Multi-Radius Aluminum Tube Bending Machine

Engineered for thin-wall aluminum fabrication, this multi-radius bending machine integrates programmable multi-axis motion to execute consecutive different radii on a single tube without manual repositioning. Built on a heavy-gauge stress-relieved steel frame, it eliminates torsional deflection during high-speed pushes. The system features a synchronized hydraulic-electric hybrid drive, delivering repeatable precision for high-volume automotive and HVAC production lines.

Multi-Radius Stack Tooling: Houses multiple radius dies simultaneously on a shifting stack, allowing automated transitions between tight and wide bends within the same cycle.
Closed-Loop Springback Compensation: Real-time sensor feedback measures aluminum elastic recovery post-bend and dynamically adjusts axis positioning to eliminate trial-and-error scrap.
Programmable Mandrel Extraction: Advanced servo-driven early extraction prevents interior wall wrinkling and cross-section flattening on thin-wall aluminum tubing (OD < 1.5mm).
Fluid-Temperature Thermal Stability: Integrated hydraulic oil cooling prevents viscosity breakdown during 24/7 continuous shift operations.

Material Loading: Raw aluminum tube is clamped onto the carriage feed collet; internal mandrel and wiper die are positioned at the tangent point.

Auto-Feeding & Rotation: Servo clamps index the tube longitudinally and rotationally to coordinate the exact spatial angle for the first bend.

Multi-Radius Execution: The pressure die and bend die synchronize pressure while the mandrel stays stationary inside the tube to support the inner wall radius.

Early Extraction & Unclamping: The mandrel retracts fractionally before the bend finishes to prevent tearing, followed by vertical die opening.

Stack Shift & Re-clamping: The tool stack shifts vertically/horizontally to align the secondary radius die for subsequent compound bends without operator intervention.

EV Thermal Management: Multi-bend aluminum cooling channels routing through battery packs.
HVAC&R Manifolds: Refrigerant distribution headers requiring tight-radius return bends.
Automotive Exhaust & Fluid Lines: Precision structural tubes requiring strict geometric tolerances.
Aerospace Enclosures: Lightweight frame components fabricated from high-strength aluminum alloys.

Standard Stack Assembly: Comprises bend die, clamp die, pressure die, wiper die, and flexible mandrel balls matched to exact tube OD and wall dimensions.
Material Selection: Tooling machined from Ampco aluminum bronze or hardened tool steel (HRC 58-62) with anti-friction coatings to prevent aluminum galling and scratching.
Quick-Change Interface: Hydraulic quick-release arbors reduce single-stack tooling changeover time to under 15 minutes.

Tailored Axis Configuration: Expandable from 3 axes (XYZ) to 7 fully interpolated electric axes for complex spatial geometries.
Loading Automation Integration: Compatible with gantry loaders, anthropomorphic robot arms, and pneumatic unloader racks.
Specialized Profiles: Custom die sets engineered for square, rectangular, oval, and specialized extruded aluminum profiles.

In-House Machining: Main frames are welded in-house, annealed at 600 deg C to relieve internal welding stress, and finished on CNC floor-boring mills to ensure bed parallelism within 0.02mm/m.
Component Traceability: Critical hydraulic valves and servo drives source exclusively from established industrial brands (Rexroth, Siemens, Yaskawa).
Factory Acceptance Testing (FAT): Every machine undergoes a strict 72-hour continuous dry-run test followed by live material test-bending. Coordinate measuring machine (CMM) inspection reports are verified and archived prior to crating.

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