Features of making a profile bender with your own hands. Making a profile bender with your own hands - drawings of a homemade machine A machine for bending a square profile

The use of shaped pipes is widespread not only in construction. Many home craftsmen adapt them to decorate the facade and gates, when building greenhouses, in others household needsoh. In many cases, the product needs to be given a curved outline. It will be expensive to order a service or purchase a factory machine. The way out will be the independent manufacture of a machine for bending shaped pipes.

Types of roll forming machines

The size of manufacture largely depends on the thickness and material of the bent pipes. Handmade pipe benders can bend products made of aluminum, steel, copper. The cross-sectional dimensions of the profile depend on the location of the shafts and the possibility of their adjustment.

By the type of installation, the bending device can be:

• stationary installation. Basically, these are massive mechanisms for large bending volumes. For the installation, you need to make a concrete base or a welded workbench box;
• portable profile pipe benders have an average weight and productivity. A welded base or a frame assembled on bolts with their own hands is arranged under them;
• wearable. Such pipe benders are created mainly for bending a thin profile, using for decorative purposes. The bending is installed on any flat, stable surface: concrete, steel, wood. Bending is carried out by hand.

By the type of drive device, machines are:

• manual - flexion is carried out through the transfer of muscle force. The disadvantage is the inconvenience of creating multiple bends and an uncontrolled bend radius;
• electric - bending is carried out by the operation of an electric motor;
• hydraulic - the force is transmitted to the element by means of a hydraulic jack. This is the most common option for self-made.

Electric homemade pipe benders can be connected to an electronic bending precision controller.

The profile bending can be roller and plate. In the first case, the pipe acquires the radius due to rolling between two rows of rollers. In the second case, it bends on the pins embedded in concrete. The second type is the easiest to manufacture, but requires effort when working with your own hands.

Difference of machines by bending method

The bending of the pipe in terms of radius and angle is very different. This is especially true for structures intended for the transport of liquids. Plastic bending of a pipe can be achieved in several ways:

• bending according to a template;
• extrusion;
• pressing;
• rolling.

A bending or bow-type pipe bender is represented by a wooden cylinder and sticks. The pipe is fixed to the structure. The ends are pulled manually. The method does not make it possible to control the bending diameter. For precise work, it is better to make a machine according to engineering calculations with your own hands.

For the safety of the pipe and the uniformity of the distribution of forces, it is filled with sand. Filling takes place by tapping with a hammer to shrink the material.

Extrusion is a dieless pressing with a single punch. Thanks to die-replacing rollers or swivel shoes, the force vector is perpendicular to the product. This gives the bending precision.

The process is characterized by the need to apply the load slowly and smoothly. Handy hydraulic jacks come in handy in this method. This option is especially common for DIY installation.

Press bending can be done using a conventional vise, brake drum and pulley. The machine is do-it-yourself mounted by attaching the punch and matrix vice to the jaws.

Drawings of the roll forming machine can be found on forums and websites. The principle of operation is the passage of pipes between two rows of rollers. The position of stationary parts can be made adjustable by adjusting the radius of curvature.

The shafts are metal cylinders with an axis of rotation. Two are attached about 10 cm from the mounting surface, the third above them must be made with the possibility of manual vertical adjustment.

Making a machine with your own hands

For making with your own hands even the most ordinary homemade profile bender, you will need a calculation. In this case, there is little likelihood of making a mistake with the size, the need for material and the effort withstand.

Thereafter:

• using a grinder, metal or wooden base elements are cut;
• the manufacture of shafts and other critical parts is entrusted to the turner. In the presence of lathe and the skills of working with it, you can do everything yourself. Shaft dimensions must be matched to the bearings and sprocket used;
• grooves and holes are drilled in the rings;
• the base for the pressure roller is being prepared. It is attached to the shelf through a key;
• the base frame is mounted;
• support shafts are mounted and a portal structure for the upper shaft is arranged;
• all movable elements of the machine are connected by a chain;
• attached to the rotation handle for manual operation or to the motor. The jack is mounted.

You need to choose the type of machine based on the wall thickness of the bent pipes.

