Mandrel bending is an advanced metalworking technique that enables precise and uniform bending of pipe and tubes, as the classical rotation-pull-bending technique. This method is especially preferred for complex projects that require high precision. Mandrel bending is performed with the help of a mandrel (support rod) inserted into the inside of the tube. The solid support bar prevents collapses during bending. It also prevents the pipe from keeping its shape and deforming during bending. Therefore, a smooth, flawless bending process is performed with pipes whose inner part is supported.

As SBFM Machinery, we offer innovative solutions in mandrel bending technologies. You can find more information about different application areas, types and processes in this blog post.

Mandrel Bending Process and Application Areas

Madrel bending is a critical industrial metal forming technology. This method provides high precision and quality in narrow radius bending of metal pipes or tubes. Therefore, it is required in the metal industry because of the solutions it produces to suit the needs.

Madrel bending is applied in a wide range of industries such as automotive, aerospace, shipbuilding and construction. For example, it is widely preferred in the production of vehicle components in the automotive industry, in the shaping of aircraft parts in the aerospace industry and in the bending of metal structural elements in shipbuilding. Madrels are also used in the production of gym equipment, lifting machines, rods and similar parts. In furniture frames and roll cages, the madrel bending technique, which also has a bending angle, is applied. Madrels not only facilitate pipe bending but also increase the strength of the bent pipe.

The with manipulator systems used in Hydraulic Dishing Presses are similar to the madrel bending process. Both methods provide high precision and automation in the shaping of metal sheets. Hydraulic dishing presses are used for pressing large metal sheets into curved shapes, while the madrel bending process is effective for narrow radius bending.

These technologies ensure cost effectiveness and continuity in industrial production processes. They also improve production efficiency by minimizing material loss and reducing labor errors.

How is Mandrel Bending Done?

The mandrel bending process starts with selecting the right equipment and techniques. This process involves preparing the pipe, inserting the mandrel and performing the bending process. Each stage requires high precision and attention. Here are the main steps of the mandrel bending process:

1. Preparation Of The Metal To Be Bent: This is the stage where the pipe or profile material is prepared according to the shape to be bent in the correct dimensions, cut and cleaned. At this stage, elements such as clamp mold, bending mold, wiper mold, pressure mold are needed.
2. Mandrel Placement: A suitable mandrel is placed inside the pipe. At this stage, the mandrel should be determined in accordance with the inner diameter of the pipe.
3. Bending Process: The mandrel and the pipe are placed in the bending machine and the bending process is ensured to bend according to the desired angle. Thanks to the mandrel supporting the inner part of the pipe, the deformation rate is minimized during the bending process.
4. Final Controls: Before this stage, where the measurements and quality of the bent pipe are checked, the madrel is removed from the pipe. Inspections are made to ensure that the bending is precise, smooth and with minimal errors.

Types of Mandrel Bending Machines

Mandrel bending is divided into different types depending on the equipment and techniques used. These types include fixed mandrel, flexible mandrel and ball mandrel. Each type is preferred according to different application needs and bending requirements. Each of these machines below is optimized for specific bending processes and requirements.

1. Fixed Mandrel Machines: Ideal for low complexity bending operations.
2. Flexible Mandrel Machines: Used for operations requiring high precision and flexibility.
3. Ball Mandrel Machines: Suitable for very tight radius bending operations.
4. Plug Mandrel Machines: It is needed for bending pipes with long radius. A solid rod is slid into the pipe before bending. There is no need to use the wiper mold here.
5. Form Mandrel Machines: A metal rod with a curved end is used to provide additional support.
6. Ball Mandrel Machines: There is a spherical ball at the end of the mandrel facing the curve direction. A precise bending is achieved thanks to the support from the curve area during the bending phase.
7. Sand Mandrel Machines: Hollow tubes are filled with sand to provide support. At this stage, the tube must be heated before bending.
8. SBFM Profile and Pipe Bending Machines: Among the pipe benders, this machine performs bending with mandrel system. It is suitable for many bendable metal materials.

Alternatives to Mandrel Bending

Although mandrel bending offers high precision and quality, it may not be suitable for every project. In this case, other bending methods should be considered. Here are some alternatives:

1. Free Bending: This is bending without the use of a mandrel. It is very economical as it is useful for small diameter pipes and profiles.
2. Mold Bending: Bending process using special molds. It covers simple, fast and repeatable processes.
3. Roll Bending: It is especially used for bending large diameter pipes. It is used for large radius bending of large diameter profiles.

Stay tuned to our blog to learn more about mandrel bending processes and how we can help you with your projects. As SBFM Machinery, we always aim for the highest quality and customer satisfaction.