TPT May 2007

T ube B ending, H ydroforming & E nd- Fo rming

Latest all-electric 100mm tube bender from Unison

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Breeze-100 can cold-bend the most demanding materials with total precision, such as 100mm/4" titanium tubing

Unison, UK, has added a 100mm/4” diameter, multi-stack CNC tube-bender to its all-electric machine range. Called Breeze-100, the machine is optimized for high-precision applications, and includes unique operating software. The company claims that the machine virtually eliminates the high costs normally associated with machine configuration for precision small- batch and just-in-time parts production. Mr Alan Pickering, managing director of Unison, says, “This latest machine extends the benefits of all-electric machines to new applications including automotive and aerospace manufacturing, and shipbuilding.” Breeze-100 offers programmable control over the rotary draw bending process

components, and thus can cold-bend the most demanding materials with total precision, such as 100mm/4" titanium tubing. Bends of up to 180º can be made, with a high degree of repeatability of ±0.05mm of distance between bends, and ±0.05º of bend angle, plane of bend or rotation. This ensures good control of fluid flow around tight bend radii and compatibility with the hydroforming tools used in some volume manufacturing processes. A key element of the new machine is the Unibend Control Software, which now includes advanced features such as an automatic setup routine. This automatically senses and clamps a tube, ready for bending – thus reducing initial setup time.

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box’, which automatically stores the last 500 instructions entered by the operator, Unison can help users to optimize their processes, as well as provide remote maintenance. Tube bending operations may be programmed in three ways. They can be automatically generated by transferring data from CAD software, with interfaces for all popular packages. A simple programming template is also available, allowing users to create a program by entering the distance between bends, the angle of bend required, and rotation of the tube. A further option is copy or reverse engineering, by using a tube measuring system to recreate the coordinates from a sample or prototype. The Breeze-100 uses servomotors to control the bend process, including clamp, pressure die, mandrel and follower. This all-electric actuation provides significant benefits related to energy consumption, repeatability, and noise reduction. As the actuation elements of the machine require energy only when a bend is being made, total consumption is greatly reduced. In a measured comparison made by one of Unison’s users, consumption showed a ten-fold reduction. Further energy is saved as Breeze machines can be switched off when unused – avoiding the practice of leaving hydraulic machines on when idle to maintain oil temperature and consistency. The new machine can be supplied to interface with a manufacturer’s existing tools, or as a turnkey system complete with tooling. Unison also offers a range of complementary equipment, allowing the machine to be provided as a complete automated cell, including downstream equipment such as end-forming. Unison – UK Fax : +44 1723 582379 Email : enquiries@unisonltd.com Website : www.unisonltd.com Horn Machine Tools (US agent) – USA Fax : +1 559 431 4431 Email : hmt@sierratel.com Website : www.hornmachinetools.com

Users have complete control over the bend operation, and can modify the standard bend speed, clamping pressure, pressure die position and force, and mandrel positioning parameters that are applied to achieve the ideal bend. The machine includes a webcam, which Unison can remotely access over the internet. In combination with a software ‘black

fi Unison’s Breeze-100, a new all-electric 100mm/4" tube bender

Forming/rolling machine for corrugated tubes The MPF rolling machine, from ORT Italia, is designed for corrugated tubes with a stationary workpiece and rotating head. The machine has one rolling head with three rotating corrugating tools, and is designed for a maximum corrugation length of 1,000mm and a tube diameter range from 6-20mm. The MPF is designed for a fast and easy set-up and changeover, typically 10-15 minutes. Machine operation and part programming is undertaken via the machine PLC with touch screen control panel. Programming is user friendly and easy to learn, with minimal time required to create complete programs for corrugating operations. Automatic loading and unloading equipment is also available for tube lengths up to 1,000mm. Established in 1964, ORT Italia is a leading manufacturer of tube rolling and forming equipment, with over 4,000 installations worldwide.

ORT Italia SpA – Italy Fax : +39 0374 370338 Email : info@ortitalia.com Website : www.ortitalia.com

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