Freeform Tube Bender

3-Axis Freeform Tube Bender

• X, Y, and Z axes: The X and Y axes are used for freeform bending, while the Z axis functions as the feed axis for the profiles.

6-Axis Freeform Tube Bender

• X, Y, and Z axes: The X and Y axes are used for freeform bending, while the Z axis functions as the feed axis for the profiles.
• A, B, and C axes: Twist bending deformation for 3D freeform bending square, rectangular, and other non-circular irregular profiles (such as aluminum extrusions).

• Aerospace: Various shapes of piping systems;
• Nuclear power: Pipeline loops, steam generators, heat exchangers, condensate water supply pipelines;
• Medical: Medical devices assisting human movement;
• Building materials and decoration: Complex-shaped bent products
• Automotive: Employed in manufacturing exhaust systems, roll cages, chassis components, and other bent tubing for vehicles.
• Manufacturing: Employed in various manufacturing processes requiring complex tube bending, such as furniture production, machinery fabrication, and industrial equipment manufacturing.

The six-axis freeform bending forming system consists of four main components: the active bending die, the guiding mechanism, the clamping mechanism, and the feeding mechanism.

Profiles are continuously pushed through the feeding mechanism, passing through the guiding mechanism and the bending die. As the profile passes through the bending die, it undergoes specific angular deviation and twisting movements in space. The distance in the vertical direction between the center point of the bending die and the center point at the exit of the guiding mechanism is called the eccentric distance U, and the distance in the horizontal direction represents the length “A” of the component’s bending and twisting deformation zone.
During the forming process, the profile is subjected to axial force PL, pushing it into the bending die, while the bending die applies a force Pu perpendicular to the feeding direction and a twisting force τ around the axis. The twisting force τ generates torque T, causing the profile to twist, with the magnitude of torque T determined by the motor parameters of the twisting axis and the material properties and cross-sectional shape of the formed profile. Under the action of Pu and PL, bending moment M is simultaneously generated, causing the profile to undergo bending deformation.

• Multi-radius Bending: Seamless bending of multi-radius workpieces.
• True Freeform Geometries: Changes in bending geometry in complex geometries can be easily accommodated, offering greater design freedom.
• High Precision: Achieve precise bending angles and dimensions, ensuring accuracy in the finished products.
• Wall Thickness: Due to the tubes being continuously pushed instead of pulled, there is almost no reduction in wall thickness at the outer bend.
• High-Quality: Even sensitive materials like aluminum and stainless steel can be bent with the highest surface quality.
• Without Molds: Bends tubes or profiles into various shapes without the need for traditional molds or dies.
• Efficiency: Freeform bending is many times faster for many bent parts than traditional methods.