Tech Talk

Winton U - Shared Knowledge & Software Tools for Bending, End Forming, Cutting, and More

A Progressive Movement In Tube Forming
A progressive die set used in a stamping process is common. It involves a spool of bulk material being fed into a series of dies that quite often transform the flat raw material into a useful component. The idea of a series of dies to form a part has been around for a long time.

Are Your Ovality Requirements Impeding Your Tube Bending Process?
If you have ever been involved with bending tubing , chances are you have had a need to control the roundness of the tube/pipe in the bend zone.

Assessing the Arc
Evaluating the methods for measuring large radii

Bending Tubes Without Wrinkles
What can you do when a bend starts out good but then transitions into wrinkles?

CNC Extrusion Bender - The Basics
The basics you should know about CNC Extrusion Benders.

Coax Facts
Continuous improvement and statistical process control are useful,time-tested techniques—they have been used since the 1950s—buttheir use must be tailored to specific applications. For example, atypical manufacturing metric is parts per minute, but many rollformers should measure feet per minute. This and other tips can helproll formers accurately evaluate their productivity and measure theimpact of process improvements.

Direct Acting or Toggle: Clamping on a Tube Bender is Not Always Straight Forward
Over the previous decades tube rotary draw bending machines have made use of numerous devices to hold/clamp a tube in position as the tube is being bent. For example, the job of a clamp die on a tube bending machine is to firmly clamp the tube and thus prevent it form slipping relative to the bend die as the bend die pulls the tube around itself.

Embracing the Wrinkle
How turning the tables on an unwanted wrinkle can be profitable.

Extracting The Heat Within a Refrigeration System
Refrigeration systems are designed to transfer heat whereby the goal is to remove heat from a warm area and make the local environment cooler. You will find this process in household air conditioners, refrigeration systems, and anywhere where heat is not desired.

Feeding The Process - How Seemingly Insignificant Forces Can Influence a Tube Fabrication Process
The process of advancing or feeding a tube during a forming process can seem straight forward. Simply don’t loose track of the length of tube advanced and you have it made. Quite often it is not that simple.

Getting A Grip On Tube Bending
A collet closer is found on a CNC or NC tube bender and serves an important role in the overall bending process. When quality is good, little attention is paid to its operation. However, when one or more quality features of a bent tubular product fall outside of acceptable limits, tracing the origin of the problem correctly back to the collet closer can often be initially overlooked.

Getting the Most Out of Your Bender / Saw Combination
George Winton from Winton Machine explains the value of having a CNC tube bender with a saw attachment.

Getting The Slug To Exit
Punching features in a tube perpendicular to the center axis of the tube is an everyday event worldwide. Whether you are punching with or without a mandrel, there is most often an unwantedpiece of metal (the slug) to contend with. The slug usually takes the shape of the male punch that is forced thru the wall of the tube. When it comes to removing the slug from inside the tube, there are several options... and as you will see not all options are equal.

Going Straight: How a Tube Straightener can Affect the Curves in a Tubular Profile
The need for straightening a tube is all throughout the tube fabrication industry. You may have a coil in bulk form that feeds a forming process. You may have purchased a straight tube, as defined by your supplier, and you need it straighter. In both cases, a tube straightener may be of interest. Choosing the right type straightener can make all the difference. Tube straighteners are nothing new. They have been around for years. The US Patent Office documents various straightening devices going back decades. The need has always been there. The problem is simple: take a bent metal tube and straighten it. Sounds straight forward. Sometimes it is….sometimes you may get a curve.

Holding The Dies
There are a few popular ways to hold/support the clamp and pressure die on a rotary draw bending machine. They all aim to accomplish the same thing. Namely, provide for a means of precision vertical alignment to the mating bend die (as needed) and be able to provide rigid support to the respective die when under bending conditions. In this article we will discuss only two of several means of holding a clamp die.

How to Accurately Measure Bend Angles in Tube Fabrication
Regardless of the bending process used to bend a tube, the vast majority of tube fabricators are interested in the quality of the bend angle produced. Bend angle quality often translates into a tolerance surrounding a target angle.

How To Do More With Less - Adding a Loader to an Existing Tube Bending Process Can Increase Capacity and Free Up Labor
Why a Loader? In short, a device to auto load a fabrication process can often make the difference between questionability profitable and profitable. Let’s face it, direct labor can be expensive and is somewhat susceptible to human error.

