How to make a pipe bender for a profile pipe with your own hands

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Pro­file pipes of square or rec­tan­gu­lar sec­tion are wide­ly used in con­struc­tion and repair. Arbors, sheds, green­hous­es, frames for var­i­ous struc­tures, fences are made from them. To give the ele­ment a curved shape, use a spe­cial device — a pipe ben­der.

pipe ben­der

Com­plex spa­tial struc­tures are pro­duced by spe­cial­ized work­shops on high-pre­ci­sion pow­er­ful machines. At home, hand tools of indus­tri­al pro­duc­tion or home-made are more often used. If you need to bend sev­er­al ele­ments, it is advis­able to make a pipe ben­der for a pro­file pipe with your own hands. A sim­ple reli­able device will cope with the task no worse than the fac­to­ry one, while it will cost sev­er­al times cheap­er.

The principle of operation of the pipe bender

The pipe bend­ing machine is designed to bend pipes at an angle of up to 90°. Such pro­cess­ing of a rigid all-met­al ele­ment makes it pos­si­ble to avoid weld­ing pipes and cre­at­ing thread­ed con­nec­tions.

When bend­ing, the prin­ci­ple of mechan­i­cal cold defor­ma­tion is used. The mate­r­i­al is not adverse­ly affect­ed by high tem­per­a­tures. Rolled met­al is placed between the sta­t­ic rollers of the device, and the mov­able pres­sure roller cre­ates a force that bends the pro­file at the desired angle.

The prin­ci­ple of oper­a­tion of the roller pipe ben­der

To avoid dete­ri­o­ra­tion of tech­ni­cal char­ac­ter­is­tics and destruc­tion of the met­al, the bend­ing radius of the pipe is lim­it­ed.

Its min­i­mum val­ue depends on the type of mate­r­i­al — steel, cop­per, alu­minum — and wall thick­ness. In this case, the thin­ning of the sec­tion does not exceed 20–25%. As a result of plas­tic defor­ma­tion, the pro­file acquires a curved shape with­out loss of strength.

Table of min­i­mum radii for steel pro­file bend­ing

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To obtain a sec­tion of the angu­lar con­fig­u­ra­tion, use the local impact tool. The force is applied point­wise. The bend is formed by extru­sion.

A pro­file ben­der dif­fers from a con­ven­tion­al round pipe ben­der in that it is designed to deform a pro­file that is more resis­tant to bend­ing loads. For the man­u­fac­ture of arcs or arch­es, the work­piece is drawn on a rolling machine with one or more rollers and a large bend­ing radius.

Types of pipe benders and their design

The con­struc­tion indus­try pro­duces a wide range of roll form­ing machines. They are designed for pro­cess­ing rolled met­al with var­i­ous tech­ni­cal char­ac­ter­is­tics and solv­ing spe­cif­ic prob­lems.

Manual

Com­pact mobile devices are used for the man­u­fac­ture of arc ele­ments from pro­file pipes of small sizes. A hand tool works due to the mus­cu­lar efforts of a per­son.

Vari­eties of man­u­al pipe ben­ders:

  • with a lead­ing cen­tral shaft;
  • with mov­able edge roller;
  • turn­ing.

The design of a man­u­al pipe ben­der with a lead­ing cen­tral shaft con­sists of a base, two sup­port rollers and one mov­able one. The impact is reg­u­lat­ed by a clamp­ing screw col­lar insert­ed into the upper part of the mech­a­nism.

Roller tube ben­der with clamp­ing screw on the cen­tral shaft

The pipe is pulled through the shafts man­u­al­ly using a han­dle and a chain fixed on the roller axles. The pres­sure is increased by low­er­ing the pres­sure bolt. The pro­file grad­u­al­ly bends and takes the form of an arc.

The man­u­al pro­file ben­der can be equipped with a mov­able end roller. It is fixed to a part of the frame con­nect­ed to the bed with pow­er­ful loops.

The height of the lift is changed with a jack, rais­ing the edge of the table. The han­dle for pulling met­al prod­ucts is attached to the cen­tral fixed roller.

Pipe ben­der with a mov­ing part of the bed

For the man­u­fac­ture of steeply curved sec­tions from a pipe 20x20, 30x20 and 40x20 mm with a wall thick­ness of up to 1.5 mm, rotary man­u­al pipe ben­ders are used. They allow you to bend the pro­file at an angle of up to 360 °.

Rotary pipe ben­der

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The device is fixed on a frame or table hor­i­zon­tal­ly, a met­al struc­ture is insert­ed into the groove of the desired size. By turn­ing the long han­dle, the pro­file is pressed around the tem­plate and a bend is formed.

hydraulic

In such pipe ben­ders, the force is pumped by a hydraulic motor. Hydraulic cylin­ders trans­mit pres­sure up to 12 tons to the pipe sec­tion, which makes it pos­si­ble to bend even large work­pieces.

