100NCX 150NCX 200NCX 325NCX 400NCX
Model Unit
30NCXR 65NCXR 80NCXR 100NCXR 150NCXR 200NCXR 325NCXR 400NCXR
Max. tube capacity (Dxt)* mm 32 x 2 65 x 4 80 x 2 114 x 6 168 x 11 219 x 13 324 x 17 419 x 21
Min. tube capacity (D)* mm 6 10 10 25 50 76 89 114
Max. bend radius (CLR) mm 120 300 300 500 600 600 1000 1200
Min. bend radius mm 20 24 24 38 100 150 178 228
Min. bend radius in terms of D 1.5D 1.5D 1.5D 1.5D 2D 2D 2D 2D
Length over mandrel m 2 2 2 2 4 4 6 6
Bend angle range deg 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180
Max. bend speed (accuracy) deg/s (deg) 30 (±0.2) 24 (±0.2) 18 (±0.2) 12 (±0.2) 3 (±0.25) 2 (±0.25 ) 2 (±0.25) 1 (±0.5)
DBB & POB accuracy
(in NCXR models) mm & deg ±0.2 ±0.2 ±0.2 ±0.2 ±0.25 ±0.25 ±0.25 ±0.5

Connected load (approx.) kW 3.7 7.5 7.5 15 30 37 55 75

1300 2300 2500 4500 16000 25000 55000 70000
Weight (approx.) kg 1500 3000 3200 5000 19000 30000 62000 80000
*For ferrous tubes with UTS of 45 kg/mm . Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC.
2
For models 150NCXR onwards, linear and rotary indexing arrangement is powered.
Note:
D = Tube outside diameter
t = Wall thickness
CLR = Centre Line Radius
DOB = Degree Of Bend
POB = Plane Of Bend
DBB = Distance Between Bends

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 Features Options
n No. of multi-plane bends settable = 8 (POB & DBB) n Increased bend radius (on select models)
(in NCXR) n Extra mandrel length and extended arm for
n Programmable DOB in automatic open loop control. specific applications
Pre-selectable POB (in NCXR) n Modified versions with split tools, heated tools, etc.
n Programmable bending angle and preset bending sequence to suit component requirements
n Memory capacity of 50 programs with 15 bends/program n Safety mat and safety flap on bend arm
n Electropneumatics' make Micro PLC with 3'' touch screen n Automatic mandrel lubrication
MMI n Hydraulic oil cooler
n Counter-clockwise bending

325NCXR

7 Forming Tomorrow. Today !

 CNC3W
CNC Wire Benders

Electropneumatics' CNC Wire Benders The 6CNC3W model is a compression bend type wire
are capable of bending steel wires from bender ideal for automotive remote rods for door locks,
OD 2 to 6 mm. They can bend wires in hood support, actuator levers and also for consumer
both clockwise and counter-clockwise and decorative items. The 6CNC3WA model integrated
directions. The push, turn and bend axes with decoiler, straightner and servo feed unit is an
are driven by AC servo drives. These extended rotary head type machine capable of
machines can be supplemented with producing zigzag, multi-plane, curvature and helix
wire decoilers, straightners, cut-off and bends in wires. Complex curved parts are possible by
feed units. interpolation of the feed and bend axes. The electric
drives consume less power, reduce noise levels
drastically and provide a clean machine and working
environment.

6CNC3W 6CNC3WA-S

Specifications
Model Unit 6CNC3W 6CNC3WA-S
2
mm 6.0 (UTS 65 kg/mm ) 6.0 (UTS 65 kg/mm2)
Max. wire capacity (D)
5.0 (UTS 110 kg/mm2) 5.0 (UTS 110 kg/mm2)
Max. bend radius (CLR) mm 25 Infinite
Min. bend radius mm 0.5 2
Min. distance between successive bends mm 7.5 7.5
Push (Y) mm 1000 Infinite (Coil feed)
Max. range Turn (B) deg 0 - 360 0 - 360
Bend (C) deg 0 - 110 0 - 180
Push (Y) mm/s (mm) 1200 (±0.1) 1300 (±0.1)
Max. speeds (accuracy) Turn (B) deg/s (deg) 500 (±0.1) 300 (±0.1)
Bend (C) deg/s (deg) 150 (±0.1) 1300 (±0.1)
Connected load (approx.) kW 5.5 16
Weight (approx.) kg 1000 3000
Power supply: 415V, 50Hz, 3-phase AC.