How to Expand the End of a Tube in Production
Throughout the world of tube end forming, one of the common types of end forms involves expanding the end of a tube. The reasons for expanding a tube’s end are many. For example, lawn & garden equipment often requires that one tube slips into the end of another for quick assembly.

How to Fabricate Coax Cable in Production
Coax cable is a common means to transport high frequency signals in microwave communication systems. Coax cable can be found in commercial and military applications all over the world.

How to Form Tubular Coils in Production
It may not be obvious but most folks pass within a few feet of a circular coil every day. Circular tubular coils can be found in beverage dispensing machines, oil & gas processing equipment, swimming pool heat pumps, laboratory equipment, and transportation equipment. The list goes on and the applications are endless. However, coils formed in production are most often fabricated using just one of a few common roll bending techniques.

How to Maneuver a Race Track When the Conditions are Tight
Every once in a while you may take on a job that presents unforeseen challenges. I’m sure the flash backs are whizzing through your mind’s eye now. When they first happen they can be painful at first. However, when you figure out the puzzle, a great sense of accomplishment is realized. That is the good part. It is getting to that part that we all strive for.

How to Process Coax Cable
In this article, George Winton explains the basics of cutting, stripping and bending coax cable for many different applications.

How To Reduce Cost of Goods Sold in a Tube Fabrication Shop
During the bulk of 20th century most manufacturers in the United States enjoyed a long ride immune to foreign import pressure. As the century approached an end, several industries witnessed the relocation of their manufacturing base.

How To Reduce Operating Costs When Bending Steel Serpentine Profiles
In the world of heat transfer there is often a need to bend a tube in the shape of a serpentine. This happens worldwide every month consuming tons of aluminum, copper, steel, and stainless steel tubing.

June 2015 - Newsletter

Making a Work Horse Hum: How to Maneuver Through Tube Bending Quality Problems on a Vertical Compression Bender
Vertical compression tube benders have been around for more than 50 years. Historically associated with high volume bending, press benders continue to play a role in production environments where parts consist of 1 or 2 bends. Press benders have stood the test of time mainly due to their speed and ability to produce consistent bends. It is not un- common to get 500 to 900 bends per hour thru a vertical press bender.

Making Use Of The Right Hydraulic Power
Choosing the right type of hydraulic power supply can make all the difference.

Managing "Tail Off" in Tube Bending
Sometimes a bent tube has a bend very close to the end of the tube. If it happens to be the last bend on a rotary draw process, the possibility of "tail off" exists.

No Time To Sit - How Software Can Improve the Flow of Bent Fabricated Parts Through Your Shop
So you have been thinking about how you can make improvements to your existing tube fabrication processes. You have been talking to the folks on the shop floor, a few people in the office, and anyone who might be able shed light on your needs. You have some ideas, yet you are searching for the big one...the one that will really affect the bottom line.

Peeling Back the Bennies
At times the cost of certain products can amaze me. You stand there looking at a product and think “Wow, how can that widget cost that much?” Yes, we are all trying to eat next month and it takes money to do that. However, every once in a while you can peel back the specifics and get a better understanding of the technical details. This happened to me recently. I was searching the market for a weld seam detector that used the eddy current process.

Pulling The Wrinkles Out of Copper Tube
The vast majority of copper tube bending never comes close to producing wrinkles on the inside of a bend. However, the design of some bent tubular parts is prone to wrinkles.

Ram End Forming - A Few Basics
A significant majority of fabricated tubing needs to have one or both ends formed into a specific shape. Quite often one or both ends of a tube needs to be formed so that it can be mated to another part. The mating part might be another tube, a fuel pump, or even a bulk head inside a diesel engine. Forming a specific shape takes planning. An understanding of a few basics during the planning stage can go a long way.

Reducing Your Programming Time on a CNC Tube Bender
A fair amount of industrial equipment consumes a significant amount of metal tubing. Some of this tubing gets bent into specific shapes as often described by a 2D drawing. A 2D drawing contains the necessary information used to program a CNC tube bending machine.

Regripping a Short Pressure Die in Tube Fabrication
When the magazine is empty, what do you do? You reload. When the gas in the tank is low, what do you do? You refill. Therefore, when the pressure die is too short, what do you do? You regrip! It’s that simple.

Serpentine Bending in Production
Bending serpentine profiles—successive 180-degree bends, which typically are used in refrigeration systems—can be a challenge.

Serpentine Tube Benders Made Simple
Why Serpentine Tube Bending The answer is simple; to transfer heat. A tube bent into a shape of a serpentine allows an original equipment manufacturer (OEM) to extract heat from one environment and transport that heat to another area.

