TPT May 2009

P roduction & P rocessing of A utomotive T ube

Complex bending for automotive applications

Pedrazzoli Tube Technology (PTT) Ltd, UK, a new division of Italy’s Pedrazzoli IBP SpA, is the manufacturer of tube bending machines with specialist models for automotive and aircraft applications. The range now features the new models EB20, EB76 and EB120/150, which are based on the highly acclaimed Ebwin control. In the area of large dimension tube bending and the automotive field, Pedrazzoli offers the Bend Master 120EB and the Bend Master 168 EB. These models are specifically designed for the sectors where modern rolled sections are increasingly complex. The new all-electric machines have multiple (triple) stacks for compound draw bending with one rollforming module (for variable radii in 3D forms). This is coupled with a powerful electric boost capable of continuous collet boosting of over 380KN. This feature has proved to be extremely versatile in the production of frame sections that are advanced in design. It allows for accuracy and repeatability with far tighter tolerance bends than the generally accepted industry standard. Existing rollforming machinery available today utilizes the bend axis to form the Weil engineering, Germany, has introduced a revolutionary clamping concept for thin- walled tubes. The roll-forming and laser welding machines enable tube production without tool change, cycle time loss, and any additional costs. The new Flexistar production cell can change the diameter automatically without an increase in cycle time after each rolling and welding process. There is program control within the machine parameters, and any diameter or tube length can be rolled and welded down to a lot size of 1. This totally eliminates all tool costs and changeover times. The automatic diameter adjustment for rolling and welding is the core of the unit. The tube is guided with the help of outside positioned, flexible clamping rails underneath a fixed welding source, which continuously welds. With this unique process, there is complete automation

rolled radii, this being a simple solution and one that works well for simple run of mill products. The only other option being hydroforming, but it requires a far higher investment as well as a high cost of any design change. The new effective

 Pedrazzoli’s Bend Master 168 EB is ideal for automotive applications

Pedrazzoli system achieves new levels of technology. It includes a sophisticated twisting head assembly, that allows effective use of three interpolated rolling axes and combined bending on a different plane. This is particularly useful in those areas where complex shapes and reduced radii are required. All axes are in true interpolation mode, even mandrel positioning, which is an important factor in repeatable production. The finite positioning of these axes has proved to be very critical in repeatable production. The rollforming software has a built-in learning function that absorbs results and self educates for continual honing of success results (ie working to remedy the nature of material during bending). of production from blank to the finished welded tube. The current machine concept is designed for diameters of 2-16", with lengths between 10-90", and metal gauges of 0.008" to 0.100". Tubes can now be continuously produced with a total cycle time of less than 20 seconds. Typical applications are tubes for exhaust systems, catalytic

The Ebwin control system and software is developed in-house by the company’s R&D department and is equipped with a user-friendly operator interface with touchscreen. It is also possible to supply the machines with the IMS2 new generation control for compatibility with existing Pedrazzoli IMS machines in their workshops. The establishment of Pedrazzoli Tube Technology (PTT) Ltd took place following Pedrazzoli IBP SpA acquiring the intellectual rights of Eurobend Ltd. Pedrazzoli IBP SpA – Italy Fax : +39 0424 509049 Email : elunardon@pedrazzoli.it Website : www.pedrazzoli-ibp.com

Short, thin-walled tube production without tool change

representatives around the world and a subsidiary, Weil Engineering North America LLC, USA. Weil engineering GmbH – Germany Fax : +49 7631 18 09 49 Email : info@weil-engineering.de Website : www.weil-engineering.de

 The Flexistar production cell for thin-walled tubes

systems, double/triple- walled tubes (such as metal bellows), and chimney tubes. Weil engineering is the leader in manufacturing laser welding systems. The company has an extensive network of numerous sales

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M ay 2009

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