Hydraulic pipe ben­ders are pro­duced by the indus­try in two ver­sions:

  • Man­u­al. The pipe is insert­ed into a replace­able tem­plate of a suit­able size — a sup­port shoe that secure­ly fix­es the prod­uct dur­ing bend­ing. The hydraulic cylin­der is actu­at­ed by a han­dle, returned to its orig­i­nal posi­tion by means of a check valve. The tool is portable, used for pro­cess­ing pro­files up to 50 mm in size.
Hand hydraulic tool
  • With elec­tric dri­ve. More pow­er­ful devices allow you to bend a pipe with a cross sec­tion of up to 150 mm and a wall thick­ness of up to 3 mm. Elec­tric motors are equipped with two-stage tele­scop­ic hydraulic cylin­ders. Due to this, a large force is devel­oped at the end of the work­ing stroke.
Elec­tric Hydraulic Pipe Ben­der

Hydraulic pipe ben­ders have high pro­duc­tiv­i­ty and process struc­tures with high pre­ci­sion. To give the work­piece a giv­en bend­ing angle, a grad­u­at­ed scale is locat­ed on the device body.

Electromechanical

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Elec­tric roller pro­fes­sion­al pro­file bend­ing machine is a tech­no­log­i­cal equip­ment for the man­u­fac­ture of curved thin- and thick-walled met­al struc­tures. Allows you to auto­mate the exe­cu­tion of large vol­umes of work.

Electro­mechan­i­cal pipe ben­ders can be man­u­al or sta­tion­ary. The for­mer are used for bend­ing pipes with a diam­e­ter of up to 50 mm in con­di­tions where pow­er is avail­able. The sec­ond are large-sized machines with pow­er­ful engines installed in indus­tri­al work­shops. They are con­trolled by CNC oper­a­tors.

CNC electro­mechan­i­cal machine

Pro­file bend­ing is formed by one or more shafts. Accord­ing to the bend­ing method, pipe ben­ders are dis­tin­guished:

  • wind­ing — the ele­ment bends when rotat­ing around a fixed pul­ley;
  • rolling — the cur­va­ture of the part is giv­en by a mov­able roller, which press­es it against the tem­plate dur­ing the pas­sage;
  • rolling — the pro­file is pulled through three rolls, two of which are sta­tion­ary, and the third moves rel­a­tive to the oth­ers;
  • extrud­ing — works like a cross­bow, bends the work­piece with a retractable punch with a noz­zle made for a pipe of a cer­tain size.

The steel pro­file is most often bent by rolling machines, where the force is dis­trib­uted more even­ly.

In roller pipe ben­ders, rolled prod­ucts of square or rec­tan­gu­lar sec­tion expe­ri­ence less defor­ma­tion, at which the sta­bil­i­ty of the walls is main­tained.

Do-it-yourself manual pipe bender for profile pipes

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To bend a pro­file pipe with small cross-sec­tion­al dimen­sions with­out a pipe ben­der, crafts­men use tem­plates of the desired cur­va­ture made of met­al or wood. The work­piece is pressed man­u­al­ly to the edges of the seg­ment, rigid­ly fix­ing one end.

wood pat­tern

The thin-walled ele­ment can be deformed when heat­ed. The area is heat­ed with a blow­torch to a tem­per­a­ture of 350–400°C and, using man­u­al force, the pro­file is arched.

If you use sim­ple meth­ods that do not allow prod­uct para­me­ters, you can design a man­u­al roller pipe ben­der for a pro­file pipe. With its help, arch­es and arcs are made for canopies, green­hous­es and oth­er struc­tures of com­plex shape.

Required materials and tools

To make a device, you will need:

  • chan­nel No. 8 or No. 10 for a rigid frame;
  • 2 cas­tors made of hard­ened steel with steps for pro­files of dif­fer­ent heights or restric­tive rings;
  • notched roller for the mov­able shaft;
  • fin­ished bear­ing units;
  • 2 or 3 gears or “sprock­ets”;
  • steel chain;
  • clamp­ing screw;
  • thin pipe for the gate;
  • lever;
  • weld­ing machine;
  • drill;
  • “Bul­gar­i­an”;
  • a ham­mer.

Still need cot­ter pins, nuts, thread­ed bush­ings, wash­ers. To process the fin­ished struc­ture, paint and lubri­cant will be required.

Blueprints

The draw­ing is the basis that will help you make a pipe ben­der with­out gross errors. This is espe­cial­ly impor­tant when work­ing with met­al.

Ready-made draw­ings are post­ed on the Inter­net. With suf­fi­cient expe­ri­ence, they are easy to under­stand and adjust to your capa­bil­i­ties.

You can imag­ine an exem­plary pipe ben­der device when study­ing the fac­to­ry ana­logue, and then devel­op a detailed dia­gram of your mod­el.