Shaping Profits With a Mandrel Extractor
Bending a tube and preventing it from collapsing is a mystery to most folks. This is especially true for those whose lively hood does not depend on bending tubes. For those that bend tubing for a living, knowing how to improve the ovality of a bend can be of interest.

Sizing Up The Job - Quoting Strategies for Tube Bending
It is something we are often faced with; putting a price on a fabricated tube that we are asked to quote. Many factors can come into play. Some so obvious we tend to gloss right over them. And some factors are not so obvious. Getting a quote right so that both parties are satisfied can sometimes be separated by a fine line.

Taking The Path Of Least Resistance
Learn how welded seams can affect the quality of tube forming when using a ram tool or using segmented fingers.

Telescopic Tube Fabrication Made Easy
It would be nice if one size fit all. But the world is not quite like that. This is true for political leaders as it is for tubular assemblies such as a camera tri pod. I’m sure you can see it now. Clearly a tripod has a need to be positioned in an infinite number of positions. This is where the elegance of smooth telescopic tubing can come into play.

The Axis of Safety
A tube bender can be considered a collection of power presses and, as such, it needs more than just a few conventional barriers between the operator and the machine. Safety mats, interlocked switches, emergency-stop switches, and interlocked side plates are a few of the safety devices available to machine tool manufacturers.

The Crackle You Don’t Need
Are you suddenly having trouble making quality bends on your hydraulic bender? Could it be the hydraulic power supply? Is it building full pressure? Have you inspected the quality of the hydraulic fluid itself? Read on to learn how you can troubleshoot your hydraulic power supply. This may be your problem.

The Difference Between Black and White Can Be Eye Opening
Finding the weld seam in a tube can add consistency to a tube fabrication process.

The Unexpected Twist - When the Bending Process Goes Sideways
Here’s the situation. You have been bending round profiles, square profiles, and sometimes even rectangular profiles. You have even bent the rectangular profiles the easy way and the hard way. Up until this point you have worked your way thru years of technical problems. At some point you are then asked to bend a simple angle. You’re thinking “no problem….”

Tips for Bending Small Diameter Copper Tubing with a CNC Machine
Copper tubing is used in several markets including refrigeration, laboratory equipment, and process equipment. Copper is one of the softest metals to bend. Being a soft metal is helpful yet at the same time can be a disadvantage when making a tight radius bend. This is often the case for copper tubing below ¾” in diameter.

Tracking the Material Efficiently
Consistency is the name of the game. And this holds true for cutting tubing, bending tubing, or even laser cutting.

Trading the Wrinkles In For a Fresher Look
Truth be told, not all wrinkles are discussed over the cosmetic counter at the local department store. Truth be told, some wrinkles are found right on the shop floor. You may recall the wrinkles in a bent tubes that appeared apparently out of nowhere. One week you are making quality parts and the next week it was wrinkle city. It seems like the wrinkles just starting showing up…uninvited. There are numerous reasons as to why a wrinkle is present. Read on to learn about a few of these reasons.

Trimming the Neck on a Bellow
Learn how to use rotary shear cuts and lathe cuts to make smooth, finished neck on tube bellows.

Tube Bending Made Simple - Making Use of the Compression Bending Process
Bent tubing is everywhere. Just look under the hood of a car, in the back of a pool, or inside a plane. Tube benders are used everyday to support all kinds of equipment. Knowing how to design and then bend the tubing can often translate into products that are easy to build and service.

Understanding Vertical Compression Tube Benders
Manufacturers who bend tubing using the same process day in and day out are often searching for faster and more efficient tube bending machines that are capable of producing precision bent tubes. Daily applications range from aerospace to medical devices to children's toys.

Using Segmented Dies to Expand a Tube's End
Throughout the world of tube end forming, one of the common types of end forms involves expanding the end of a tube. The reasons for expanding a tube’s end are many!

When a Cylinder Won't Move - Troubleshooting
The basics of troubleshooting a hydraulic or pneumatic cylinder on an industrial machine

When There is Trouble Around the Bend
As you probably already know, getting the bend quality that you need is not always a 10 minute job. The variables can be endless. Wall thickness, material, material hardness, bend radius, degree of bend, and on and on.

When There's No Straight in the Mix
Having back to back bends in a tube with "no straight" segment has been frowned upon for years! In this article, George Winton describes how, with the right tooling, back to back bends can be simple and easy.