TPT May 2007

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

Versatile 3D tube bending without tool change

The Nissin Freeformbender from Neu Machinery, Germany, enables 3D tube and profile bending of different radii without tool changes. Based on patented tooling and CNC-control, products can be bent on different planes with continuous radii and no straights in-between. fi The Nissin Freeformbender can bend different radii without tool changes

An alternative to conventional mandrel bending, this technology reduces cycle times as every forward movement of the feeder bar continually supplies the workpiece. Several test results have shown this bending principle to be ideal for follow- on hydroforming processes, as the wall thickness remains almost untouched in the bending range. With a coefficient power distribution board, the machine can bend tubes with a homogeneous wall thickness.

Pipes are now used in automotive manufacture as design features

and line elements. Automotive design now relies upon

increasingly tight spaces, even closer radii and the thinnest possible material for lighter products. The Nissin Freeformbender can also undertake high precision mandrel bending of thin-walled pipes up to a diameter of 90mm. The smallest radius that can be produced is close to 2DR up to infinity. The machine has recently been improved due to the close cooperation of J Neu with a renowned German car manufacturer who used the first benders in their production. This partnership has led to advanced bending of flat oval tubes and profiles in addition to round pipes. › High precision mandrel bending of thin-walled pipes is possible with the Nissin Freeformbender

High performance lubricants from tube-bending expert AddisonMckee has developed a range of environmentally friendly, non-solvent based gels that offer benefits over traditional tube gel compounds. Initially available in AmGel™ (tube bending) and AmForm™ (tube cutting and forming) variants, the product range has been developed in association with Gramos Applied Chemicals, and will be expanded to include AmCut™ (tube cutting) and AmWash™ (tube degreasing) formulations. AmGel is mainly water-based, and is available in ‘standard’, ‘plus’ and ‘ultimate’ grades. The products are non-drip and can be easily applied by brush, wipe or mandrel lubrication. They have the viscosity of a gel solution and have been developed to provide a reliable lubrication barrier for the majority of light, medium and extremely heavy-duty tube manipulation applications. One considerable benefit of using AmGel is that bent tubes and components can progress to MIG, TIG, resistance weld and other processes without the need for washing. At the end of the manufacturing process, the oil-free gel can then be removed by washing in a mildly alkaline, water-based solution, thus removing the need for costly, potentially caustic, cleaning solutions. The AmForm range is purpose-developed to provide superior lubrication during general forming and cutting operations, and includes traditional oil-based formulations along with high-capability synthetic products. Formulated to meet a range of specific tube forming and cutting requirements, AmForm lubricants can be applied by brush, swab, roller, flood, spray or misting.

The Easy Programming Software has various functions such as preview, mirroring, and rotation. These functions are combined with the option of a measuring arm so that bent parts can be compared and corrected automatically. The MS Windows based PC can be connected to LAN and uses all features of modern computers. › A recent collaboration with a German car manufacturer has led to improvements in bending of flat oval tubes

J Neu GmbH – Germany Fax : +49 6359 924257 Email : info@neu-gmbh.de Website : www.neu-gmbh.de

AddisonMckee Ltd – UK Fax : +44 1772 323 227 Email : info@addisonmckee.com • Website : www.addisonmckee.com

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M ay /J une 2007