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 CNC3X
CNC Three-Axes
Tube Benders

18CNC3X-O

30CNC3X

9
 Electropneumatics' 3-Axes CNC Tube Benders
are ideally suited for bending of automotive
parts because of their high productivity. These
machines have a direct-acting clamp, pressure
die and pressure die assist along with a mandrel
extractor, power chuck, tube support and
automatic machine lubrication. They are
available in all-electric or combination of
electric-hydraulic versions.

65CNC3X

100CNC3X

10
 Features n Capability of programming in inches or millimeters
n Electropneumatics' make user-friendly microprocessor- n Automatic tube length computation based on set
based 'SMARTBEND 430' controller with colour LCD parameters
monitor and keyboard access n Spring back calculation and off-line compensation
n Fully programmable axes movement in closed loop facility
position and velocity feedback mode n Programmable tube loading position
n Advanced on-line diagnostics with closed loop n Multi-sequence bend capability for up to five parts with
monitoring of servo axes, display of axes position/speed, common bend radius and diameter
on-going, sequence and error messages n Program retrieval by alphanumeric code, password
n Data entry as Push-Turn-Bend (Y-B-C) values or X-Y-Z protection for data entry, tool part data storage and
co-ordinates on-screen part counter with reset facility

Options
n Extra mandrel length and extended arm for specific n Automatic mandrel lubrication
applications n Hydraulic chilling unit
n Modified versions with split tools, heated tools, etc. n Counter-clockwise bending
to suit component requirements
n Servo controlled independent pressure die assist
n Safety mat and safety flap on bend arm and/or carriage boost

Specifications
Model Unit 30CNC3X 65CNC3X 100CNC3X 150CNC3X 200CNC3X 325CNC3X 400CNC3X
Max. tube capacity (Dxt)* mm 32 x 2 65 x 4 114 x 6 168 x11 219 x 13 324 x 17 419 x 21
Min. tube capacity (D)* mm 6 10 25 50 76 89 114
Max. bend radius (CLR) mm 120 300 500 600 600 1000 1200
Min. bend radius mm 20 24 38 100 150 178 228
Min. bend radius in terms of D 1.5D 1.5D 1.5D 2D 2D 2D 2D
Length over mandrel m 2 3 4 4 4 6 6
Bend angle range deg 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180
Push (Y) mm/s (mm) 1200 (±0.1) 650 (±0.1) 400 (±0.1) 200 (±0.2) 150 (±0.2) 100 (±0.2 ) 75 (±0.2)
Max. speed
Turn (B) deg/s (deg) 300 (±0.1) 300 (±0.1) 120 (±0.1) 50 (±0.2) 30 (±0.2) 24 (±0.2 ) 15 (±0.2)
(accuracy)
Bend (C) deg/s (deg) 150 (±0.1) 60 (±0.1) 30 (±0.1) 15 (±0.2) 2 ( ±0.2) 2 (±0.2) 1 (±0.2)
Connected load (approx.) kW 10 19 22 37 37 55 75
Weight (approx.) kg 2500 3500 9000 15000 30000 62000 80000
*For ferrous tubes with UTS of 45 kg/mm . Standard bend direction is clockwise. Power supply : 415V, 50Hz, 3-phase AC.
2

