Tube Bending
Objectives
At the end of this training you will be able to:
1. Explain the key features of the tube bender
2. Layout tubing to make bends
3. Use the tube bender to make a variety of bends
4. Diagnose problems with tube bends
5. Design tube runs for safety and maintenance
TurnPro Indexing Handle Tube Bender
Features
• Makes bends greater than 90° in a single operation
• Eliminates crossed handles
• No assembly and reassembly of bender handles
• Durable Construction
– Suitable for heavier wall tubing
– Vise mountable
• 1/4, 3/8, 1/2 in. (6, 8, 10, 12 mm) sizes
• Training available
TurnPro Indexing Handle Tube Bender
Indexing Lever Handle
Roller
Housing
Indexing Trigger
Alignment Marks
Bender
Die
Tube
Lock Hook
Bend Angle Marks
Die Radius
Indicator
Tube Selection and Preparation
Selecting Tubing
Description
Material
Hardness
Standard
Carbon Steel
Soft Annealed,
Seamless
72 HRB (130 HV) or less
ASTM A179
304 Stainless
Steel
Fully-annealed,
seamless or welded and
drawn
90 HRB (200 HV) or less
ASTM 269 or A213
316Stainless
Steel
Fully-annealed,
seamless or welded and
drawn
90 HRB (200 HV) or less
ASTM 269 or A213
Selecting Tubing
Tube
OD
Approx Bend
Radius
Carbon Steel Wall
Thickness Min/Max
Stainless Steel Wall
Thickness Min/Max
9/16
0.028/0.065
3/4
0.028/0.065
1/4
3/8
15/16
1/2
1 1/2
0.035/0.065
0.035/0.083
0.035/0.083
Selecting Tubing
Tube
OD
Approx Bend
Radius
Carbon Steel Wall
Thickness Min/Max
Stainless Steel Wall
Thickness Min/Max
6
15
0.8/1.5
8
24
1.0/1.5
10
24
1.0/1 5
1.0/2.0
12
38
1.0/2 .2
1.0/2.0
Selecting & Handling Tubing
• Check for
–
–
–
–
–
Clean
No scratches or gouges
Out of round ends
Burr
Seams
• Handling
–
–
–
–
Dragging
Capping
Uncoiling
Cutting
• Tube Cutter
• Sharp saw
• Cutting wheel
– deburr
Tube Installation
Bend Allowance
T - Tube OD
R – Bend Radius
L - Length of straight
tube required
Tube Installation
Bend Allowance - Fractional Tubing
T Tube OD
R Bend Radius
L
1/4
9/16
13/16
3/8
15/16
15/16
1/2
1 1/2
1 3/16
Tube Installation
Bend Allowance – Metric Tubing
Tube OD
R Bend Radius
L
6
15
21
8
24
23
10
24
25
12
38
31
Laying Out & Bending Tubing
Layout
Sequential Layout Example
3 in.
3 in.
Layout
Sequential Bend Method
1.
Add the lengths or all section together to estimate the overall length
of tubing required for the job.
2.
Mark the starting point (reference mark) for your project.
–
3.
Remember to make all marks completely around the tube.
Measure from the reference mark to the vertex of the first bend.
–
The vertex is the point where the center lines of the two legs of the angle
meet.
4.
Bend the tube.
5.
Using the vertex of the previous bend as the reference mark, mark the
vertex for the next bend the next bend.
6.
Repeat steps 3 and 4 for the next bend
Sequential Layout
3 in.
Vertex
Reference
Mark
3 in.
Vertex
3 in.
1.
Add the lengths or all section together to calculate the overall
length of tubing required for the job.
Sequential Layout
Reference
Mark
2.
Mark the starting point (reference market) for your project.
Remember to make all marks completely around the tube.
Sequential Layout
Reference
Mark
3 in.
Vertex
3.
Measure from the reference mark to the vertex of the first
bend. The vertex is the point where the center lines of the two
legs of the angle meet.
90° Bends – Reference Left
Reference Mark
Align Vertex Mark
