Multi-Stack Tube Bending Machine

The multi-stack tube bending machine executes complex multi-radius components within a single loading cycle. By stacking multiple tooling tiers vertically or horizontally, the machine shifts between different centerline radii (CLR) and bending directions without manual tooling changeovers.

Driven by multi-axis CNC architecture, the system coordinates carriage rotation, feeding, and bending via absolute servo drives. Heavy-duty cast Meehanite frames absorb torsional stress during high-load stainless steel and carbon steel forming. This configuration suits high-mix, high-volume production lines in automotive exhaust fabrication, HVAC manufacturing, and aerospace structural assembly where cycle time and positional repeatability directly dictate manufacturing margins.

The CNC Servo Electric Tube Bending Machine utilizes multi-axis absolute servo motor drives (Siemens Sinumerik CNC architecture) to execute high-precision, programmable cold bending operations for metal tubes and profiles. Operating without hydraulic oil systems, this architecture eliminates thermal drift, reduces energy consumption by up to 45%, and achieves angular repeatability of +/-0.05 deg. Built with a rigid Meehanite cast iron frame and finite element analysis (FEA) optimized stress distribution, the machine handles complex multi-radius geometries across stainless steel, carbon steel, copper, and aluminum alloys for tier-1 manufacturing environments. Built under ISO 9001:2015 quality management standards and fully compliant with CE safety directives.

Multi-Stack Tooling Architecture: Accommodates up to four different radii or tool configurations on a single stack slide. Reduces part handling, eliminates secondary clamping errors, and shortens per-part cycle times for complex geometries.

Rigid Meehanite Cast Bed: The machine base utilizes stress-relieved Meehanite cast iron, machined on 5-axis gantry milling centers in a single setup to maintain structural alignment and resist deflection under peak loads up to 250 kN.

Closed-Loop Servo Control: Eliminates hydraulic drift through absolute encoder feedback on all primary bending and feeding axes, maintaining positional repeatability over extended operational shifts.

Dynamic Pressure Booster & Mandrel Extractor: Programmable early mandrel extraction limits internal tube friction, preventing wall thinning and wrinkling on tight-radius bends (R <= 1.5D).

Off-Line 3D Programming Interface: Operators import STEP or IGES CAD files directly into the industrial IPC. The software automatically calculates elongation factors, springback parameters, and interference zones prior to physical execution.

[ Raw Material Loading ]

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[ Hydraulic Front Collet Clamping ]

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[ Mandrel Positioning & Internal Support ]

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[ Servo-Driven Carriage Feeding (Y-Axis) & Rotation (B-Axis) ]

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[ Multi-Stack Stack Shift (X-Axis) to Target Radius ]

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[ Rotary Draw Bending Execution (C-Axis) with Pressure Die Assist ]

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[ Mandrel Extraction & Part Unloading ]

Material Loading: The operator places the raw tubular stock into the hydraulic collet.

Clamping & Support: The front collet clamps the tube while the internal mandrel advances to the tangent point to prevent cross-sectional flattening.

Feeding & Rotation: Servo motors drive the carriage to position the tube longitudinally and rotationally for the first bend.

Stack Selection: The stack slide shifts horizontally or vertically to align the specified tooling radius with the bend die centerline.

Bending: The main bend arm rotates while the pressure die booster applies synchronized linear force, keeping material tension uniform along the outer wall.

Extraction & Release: The mandrel retracts slightly ahead of the completion angle, the clamp die opens, and the finished component releases.

Automotive Exhaust Systems: Forms complex catalytic converter pipes and multi-radius tailpipes from 409L and 304 stainless steel tubing without cross-section ovality exceeding 3 percent.

Commercial HVAC & Refrigeration: Bends thick-walled copper and aluminum distribution headers, minimizing thinning at the bend extrados to sustain internal operating pressures up to 4.5 MPa.

Aerospace Fluid Lines: Processes high-strength titanium (Grade 9) and Inconel alloy tubing for aircraft hydraulic systems, requiring strict adherence to bend radius tolerances (CLR = 1D to 3D).

Commercial Furniture & Fitness Equipment: Handles high-tensile structural steel tubes (Q235 / Q355) for gym frames and ergonomic office furniture, executing compound bends in a continuous sequence.

Precision bending relies entirely on the kinematic coordination of five primary tooling components, manufactured in-house from high-grade alloy tool steels (H13, Cr12MoV) through vacuum heat treatment to achieve hardness levels of HRC 58 - 62.

Standard models cover the majority of industrial requirements, but application-specific variations are engineered upon request:

Extended Bed Lengths: Carriage travel distance expandable from standard 3000 mm up to 6000 mm for long structural members.

Specialized Tooling Profiles: Custom multi-stack combinations for non-circular geometries (oval, square, rectangular, and D-tubes).

Automation Integration: Robotic loading/unloading arms and automatic bundle feeding magazines interface directly with the machine's PLC via digital I/O or Profinet protocols.

Pneumatic / Hydraulic Boosters: Secondary booster configurations added to the carriage slide for tight-radius bending of high-strength alloys.

Structural integrity and mechanical precision are verified prior to factory shipment through strict internal verification protocols:

Bed Machining & Annealing: All structural weldments undergo high-temperature annealing (600 deg C to 650 deg C) to release residual welding stress, followed by machining on large-scale CNC floor boring machines.

Laser Interferometer Calibration: Linear and rotational axes are calibrated using Renishaw laser interferometers to verify positioning accuracy and eliminate backlash.

Continuous Load Run-Test: Each machine completes a 72-hour dry-run endurance test followed by a live material test using customer-supplied tube samples.

Dimensional Inspection: Finished sample bends are measured using Faro arm portable CMM systems to verify CLR radius, wall thickness reduction rates, and angle springback compensation.

Compliance Certification: Electrical cabinets conform to CE/UL safety standards, utilizing Schneider and Siemens low-voltage components.

Procurement timelines for capital machinery require exact validation of part geometry, cycle times, and tooling lifespans. Our engineering team reviews incoming CAD files to provide a comprehensive production feasibility report within 48 hours.

To initiate a technical review, please provide the following parameters in your inquiry:

Part Geometry: STEP or IGES 3D CAD file of the tubular component.

Material Data: Tube Outer Diameter (OD), wall thickness, and material grade (e.g., SUS304, Q235, Titanium Grade 9).

Production Volume: Annual batch size and target cycle time requirements.

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