11 Forming Tomorrow. Today !

 CNC Multi-Axes
Tube Benders

19CNC4X3

Specifications
Model Unit 10CNC4X3 19CNC4X3 38CNC5X3 65CNC5X3 80CNC5X3 16CNC5X2-LR
Max. tube capacity (Dxt)* mm 10 x 2 19 x 2 38 x 2 65 x 3 80 x 3 16 x 2
Min. tube capacity (D)* mm 3 3 6 10 10 3
Max. bend radius (CLR) mm 30 80 180 250 250 70
Min. bend radius mm 12 24 20 38 38 12
Min. bend radius in terms of D 1.5D 1.5D 1.5D 1.5D 1.5D 1.5D
Max. radius difference mm 15 35 50 80 90 30
(max. - min.)
Tooling stack nos. 3 3 3 3 3 2+2
Length over mandrel m 2 2 3 3 3 2
Bend angle range deg 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180 5 - 180
Clockwise &
Bending direction Clockwise Clockwise Clockwise Clockwise Clockwise counter clockwise
Axes drives Electric Electric Electric Electric Electric Electric
Push (Y) mm/s (mm) 1200 (±0.1) 1200 (±0.1) 1200 (±0.1) 800 (±0.1) 700 (±0.1) 1000 (±0.1 )
Max.
Turn (B) deg/s (deg) 360 (±0.1) 360 (±0.1) 300 (±0.1) 250 (±0.1) 200 (±0.1) 360 (±0.1 )
speed
(accuracy) Bend (C) deg/s (deg) 300 (±0.1) 180 (±0.1) 150 (±0.1) 100 (±0.1) 60 (±0.1) 150 (±0.1)
Radius (X) mm/s (mm) 180 (±0.1) 180 (±0.1) 150 (±0.1) 100 (±0.1) 100 (±0.1) 300 (±0.1)
Stack (Z) mm/s (mm) - - 100 (±0.1) 100 (±0.1) 100 (±0.1) 500 (±0.1)
Connected load (approx.) kW 9.7 12 17 26 32 14
*For ferrous tubes with UTS of 45 kg/mm . Standard bend direction is clockwise. Power supply : 415V, 50Hz, 3-phase AC.
2

Assembly Line for

Tube Bending Machines
12
 Electropneumatics' Multi-Axes CNC Tube
Benders have a wide variety of features and
a combination of electric and hydraulic drives for
the programmable axes. They are designed to
bend complex parts of different materials in
high-volumes for all industries, specifically
automotive.

38CNC5X3

65CNC5X3

16CNC5X2-LR

13 Forming Tomorrow. Today !

CNC2X-B /
CNC2XR-B
CNC2X-B/CNC2XR-B
CNC CNC
Boost Benders
Boost Benders

Features
n Minimum R = 1D bending on tubes with D/t ratio £ 9
n Achievable parameters on R = 1D in 'boost' mode
Ovality: 8 - 10%,
Thinning:12 - 13%
n Capability of serpentine bends (with suitable tooling)
n Fully programmable closed loop (servo) 'bend-boost'
speed and position control
n Unlimited tube length and capability of serpentine bends
n Mandrel-less and tie rod-less operation in 'boost' mode
n Suitable for both boost and normal (higher capacity)
bending

Options
n Provision of carriage with manually pre-settable linear
and rotary indexing facility for multi-plane bends
(in CNC2XR-B models)
n Extra mandrel length or deletion of mandrel
n Split tool arrangement for R ³ 57 mm

65CNC2X-B

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 Electropneumatics' CNC Boost Benders meet
the stringent ovality/thinning requirements
of bending thick-walled, tight-radius tubes
required in the boiler, chemical and process
industries. Synchronisation and programmability
of speed and position through servo controls
results in excellent control on the bend quality.

100CNC2X-B

Specifications

Model Unit 65CNC2X-B 100CNC2X-B

65CNC2XR-B 100CNC2XR-B
Max. tube capacity (Dxt)* mm 63.5 x 6.35 114 x 6
Capacity in boost mode mm 50.8 x 5.5 63.5 x 6.35
Max. bend radius (CLR) mm 300 500
Min. bend radius (mandrel-less) mm 24 38
Min. bend radius in terms of D 1D (on D/t £ 9) 1D (on D/t £ 9)
Speciality/suitability Serpentine bends (max. 150 CLR) Serpentine bends (max. 150 CLR)
Length over mandrel m 2 2
Bend angle range deg 5 - 180 5 - 180
Max. bend speed (accuracy) deg/s (deg) 18 (±0.2) 12 (±0.2)
DBB and POB accuracy mm & deg ±0.2 ± 0.2
(in CNC2XR-B models)

Booster unit Hydraulic clamp & boost unit for axial compression with programmable
controls for synchronised bend-boost speed relation
Connected load (approx.) kW 11 18.5

Weight (approx.) kg 5000 8000

6000 9500
*For ferrous tubes with UTS of 45kg/mm . Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC.
2

15 Forming Tomorrow. Today !

 Special
Tube Benders

Chassis Benders
For bending of square, rectangular or
tubular sections for chassis long
members of jeeps, trucks and
commercial vehicles.