With “L”
Sequential Layout
4.
Bend the tube.
90° Bends – Reference Left
Bend until 90 meets 0
Reference Mark
Layout
Vertex
New Reference
3 in.
Vertex
5.
Measure and mark the next segment.
Sequential Layout
Tip – Mark the
vertex of the
next bend to help
alignment
45° Bends
Vertex 1
30° Alignment
Vertex Mark
45° Bends
Bend until 45 meets 0
Sequential Layout
Vertex
6. Bend the tube
Bend Calculations
Layout Calculations
Offset Calculations
3.5
?
3.5 x 1.414 = 4.494 or approx. 5 in.
Layout Calculations
Offset Calculations
Offset Bend
Angle
Offset Bend
Allowance
22 ½
2 .613
30
2 .000
45
1 .414
60
1 .154
Layout Calculations
Offset Calculations
3.5
5
Solution
3.50 x 1.414 = 4.949 or approx. 5 in.
Layout Calculations
Reference
Mark
Adjustment (Gain)
Calculations
3 in.
1/4 in. OD
Tubing
3.5 in.
3 in.
Original Calculation
11 1/2 in.
Layout Calculations
Adjustment (Gain)
Calculations
Layout Calculations
Reference
Mark
Adjustment (Gain)
Calculations
3 in.
3 in. + 3.5 in. – 5/16 in. = 6 3/16 in.
6 3/16 in.
3 in.
3.5 in.
in.
New Calculation
9 1/2 in. – (2 x 5/16) = 8 7/8 in.
6 3/16 in. + 3 in. – 5/16 in. = 8 7/8
More Bending
Bends Greater than 90°
Bends Greater than 90°
Bend until 0 meets 180,
then a little more
for spring back
Right Reference Bends
Reference Mark
3 in.
3 in.
9 in.
Tubing
3 in.
Reference Right Bends
Align Vertex Mark
with R
90° Bends – Reference Right
Changing
Planes
90°
90°
Multi-Plane Bends
2 1/2 in.
30° x 30°
90°
2 1/2 in.
4 in.
2 1/2 in.
Multi-Plane Bends
30°
15°
0°
15°
30°
45°
45°
60°
60°
75°
75°
90°
90°
Bend Direction
Multi-Plane Bends
30°
15°
0°
15°
30°
45°
45°
60°
60°
75°
75°
90°
90°
Bend Direction
Multi-Plane Bends
30°
45°
60°
75°
90°
15°
0°
15°
30°
45°
60°
75°
90°
Multi-Plane Bends
30°
45°
60°
75°
90°
15°
0°
15°
30°
45°
60°
75°
90°
Imperfect Bends
Common causes of imperfect bends
Sometimes produced when thin
wall tube is bent without a
support mandrel.
May be caused by:
• Not having the mandrel forward
far enough in the tube
• Bending thin wall tubes without
a mandrel
• Trying to bend too short a radius
• Bending smaller diameter tubing
in a larger radius block.
May be caused by the tube
slipping in the bender. A kinked
bend may also result from the
use of non-annealed tubing.
Installing Tube Runs
Installing Tube Runs
•
•
•
•
Avoid creating ladders
Run tubing close to the wall
Use support hangers every 3 – 5 ft.
Support valves, transmitters etc, independent
of the tubing
• Run tubing vertically
when possible
Installing Tube Runs
Stagger Connections
Installing Tube Runs

Installing Tube Runs
Avoid straight line connections whenever possible

Installing Tube Runs
Avoid straight line connections whenever possible
Installing Tube Runs
Bend up staggers for easier access and maintenance
Expansion
Installing Tube Runs

Installing Tube Runs
Installing Tubing Runs

Installing Tube Runs
Installing Tubing Runs
Installing Tubing Runs
Final Exercise
Tube Bender Training
Final Exercise
1 3/8
1 3/8
1
7
30°
6
30°
2
6
6
2 1/2
3
15°/90°
150°
15°/90°
4
18
5
150°
2 3/4
15°
Final Exercise
Vertex #
Distance to
Bend°
Rotation°
Reference
0
1
Direction
1 3/8
30°
0°
2
6
15°
90°
Left
3
2½
150°
90°
Right
4
18
150°
0°
5
2 3/4
15°
90°
Right
6
6
30°
90°
Left
7
1 3/8
A Better Hook
1 1/4
1 1/4
60°
60°
60°
3/4
1 1/2
45°
45°
1 1/2
Overall Length – 9 in.
1 1/4
Quantity 500
Thanks