By assembling the machine yourself, you can avoid unnecessary costs for factory equipment. The advantage of a personal machine will be its complete adaptation to specific needs and requirements. If necessary, a self-made unit can be improved and re-equipped.

To consolidate the skills of making a manual bending machine, you can watch the video:

Profile pipes have firmly entered the life of a person, thanks to their inherent properties: increased strength, the presence of stiffening ribs and convenient geometry. Due to the widespread use of products, it is often necessary to bend such pipes in one or more places and at different angles, for which equipment for bending shaped pipes is used. This article will tell you about the types of pipe benders, working with them and making the device yourself.

Types of pipe benders

As mentioned above, often - and in household, and on an industrial scale - it becomes necessary to change a round or profile pipe, bending it at the required angle in one or more places or giving it a smooth bending radius. This is required both for the technological conditions of pipe operation and for aesthetic (for example, when creating patterned structures and elements - for canopies, awnings, etc.).

In most cases, it is either physically impossible to bend the pipe manually, or possibly with significant violations of the profile geometry, which complicates further use products.

Therefore, they use professional or do-it-yourself machines for bending a profile pipe - pipe benders.

According to the principle of interaction with the corresponding products, pipe benders are divided into:

1. Hydraulic Linkage Devicesbending products at a given angle. In this case, all the effort is concentrated by means of the lever at one point - the place of bending.
2. Roller attachments (profile bending), providing the ability to give the profile pipe smooth bending radii. When using this tool, the product is expanded (rolled out) by means of rollers.

It should be additionally noted that, no matter whether purchased or made by hand, machines for rolling shaped tubes can only work with plastic non-breakable material, that is, with metals and alloys (read: ""). For bending rigid plastics, asbestos cement, etc. they are not suitable. Soft plastic bends by hand and effortlessly.

By appointment, pipe benders are:

• for profile products - pipes with a cross-sectional geometry other than round (oval, rectangular, square);
• for copper pipes and products from other metals and alloys (read also: "");
• for pipes made of metal-plastic, etc.

Working with the device

The use of quality tools ensures that the pipe bends in compliance with the quality requirements of the resulting product.

Correct use of the profile pipe bending machine ensures uniform bending of the product, eliminates creases and flattening during pipe processing.

Giving the pipes a curved shape, in turn, provides the most successful arrangement of pipelines and other structures, without using unnecessary space. In addition, in some cases, by correctly bending some elements, you can avoid the use of welding and various pipe fittings (couplings, flanges, angles, tees, etc.).

Equipment selection

Now on the market there are a sufficient number of pipe benders of various manufacturers, purposes and price category, which allows each master to choose for himself necessary tool, guided by the intended area of \u200b\u200buse and the availability of funds.

Depending on the intended purpose of the device, you should purchase:

• manual pipe benders for metal and metal-plastic - they are suitable for bending pipes made of different grades of steel, cast iron and, of course, composite products;
• profile benders - as the name suggests, they are used to give the necessary shapes to shaped pipes, which are usually made of steel;
• manual tube benders for copper pipes - have the least bending power, since copper is the most ductile.

If we list the most popular pipe bending devices in Russia, we should mention such popular brands of hand roll forming machines as PG-1, PG-2 and PG-4. All of them are of domestic production and, according to the statements of the people who used them, are not inferior to imported analogues.

Making a device for bending pipes with your own hands

In addition to purchasing a product, there are other options: to borrow a professional pipe bender from friends or to rent it. In addition, guided by the corresponding drawings for the profile pipe bending machine, you can try to assemble the tool yourself.

Among the advantages of a self-assembled machine for bending a profile pipe are:

• the ability to control the entire manufacturing process, from the stage of selection of materials to the final painting, which means the owner homemade machine can be sure of its reliability and safety;
• saving money - many parts for assembling the device or are already in the arsenal home master, or you can buy it profitably, for example, at scrap metal collection points. Read also: "".