Section Coilers
These machines can form coils
of condensers and evaporators used
in refrigeration products. They can
bend square, rectangular, round or
any other section. They are usually
provided with a decoiler, straightner,
D-profile former and cut-off unit.

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 Electropneumatics' has indigenous expertise in
developing customised solutions for the most
demanding bending requirements. We work with our
customers to offer the right equipment and
automation, either as a single product or a production
line, that can give the best productivity and quality
using the latest techniques. These custom-designed
machines can bend sectional profiles, tight-radii,
different tube materials, thin-walled and thick-walled
tubes, solid rods in cold or hot condition.

Section Benders
Sections used in luggage frames, furniture
frames, automobile accessories, etc. can
be bent on these machines. They are
usually adapted to have an extended
arm and reduced bend spindle height
to accommodate complicated bend
configurations.

Multi-Plane
Hot Bending Modules
Solid stabiliser bars, torsion bars, etc. have
complicated bend geometries and are bent
in hot condition on our multi-plane hot
bending modules that are specifically
designed for these complex parts shapes.

Portabend
This universal mobile multi-purpose tube
working station has a sawing, ID/OD
deburring, bending and ferrule pre-setting
unit. They are most suitable for hydraulic
piping work in hydraulic shops, hydraulic
machine tool factories and also for on-board
and off-shore tasks.

17 Forming Tomorrow. Today !

 Tube Processing
Machines

Features
n Machines available for end forming, cutting
and punching of tubular parts
n Compact and modular, yet robust designs
n Can process tubes from Ø16 up to Ø114 mm
in carbon steel, stainless steel, alloy steel,
aluminium, copper, brass and other materials
n Special purpose machines available to suit
specific needs
n Custom-designed tools offered for all operations
n High productivity machines
n User friendly Electropneumatics' NC/CNC controls
with intelligent operator interface 2-Stage, Linear Indexing
Light Duty Tube End Former

End Forming Machines

n Cold forming of intricate shapes and profiles-
heading, flaring, swaging (expanding/reducing),
beading and others are possible
n Available in one, two or multiple stages with
linear or rotary indexing facility
n Can form one or both ends of the tube
simultaneously

End Cutting Machines

n Square end trim cuts, angle, radius and scallop cuts
n Incorporates dual blade shear and supported
shear technologies
n End cutting systems can be incorporated on 2-Stage, Linear Indexing,
tube benders Heavy Duty Tube End Former

Punching Machines
n Hole punching in tubular (round, square,
rectangular, oval) and other sections
n CNC programmable hole pattern

Multi-Station Tube Processing Machines

n Suitable for performing a combination of end
forming, cutting, punching, bending, etc. on
one machine

5-Stage, Rotary Indexing

Tube End Former

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 Electropneumatics offers total solutions in tube The end forming machines are meticulously
processing including tube bending, end forming and designed, proven and reliable. The end formed parts
cutting. The end forming and cutting machines cover produced by this chipless process have increased
a wide range of diameters and applications in the strength, good surface finish and tight tolerances.
automotive, air conditioning and ventilation, HVAC, Special multi-section punching machines for
furniture, boiler, shipbuilding, piping, construction programmable punching of holes in round, square,
and such industries. rectangular, oval and other sections are also
available.

2-Station,
Special Tube End Former

Dual Shear
Tube Cut-Off Machine
Special Tube End
Preparation Machine

Multi-Section Punching Machine

2-Way, 2-Stage Special

Tube End Former

19 Forming Tomorrow. Today !

 Electropneumatics & Hydraulics (India) Pvt. Ltd.
Gat No. 254/255, Kharabe Wadi, Chakan-Talegaon Road,
Chakan, Pune 410501, India.
Tel.: +91 (0)2135 667500 Fax.: +91 (0)2135 667502
Email: [email protected]
Forming Tomorrow. Today ! www.electropneumatics.com

Tube and Pipe Benders 01/ 0110 / [email protected]