Draw­ing and gen­er­al view of a hand tool

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Construction assembly steps

The sequence of oper­a­tions for the man­u­fac­ture of a home­made roller pipe ben­der:

  1. Cut the chan­nel accord­ing to the dimen­sions of the racks and base.
  2. Drill holes in the frame parts for mount­ing the rollers.
  3. Weld the sup­port frame with the uprights from the chan­nel.
  4. Cut and weld a body with holes for installing the dri­ve roller from the chan­nel. The shaft should rotate eas­i­ly inside.
  5. Fas­ten the clamp­ing screw to the result­ing box using bear­ings. Drill a hole in the top of the screw for the gate.
  6. Insert a hous­ing with a dri­ve roller between the uprights. The struc­ture must move freely ver­ti­cal­ly. Fas­ten the cov­er with a screw nut from above.

    Scheme of the clamp­ing mech­a­nism
  7. Screw the bear­ing units to the frame.
  8. Insert the col­lar into the hole of the clamp­ing bolt.
  9. On the shaft axis from the out­side, put the gears on the key or taper split bush­ings with nuts. Attach the third “aster­isk” to the rack. Put on the chain, press the sleeve for the han­dle.
  10. Car­ry out tri­al tests, if nec­es­sary, make adjust­ments.

The last step is to dis­as­sem­ble, clean the met­al from burrs, paint the fixed parts, reassem­ble. Assem­blies that are sub­ject to fric­tion dur­ing oper­a­tion should be treat­ed with Litol or oth­er grease.

Ready home­made machine

To bend the work­piece, it is placed on fixed rollers, the clamp­ing screw is low­ered to the stop and pulled with the help of a rotat­ing han­dle alter­nate­ly in one direc­tion and the oth­er.

After each rental, the screw is tight­ened with a col­lar. When the arc has acquired suf­fi­cient cur­va­ture, the screw nut is fixed with a lock nut. This will allow you to bend sev­er­al arch­es with the same radius.

Such a home­made pipe ben­der can be used even for pro­fes­sion­al pur­pos­es. He will “mas­ter” pro­files up to 60x60 mm in size or at the same time 3 pipes with a sec­tion width of 20 mm.

Details of the man­u­fac­tur­ing process of a man­u­al machine can be seen here.

https://www.youtube.com/watch?v=W3SXjpAF1GM

Hydraulic Pipe Bender

The use of hydraulics great­ly sim­pli­fies both the oper­a­tion of the pipe ben­der and its design. The sim­plest device is a frame with two sup­port rollers. The mechan­i­cal effect on the pro­file is exert­ed by a jack with a shoe attach­ment.

The hydraulic fix­ture is designed for pipe bend­ing, as the deform­ing force is trans­mit­ted to a short sec­tion.

Tools, materials and drawing

For self-pro­duc­tion of a hydraulic pipe ben­der, you will need:

  • “Bul­gar­i­an”;
  • weld­ing machine;
  • hydraulic jack;
  • chan­nel and cor­ner for pow­er frame;
  • stop shoe;
  • rollers or guides.
Draw­ing of a pipe ben­der with a jack

Assembly steps

Scheme for assem­bling a sim­ple hydraulic pipe ben­der:

  1. Cut the cor­ner to size and weld the frame in the form of a sup­port plat­form with uprights.
  2. Weld a hor­i­zon­tal frame from the chan­nel to the frame.
  3. To adjust the bend­ing radius, drill sev­er­al holes in the frame.

    Tra­verse for adjust­ing the bend­ing radius of the pipe
  4. Set the rollers to the desired posi­tion.
  5. Put the shoe on the jack rod, install the hydraulic mech­a­nism in the low­er part of the frame.

To bend the work­piece, it is placed between the seg­ment and the sup­port rollers. Grad­u­al­ly increase the load with the jack lever.

When the desired bend­ing angle is obtained, the bypass valve of the hydraulic cylin­der is opened, the jack pis­ton is low­ered and the fin­ished part is removed.

Pipe bend­ing process

For thin-walled pro­files, mech­a­nisms with a car­ry­ing capac­i­ty of 5–8 tons are used. To bend pow­er­ful pipes, hydraulics must have great capa­bil­i­ties — up to 12 tons.

Video about the man­u­fac­ture of a hydraulic pipe ben­der:

Hydraulic home­made pipe ben­der is easy to dis­as­sem­ble. The jack can be replaced with a more con­ve­nient or pow­er­ful one. To make it eas­i­er to per­form all oper­a­tions, the design is some­times adapt­ed for hor­i­zon­tal oper­a­tion.

The most com­mon bend­ing defects with a hydraulic pipe ben­der are the for­ma­tion of cav­i­ties, cor­ru­ga­tions, cracks or pro­file break­age. To pre­vent this from hap­pen­ing, it is rec­om­mend­ed to use fac­to­ry-made shoes. They are made of durable steel, cen­tered and even­ly trans­fer the load to the pipe walls.

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