To assemble the machine, you will need the following parts and elements:

• corners and channels to create a frame on which the main mechanism will be fixed;
• supports for the machine - any options are possible: legs from round and shaped pipes, corners, etc.;
• bending rollers (shafts) that a turner can make to order;
• transmission chains and gears to create a torque on the rollers (you can, for example, use the components of an old domestic car - "six" or another);
• chain tensioner (can also be removed from the machine);
• roller guides - in order to get them, a couple of corners are welded;
• driving component for the guide roller - can be made from a profile pipe with parameters 40 to 20 mm;
• adjusting screw;
• a lever for activating the device - it can be made from any metal part;
• bolts for fixing the bending rollers - for them it is necessary to make slots in the channels, allowing, by changing the rollers, to adjust the pipe bending parameter.

Thus, having all the necessary items and the desire to work with your hands, you can assemble your own pipe bender without any problems.

The need for a device that is able to bend shaped pipes arises in many cases. A similar tool is necessary when arranging a gazebo, a shed, creating greenhouses. Today on the market are sold bent pipeshowever, the high cost makes them unprofitable to purchase. It is much cheaper to build and create bent shaped pipes yourself.

Types and design features of profile benders

Machines capable of bending shaped pipes differ in design from conventional tools. Profile materials have increased strength. Accordingly, in order to bend them, more effort is needed.

In addition, the bend of a shaped tube usually has a large radius. In this regard, the design of the profile bending device includes three rollers. Of these, depending on the preferences of the master, mobile can be:

• left roller;
• middle roller;
• right roller.

Pipe bender roller

If the middle roller is movable, the end elements are fixed to the body. They rise slightly above the base plane. If one of the extreme rollers is movable, then it moves together with the base. Others remain immovable during this time.

The principle of operation of such a tool is quite simple and is based on cold rolling. The shaped tube is placed between three shafts. The pressure that bends the metal is created by the center, middle roller. If the pipe needs to be bent only in one specific area, a special point machine must be used. The rolling machine allows you to obtain an arched profile.

Depending on the application of what force the machine works, the following types of profile bending are distinguished:

• mechanical. The bend is created by manual pressure;
• hydraulic. Additionally applied hydraulic jack, with the help of which pressure is created;
• electric. The machine is equipped with an electric motor that generates a bending force;
• electrohydraulic. The electric motor drives the hydraulic cylinder.

If the machine is designed for small pipes, tool will do with manual broaching. Otherwise, it will be impossible to stretch the profile without special devices (for example, an electric motor).

What materials and tools are needed to make a pipe bender

On modern market there is a wide variety of tools for profile bending. They differ both in capabilities and functionality, and in price. However, any master can make such a machine on his own, paying only for individual component parts. Some of them may already be in stock, others will have to be purchased.

So, to create a machine, you need to acquire:

• corners;
• chain;
• chain tensioner;
• blanks for the manufacture of rollers and shafts;
• channel bars;
• bearings;
• bearing housings;
• drive sprockets;
• hydraulic jack;
• drive shaft handle;
• springs (if a jack will be used);
• bolts and nuts.

There are many options for the manufacture of machines for bending shaped pipes. Some of the details in the list above may not be needed. It all depends on the chosen method of creating the instrument. In addition to materials, you will also need tools. In order to create a machine, the master will need:

• drill (electric);
• welding machine;
• a hammer;
• grinder (angle);
• drills (for metal);
• open-end and socket wrenches.

The most difficult task is to manufacture the pressure roller and drive shafts. To create them you will need. Not every master has such equipment. However, you can find a turner who will do all the work for a reasonable fee.

Build process

Before starting the assembly, it is strongly recommended to create a drawing of the future device. This will greatly facilitate the task. Although today there are a large number of ready-made drawings, it would be better if the master creates it himself, taking into account his own needs.

