Discussion On Problems In Pipe Bending Processing And Improvement Of Processing Methods

Discussion on problems in pipe bending processing and improvement of processing methods

Bend pipes may not seem like anything special, but they play a supporting role in many products, ranging from home water pipes to automobile exhaust pipes. However, small cracks and deformation problems that occur during the production process often lead to a significant reduction in processing efficiency and a serious reduction in the quality of the finished product.

Causes of cracks related to materials

The tiny cracks that exist on the bent pipe do not appear occasionally. They are directly related to the material properties of the steel pipe used. During processing, if the tension is too high and the deformation speed is relatively slow, the internal stress of the material will be concentrated, which will easily form cracks on the surface that are difficult to distinguish with the naked eye. These cracks not only affect the appearance, but are also hidden structural weaknesses.

Especially in some scenes with high strength requirements, such as pressure-bearing pipes or vehicle frame structures, this initial crack may expand during subsequent use, causing leakage or even breakage. Therefore, selecting high-quality steel pipes with good toughness and low impurities from the source is the first line of defense to prevent cracks.

The key to controlling deformation temperature

In the hot bending process, temperature is a double-edged sword. If the temperature is insufficient, it will be difficult to bend the steel pipe. Once the temperature is too high, it will easily cause the material to over-burn, causing the grains to become coarse and micro-cracks to occur on the outer surface. This critical temperature point will vary depending on the steel model and needs to be accurately controlled.

During the specific operation process, many processing plants rely on visual inspections conducted by experienced craftsmen. This approach leads to fluctuations in quality. Current processing is more inclined to use temperature control devices to monitor the temperature in the heating area at all times to ensure that the temperature is steadily within the optimal plastic range of the material. This can reduce the consumption of strength and ensure the stability of the material during bending operations.

The core role of equipment and molds

The core equipment relied on to achieve precise bending is the pipe bending machine. Its working principle is to apply bending moment through the upper mold, so that the steel pipe is formed according to the preset curve. The upper mold is like a "placenta". Its curve design plays a direct role in determining the curvature of the final bent pipe. Different pipe diameters and materials must match different molds.

Equipment performance is also critical. For old-fashioned equipment, when bending large-diameter pipes, it is very likely that the molding will be incomplete or excessive springback due to lack of strength. The new hydraulic pipe bending machine can provide more stable and powerful pressure, ensuring one-time molding, thereby reducing subsequent correction processes.

Operational points during the process

Processing bent pipes is not a very simple operation that can be completed in one step. Instead, it often requires multiple bending operations and is performed in a certain sequence from multiple different angles. Before each bending, the pipe must be accurately placed in the clamp equipped on the pipe bending machine, because as long as there is any extremely small misalignment, it will cause angular deviations in the final product.

When bending composite products with inner tubes or sleeves, special attention should be paid to the position of the inner tube during machining and bending to prevent it from being squeezed to the front clamp and thereby damaged. This requires operators to have a clear awareness of spatial layout, and sometimes they even have to make special tooling to fix internal components.

Cost control and design optimization

An innovative method of machining the bending problem can reduce the manufacturing cost of large-diameter bent pipes. This method is to first weld a closed shell with a polygonal cross-section, and then fill it with pressure medium to perform bulging. This method does not require the use of a large and expensive special pipe bending machine, and is extremely suitable for processing at the construction site.

The connection form of the equipment itself is also in the process of improvement. For example, the traditional flange connection form is replaced by directly connecting the motor spindle to the pump shaft, thereby reducing the loss generated during the energy transfer process and achieving a smoother and more efficient drive. Discussion of issues in bending processing and improvements in processing methods. These optimization measures not only improve the performance of a single machine, but also reduce energy consumption and maintenance costs under long-term operation.

Prevention and post-processing of quality defects

In order to avoid crack defects, in addition to controlling temperature and selecting high-quality materials for machining bending problems , adding a compression valve to the pipe bending machine is also an effective method. It can cushion the impact of overload, especially when bending hard materials such as stainless steel, and can reduce scratches on the pipe wall caused by sliding.

After the bending is completed, heat treatment is a key step to improve the final quality. Through appropriate annealing process, the internal stress formed during the bending process can be eliminated, the grain structure can be refined again, and the toughness of the material can be restored, so that the bent pipe can not only maintain its shape, but also have good durability? .

Have you ever been troubled by the quality of a bent pipe that did not meet the required level during renovation or work? Feel free to share your experiences and opinions. If you feel that this article has a subsidizing effect, please like it to support it. You are also welcome to forward it to more people who may be in need.