Table Of Contentgg
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About the Book
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This book discusses the techniques and processes of
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tube, pipe, and extruded-shape fabrication. Guidelines uu ee
for round, square, rectangular, and other shapes are
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written about in detail. This text is a reference and in-
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formation guide for tube and pipe fabricators serious
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about attaining competitive positions in the industry. FF e
Some of the topics covered are: oo s
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• process planning; mm e
(cid:127) basic cut-to-length methods; c
(cid:127) methods of bending; inin r o s i v e
(cid:127) justification and selection of equipment; gg P e n
(cid:127) end-forming methods and designs; e h
(cid:127) tube branching methods; PP p r
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(cid:127) brazing and joining techniques; oo o
(cid:127) lubrication requirements; and cc C
(cid:127) inspection techniques. ee A
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Reference data is included that details the plasticity ss u i
theory of bending and forming, mechanical behavior of ee G
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metals, and mechanics of bending and end forming. The
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book is adapted from Cold Bending and Forming Tube
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and Other Sections (1966). C C
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About the Author pp
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Greg Miller is currently president and CEO of Tubu- hh
lar Solutions in Medina, Ohio, where he takes an active ee
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role in all company operations and sales activities. He ss
has written multiple articles for various trade publica- iviv
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tions over the last 10 years. As a speaker, Miller has G G
participated in tube fabrication seminars throughout the
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U.S. In addition, he has served for three years as chair- idid
person of the Small Diameter Tube Conference spon- ee
GREG G.
sored by the Society of Manufacturing Engineers.
MILLER
Society of
Society of
Manufacturing
Manufacturing
Engineers
Engineers
MILLER www.sme.org
www.sme.org
Association for
Forming & Fabricating Association for
Technologies/SME Forming & Fabricating
www.sme.org/afft Technologies/SME
www.sme.org/afft
Tube Forming Processes:
A Comprehensive Guide
i
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Tube Forming Processes:
A Comprehensive Guide
Gregory Miller
Society of Association for
Manufacturing Forming & Fabricating
Engineers Technologies/SME
Dearborn, Michigan
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Copyright © 2003 by the Society of Manufacturing Engineers
987654321
All rights reserved, including those of translation. This book, or parts
thereof, may not be reproduced by any means, including photocopying,
recording or microfilming, or by any information storage and retrieval
system, without permission in writing of the copyright owners.
No liability is assumed by the publisher with respect to use of informa-
tion contained herein. While every precaution has been taken in the
preparation of this book, the publisher assumes no responsibility for
errors or omissions. Publication of any data in this book does not consti-
tute a recommendation or endorsement of any patent, proprietary right,
or product that may be involved.
Library of Congress Catalog Card Number: 2002112342
International Standard Book Number: 0-87263-633-X
Additional copies may be obtained by contacting:
Society of Manufacturing Engineers
Customer Service
One SME Drive, P.O. Box 930
Dearborn, Michigan 48121
1-800-733-4763
www.sme.org
SME staff who participated in producing this book:
Cheryl Zupan, Staff Editor
Walter Kelly, Editorial Consultant
Rosemary Csizmadia, Production Supervisor
Frances Kania, Production Assistant
Kathye Quirk, Graphic Designer/Cover Design
Jon Newberg, Production Editor
Printed in the United States of America
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For the “tubologist” in all of us—this book is dedicated
to the hard work, perseverance, and tenacity
of the men and women who work on our factory floors.
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Tube Forming Processes: A Comprehensive Guide
vi
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Acknowledgments
Attempting to be accurate in all subject areas of this book re-
quired the help of many industry professionals. Without their in-
put, this book would not have been possible. There is no substitute
for the first-hand experience and knowledge reflected by the fol-
lowing contributors:
• Michael B. Cone, Advanced Tubular Technologies, Inc., Water-
ford, MI;
(cid:127) Ron Duval, SMT Industries, Inc., Sidney, OH;
(cid:127) Bill Holyoak, T-Drill Industries, Inc., Norcross, GA;
(cid:127) Joe Ivaska, Tower Oil & Technology, Chicago, IL;
(cid:127) Wally Jenson, Engelhard Joining Systems, Daytona Beach, FL;
(cid:127) Jeff Johnson, Finn-Power USA, Inc., Schaumburg, IL;
(cid:127) Dale Miller, Manchester Tool and Die, North Manchester, IN;
(cid:127) Todd Smith, J & S Machine, Inc., Ellsworth, WI;
(cid:127) Ron Stange, Tools for Bending, Denver, CO; and
(cid:127) Bob Want, Tools for Bending, Denver, CO.
Organizing the vast amount of information in this text was a
difficult task. Without the help of Carolyn Ghiglione, it would have
been another 34 years before the book went to print. I thank her
for bringing her supreme effort and many skills to this project.
vii
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Tube Forming Processes: A Comprehensive Guide
viii
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Table of Contents
Preface..........................................................................................xiii
Process Planning.............................................................................1
Materials Suitable for Bending.......................................................1
Copper and Copper Alloys............................................................9
Magnesium and Magnesium Alloys...........................................10
Titanium and Titanium Alloys....................................................... 11
Nickel and High-nickel Alloys ......................................................12
Cold-bending Suitability ...............................................................13
Material Shapes and Finishes......................................................15
Designing Bends..........................................................................20
Dimensioning Drawings of Bent Parts.........................................41
References ...................................................................................44
2 Basic Tube Cut-to-length Methods.........................................47
Saw Cutting..................................................................................47
Lathe Cutting................................................................................54
Rotary Cutting ..............................................................................54
Dual-blade Shear Cutting............................................................58
Supported Shear Cutting.............................................................63
Laser Cutting................................................................................64
Bibliography.................................................................................67
3 Basic Bending Methods..........................................................69
Rotary-draw bending..................................................................72
Compression bending................................................................138
Ram Bending ..............................................................................143
Press Bending.............................................................................145
Roll Bending................................................................................150
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