The whole process of creating a pipe bender for a profile pipe with your own hands consists of the following steps:

1. Creation of a roller and shafts (in the absence of proper qualifications, it is better to entrust this matter to a professional turner).
2. Installation of bearings in races.
3. Determination of the location of the keyways on the shafts.
4. Drilling holes in the restriction nozzles, threading for clamping bolts.
5. Creates the site on which the pinch roller will be installed. In (if there is none, a thick metal plate will do) four holes (paired) are drilled, for which the cages with bearings will be attached.
6. Screwing the pressure shaft.
7. Welding lugs to the pad (M8 nuts are used).
8. Manufacturing of the bed and supporting legs using welding machine.
9. Suspension of the platform, on which the roller is installed, to the bed by means of springs (use the upper cross member of the bed).
10. Drilling holes in the base frame. With their help, a variable distance between different shafts will be provided. In this case, it is necessary to carefully monitor the distance between the holes, since in the event of an error, the pipe will not only bend, but also shrink.
11. Installation of support shafts. Installation of driven and driving sprockets, drive chain.
12. Tensioner installation, chain slack elimination.
13. Creation of the drive handle. As source material you can use a steel bar with a diameter of twenty millimeters.
14. Installation and fixing of the jack on the upper platform. Nuts and bolts can be used for fixing.

After assembly, it is recommended to conduct a test during which assembly errors (if any) will be found. To do this, put a piece of the profile pipe on the lower shafts, and press it against them with a jack. Next, you need to activate the device by turning the handle.

Another device option

You can create a machine for bending a profile pipe with your own hands in another way. This will require fewer materials. It will be possible to do without an expensive jack. The process of creating a simpler machine consists of the following steps:

1. Create a frame like a longitudinal table. Welding can be used to connect the elements. In this case, it is necessary to take into account the voltage that will be exerted on individual elements devices. It is important that the frame is stable. This can be achieved by fixing to the floor.
2. Mount two rotating shafts just above the table. The third shaft is placed even higher, between the first two. The distance between the outer shafts and the central element can be changed. This will affect the bend radius. However, it is important that both end elements are at the same distance from the center shaft. In the future, this parameter can be changed depending on the bending radius, which must be obtained in a particular case.
3. Chain drive attachment.

This machine has a simpler design. However, working with it is somewhat more difficult than with the previous device. In any case, after making the tool, it is recommended to clean it from rust and paint it. This will protect the pipe bending machine from damage.

The first machine is more sophisticated. Pipes bent on such a unit will have a more neat appearance. In addition, less force is required to machine the profile. The second machine is cheaper and easier to manufacture. However, the bending quality may be worse. What tool to make should be decided by the master himself, focusing on his needs.

Thus, the profile tube bending machines can be manufactured independently. The final cost of such tools will be lower than industrial products on the market. To create a machine, you need certain materials and tools.

There are a large number of drawings of such devices, but it will be better if the wizard creates the drawing himself, taking into account all the features. You can make a tool, focusing on the instructions above.

The profile pipe bending machine is a very popular type of metalworking equipment. This is explained by the fact that pipe products of this type are actively used today in many areas, including for solving household needs. If the profile pipe can be cut easily even with hand tool, then to bend such a product, it is necessary to use a special pipe bending machine.

There can be only two options for obtaining such a machine at your disposal: the purchase of serial equipment, for which it will be necessary to allocate significant financial resources, or making a device for bending profile pipes with your own hands. Today there are many design schemes, according to which homemade machines for bending shaped pipes can be manufactured. It is worth dwelling on the simplest of them and, accordingly, the most popular among home craftsmen.

Pipe bending machine device and instructions for its assembly

Regardless of what expendable materials and mechanisms are in your home workshop or garage, a do-it-yourself machine for bending a profile pipe can be made according to various design schemes. Having made even the simplest homemade pipe bender, in the future, if the need arises, you can improve its design by endowing such equipment with a number of additional functions.

The main structural elements of any machine on which it is performed are:

• supporting frame, which is made of powerful metal profile;
• three shafts rotating on separate axes (precisely by means of such elements, which must be of high strength, bending machines act on the profile pipe, deforming it to the required bending angle);
• a mechanism by which the working shafts are rotated;
• chain connecting the elements of the drive mechanism.

Before making homemade bending equipment, it is advisable to prepare its drawing or find a ready-made one on the Internet. Moreover, there you can find video with detailed instructionsexplaining the manufacturing process of a device for bending shaped pipes.

