Case Studies

Project Requirement
Industry: Automotive Exhaust Systems
Workpiece: Dual-outlet Exhaust Tailpipe Assembly
Material: SS304 Stainless Steel (Bright Annealed)
Tube Dimensions: Ø63.5 mm OD × 1.5 mm Wall Thickness
Bending Radius (CLR): 100 mm (Tight Radius)
Required Bends: 3-bend complex spatial sequence with variable angles
Production Requirement: High repeatability, zero wrinkling or ovality deformation.
Processing Requirement & Challenge The workpiece required precision mandrel tube bending with tight tolerance positioning between multiple spatial bends while preventing wall thinning and section collapse.
Jiangsu Hefeng Mechanical Making Co.,Ltd. Solution
Machine: HFM-CNC-65-3A-2S (All-Electric CNC Tube Bender)
Controlled Axes: 7-Axis CNC (Feeding, Rotation, Bending, Carriage Boost, Mandrel Position)
Tooling Setup: Multi-stack wiper die, flexible mandrel with 3 balls, and anti-wrinkle pressure die.
Secondary Operations: Integrated laser cutting and end-sizing.
Project Result & Verification
Trial & Quality: Passed 100% CMM (Coordinate Measuring Machine) inspection on the first sample run.
Dimensional Metrics: Ovality strictly controlled within < 1.2%; wall thinning restricted to < 10%.
Production Cycle: 35 seconds per completed part.

Project Requirement
Industry: Furniture Manufacturing
Workpiece: Ergonomic Chair Base Support Tube
Material: Q235 Carbon Steel Tubing
Tube Dimensions: Ø25.4 mm OD × 1.2 mm Wall Thickness
Bending Radius (CLR): 50 mm
Batch Volume: 50,000 pieces/year mass production.
Processing Requirement & Challenge The production required high-speed, repeatable tube bending combined with inline automatic cutting for high-volume identical components without sacrificing edge quality.
Jiangsu Hefeng Mechanical Making Co.,Ltd. Solution
Machine: HFM-DB-25 Dual-Head Automatic Tube Bender paired with Flying Cold Saw Cutter.
Bending Process: Hydraulic rotary draw bending with synchronized dual-side forming.
Cutting Process: Burr-free orbital cold cutting.
Tooling Setup: Hardened alloy steel standard bend dies and matching clamping blocks.
Project Result & Verification
Trial & Durability: Stable long-term mass production with zero tool wear failure under 10,000 cycles.
Dimensional Metrics: Length tolerance ±0.2 mm, angle tolerance ±0.1°.
Production Cycle: 12 seconds per finished component.

Project Requirement
Industry: Fitness Equipment
Workpiece: Commercial Multi-Gym Structural Upright Frame
Material: High-Tensile Structural Steel (EN10305 E235)
Tube Dimensions: Ø76.2 mm OD (Square/Rectangular profile) × 3.0 mm Heavy Wall
Bending Radius (CLR): 150 mm
Processing Requirement & Challenge The component required large-diameter, heavy-wall multi-axis controlled bends while maintaining structural integrity and an unblemished aesthetic surface finish.
Jiangsu Hefeng Mechanical Making Co.,Ltd. Solution
Machine: HFM-CNC-80RT (Right/Left Rotary Table Tube Bending Machine)
Controlled Axes: 9-Axis full servo control.
Tooling Setup: Heavy-duty pressure die assist, segmented mandrel, and non-marking polyurethane clamp inserts.
Automation: Automated hydraulic loading/unloading robotic arm integration.
Project Result & Verification
Trial & Surface Quality: Successful trial with zero surface scratching or section flattening.
Production Capacity: 300 heavy frames per 8-hour shift.
Post-Processing: Ready for direct powder coating without secondary grinding.

Project Requirement
Industry: HVAC / Refrigeration
Workpiece: Commercial Chiller Condenser Hairpin & Return U-Bends
Material: Phosphorus-Deoxidized Copper (C12200)
Tube Dimensions: Ø9.52 mm OD × 0.4 mm Thin-Wall Precision Tubing
Bending Radius (CLR): 14.25 mm (Tight 1.5D radius)
Processing Requirement & Challenge The project required ultra-precise, high-speed thin-wall tube bending and automatic cutoff without tearing or collapsing the inner diameter (ID).
Jiangsu Hefeng Mechanical Making Co.,Ltd. Solution
Machine: HFM-CNC-16-MR High-Speed Micro Tube Bending Center.
Bending Method: Mandrel-less high-speed rotary draw bending optimized for copper.
Cutting Method: Rotary disk shearing (zero-chip cutting).
Tooling Setup: Polished tungsten carbide bender dies.
Project Result & Verification
Trial & Reliability: Seamless performance over 100,000 continuous cycles.
Dimensional Accuracy: Flow restriction minimized; ID reduction < 3%.
Production Output: Exceeded target capacity by 25%, delivering 1,200 bends/hour.

Project Requirement
Industry: Automotive Exhaust Systems
Workpiece: Catalytic Converter Inlet/Outlet Reducer Pipe
Material: 409 Stainless Steel
Tube Dimensions: Expanding from Ø50 mm to Ø60 mm OD × 1.5 mm Wall
Required End Geometry: Precise beaded/expanded slip-fit connection profile with tight sealing tolerance.
Processing Requirement & Challenge The workpiece required controlled tube-end forming to achieve a leak-proof slip-joint connection geometry suited for automated robotic welding downstream.
Jiangsu Hefeng Mechanical Making Co.,Ltd. Solution
Machine: HFM-EF-60 Multi-Station Hydraulic End Forming Machine.
Forming Process: Combination of Expanding, Reducing, and Flanging.
Tooling Setup: Segmented steel forming jaws with precision-ground profile inserts.
Automation: Pneumatic slide feeder with optical part recognition.
Project Result & Verification
Trial & Testing: 100% leak-pressure test compliance at 0.5 MPa air pressure.
Finished-End Dimension: Inner/Outer diameter tolerance controlled within ±0.05 mm.
Production Cycle: Optimized to 8 seconds per end.