If the equipment for bending, equipped with working shafts, is used for rolling a profile pipe, during which it is bent, then the profile bending simplest designin question operate on a different principle. On devices of this type, it is carried out, which must first be formed from rigidly fixed elements. As such elements, durable metal pins are most often used, fixed in concrete base... An arc is formed from such pins, along which the bending of the professional pipe is performed.

To make a device on which it will be possible to effectively bend the pipe along the radius, it is best to pour the concrete platform on your own and fix metal pins on it as securely as possible.

The bending of steel pipes, for which such a simple device is used, is carried out in the following sequence.

1. One end of the pipe is securely fixed.
2. Physically acting on the second, unsecured end of the pipe, the product begins to bend smoothly and accurately, bending around the surface of the pins located in an arc.
3. After the pipe has acquired the required configuration, its second end is also fixed and the product is left in this position for a while so that the metal gets used to the new state.

Since work on such a device requires the application of significant physical efforts, to facilitate the task (especially when bending large diameter pipes), the place of the future bend is preheated with a gas burner or over a fire. You can learn more about the rules for working on such a device in the corresponding video.

Of course, such a device that can be built in the courtyard of your home has minimal efficiency and functionality. For example, with its help it is rather difficult to bend stainless pipes or to carry out complex bending. Nevertheless, it is quite possible to use it for the simplest bending work. Such work, for example, can be associated with laying a pipeline or making a frame for a home greenhouse.

Lever pipe bender manufacturing

A selection of photos and drawings for self-made a lever-type pipe bender, as well as a video with comments and explanations from the author.

This lever tube bender is not too difficult to manufacture and allows you to work with fairly thick pipes

A video from the author will allow you to understand the key points and small nuances of making this pipe bender.

Serial equipment

If working with metal pipes different profiles related to your professional activities, then the best choice for you there will be serial machines for bending shaped pipes, which are distinguished not only by high efficiency, but also by extended functionality. Today there are many of the most different models profile benders, which differ from each other both in their performance and in the set of functionality. This variety allows you to choose a machine for bending a profile metal pipe, focusing on your needs and financial capabilities.

Let us consider the most important advantages that a serial machine for bending shaped pipes has over manual devices.

1. Individual models can be equipped with an electronic control system, which allows the automation of the bending process.
2. The use of replaceable working attachments significantly expands the functionality of the profile benders.
3. In addition to the electronic control system, some models of such machines can be equipped with a remote control.
4. Serial profile benders are characterized by compact dimensions, which makes them very mobile.
5. Such equipment can be installed on any level and solid surface.
6. The technical capabilities of such machines make it possible to perform even very complex bends on pipes (U-shaped, N-shaped, etc.).

When choosing a serial machine for bending shaped pipes, it should be borne in mind that the cost of such equipment, depending on its technical characteristics and functionality starts from a few hundred US dollars and can go up to several thousand.

To carry out bending operations on serial equipment, you must have some training. If it is not there, then you can study the features of this process using videos, which are easy to find on the Internet.

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If a master is seriously working with metal, sooner or later there comes a need for a productive device that would be distinguished by simple operation.

A bending machine is simply indispensable for DIY making garden benches, frames of gazebos, workbenches, carports from a profile pipe. Thanks to the presence of such a tool, metal structures are attractive and durable.

But in order to create it with your own hands, it is important to understand the device and assembly features of the profile bending machine.

In the production process of various kinds of metal structures, a special machine is used for bending a profile pipe, which is a compact and easily transportable equipment with different types of drives.

The unit is lightweight and copes with the task of bending cold rolled metal without difficulty. And to achieve optimal curvature, together with the pipe bender, special nozzles are used for processing all kinds of metal products.

To learn how to control such a unit, it is important to study the features of its design and the basic principles of operation.

For pipes it consists of the following elements:

• bearing frame made of high strength metal profile;
• three rotation shafts located on separate axes and responsible for the process of bending the profile pipe to the current bending angle;
• working shaft rotation mechanism;
• chain for connecting elements of the drive mechanism.

Manual machine for reinforcement bending.

All factory and for bending are divided into four types, depending on the system of arrangement and functioning of the rollers:

1. Units with an upper movable roller are the simplest option in terms of the mechanical component.
   In the design of such a profiler, only the upper roller can move, and the roller can be hydraulic or upper manual. Such a structure provides the craftsman with the ability to accurately calculate the possible radius for bending metal parts with a minimum error for metal addition or a slight gradient in profile deformation.
2. The left roller machine can perform the same functions as the top roller machine.
   But, in addition to this, it is excellent for curling spirals, which the first type of profile bending cannot do. You can fit a model to control the bending gradient.
3. Units with lower rollers are suitable for bending large profiles thanks to the even distribution of bending forces on the two lower shafts and a fully hydraulic drive mechanism.
   Each video has its own location controller.
4. Rolls with all movable rollers are distinguished by the most complex mechanism, which allows them to accumulate the advantages of all types of such equipment.

On a note! Such equipment differs in size, labeling, cost and weight. But for domestic use, a home-made profile bender is also suitable, the manufacture of which will cost the master a little money.

Drawing

The initial task in the manufacture of a bending machine for a profile pipe on our own is to create a drawing of a bending machine. It is compiled independently or found ready-made on the Internet.

On numerous forums of craftsmen and craftsmen working with metal structures, you can find videos with detailed description the device of the pipe bending machine and instructions for its assembly.

Assembly

After preparing a drawing for a homemade pipe bender, you can start assembling the supporting frame. If the equipment is planned to be used for a profile pipe with your own hands, then you should refuse to use welding when assembling the frame.

Pipe bender design.

This method of connecting parts is not the maximum level of reliability. It is better to give preference to the bolts, which will give the unit strength and mobility: if necessary, the structure can be disassembled.

After installing the working shafts on the frame, the mechanism of their rotation is assembled from three sprockets and a chain: two of them are mounted on both lower shafts, and the third is below.

Important! It is imperative to provide for the possibility of changing the position of the lower sprocket, which will allow you to easily tension the chain on the roll forming unit. For easy control of the equipment, fix a sturdy handle on one of the sprockets.

Be sure to test the profile bending machine after assembly in order to eliminate the risk of rejection.

How to make a do-it-yourself profile bender?

Not every novice craftsman is able to purchase factory-type metal pipes for bending, since this is quite expensive equipment.

Bending machine drawing.

Alternatively, you can try to make a manual machine on your own, following the further instructions:

1. Place gears, bearings, and keyed rings on the pressure shaft.
   Carve out the cages for bearings and rollers according to a previously prepared drawing of such a shaft. It is also necessary to make three shafts for the unit, one of which is suspended on springs, and the other two are installed on the sides.
2. Drill holes in the rings to create grooves and tapping, and then make a shelf using a channel with pre-arranged holes and tapped threads required when installing the pressure shaft.
3. After completing the preparation, the structure of the machine is assembled using a welding machine and bolted connections.
   First, install the frame, which simultaneously functions as the legs of the pipe bender.
4. Next, the shelf is suspended on springs with a pressure shaft fixed on it, after which the side support shafts should be installed on a homemade pipe bender.
   Remember to attach the handle to one shaft.
5. Finally, a jack must be installed on the machine, and it is ready to work.

Lever pipe bender manufacturing

In domestic conditions, you can make a lever-type pipe bender for rolling a professional pipe, which can easily cope with a variety of bending radius of the product.

• the structure is mainly made of metal, but wood can also be used for this purpose;
• the pressure and central rollers should be made of metal, since they form the basis of the future machine;
• give the holder a U-shape;
• when choosing the size of the machine, take into account the cross-section of the pipes with which you plan to work: the larger it is, the more significant the load on the products should be, which means that the machine itself must be large;
• the axis for the central roller must be fixed on the base as securely as possible, but without pinching that prevents the rotation of this holder;
• on the other side of the roller, install a lever of a certain length on the holder: the shorter the lever, the more difficult it will be to perform the operation;

Conclusion

With the help of a high-quality profile bending, you can work with metal pipes of different sections. Such equipment can be purchased ready-made or assembled in a domestic environment, following the instructions described above.