Tube bending distortion ?'s

[jjmat3]

Here is a first try sample from my new bender JD2 Model 3, 3" CLR/180 die,
Material= 1", .060 wall, using for a roof rack.
http://www.lostkjwest.com/images/bendsampl.jpg
http://www.lostkjwest.com/images/bendsampl2.jpg
http://www.lostkjwest.com/images/bendsampl1.jpg

Is that normal distortion of this particular size tube? (i think not)
If not, Any ideas on what I might be doing wrong?
Would a thicker wall tubing distort less? (i think so)
NewB flame suit on, Thanks for any help! :confused:

[BadDog]

Did you check the specs on the die? Smaller CLR dies are often limited to 0.090, 0.120, or thicker wall.

[fabcam]

BadDog is correct. I checked both jd2 dealers and the pro-tools (dies are designed the same as far as the bending process) sites and pro-tools says you need to go to a 3.5 for your thickness.

The thinner the wall the larger the radius you need!!!. I have never bent that wall and dia, I would guess you will need to go to a 4.0 or 4.5 before it starts looking good IMO.

A thicker wall would definitly look better. But still a 1-to-3 (dia-to-clr) ratio is still real tight.

In your second pic you should get very little growth that direction. Hardly noticible.

In your 1st and 3rd pics you will get some loss but not even close to that.

I think you are using bend-tech ez-3d. If so, what are you getting for calibrated CLR numbers?
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[fabcam]

Let me ask a question. Your 1.00" x 3.00" die isn't a die for pipe, is it? A pipe die for 1.0 would be larger and would allow it to distort like that. I think the smallest rad die the make for 1.0" pipe is 3.50". Set you tube into the die and see if fits in there nicely relative to your tube. Look for light about 10 to 15 degrees from center where the tube touches the die.

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[fabcam]

Sorry, things keep coming to me as I am working here.

Double check your material wall thickness (if you havn't) and make sure you didn't get ahold of some thinner wall than you were expecting. Clean out the burr and check with a caliper.
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[BadDog]

Looking at the pic again, you may be right about that pipe die thing. That's awfully wide in the bend for a tube die, I think it would not even fit between the walls, but I suppose it could be the perspective in the pic.

[jjmat3]

The die I got is the 10-2015, minimum tube wall .058, 3"clr. It is for tubing, not pipe.

[jjmat3]

Crap! So between what I read in my Previous Post (http://www.pirate4x4.com/forum/showthread.php?t=326809) and the info the site gave me about the minimum tube wall of .058, I thought I would be fine w/ that die. Guess I could try it w/ the .090 wall tube? Learning curves suck. :)

[BadDog]

Based on that info, I think something else is wrong, but I never tried anything that thin. Is it possible you have the follower in the wrong hole? Did they ship you the correct die? Just clutching at straws, but at this point, I would be rechecking all assumptions on setup. I don't see how it could have flattened/widened like that unless the die didn't fit or it came out of the die (maybe due to too much space with the follower?)...

[jjmat3]

Would lubing the tube help or make it worse? The destructions say not to on thinner tubing, hmmm.... maybe the coating of oil that is already on the tube is causing trouble? The die appears to be fine, I will double check on that. The tube fits into it fine, to my untrained eye. I will post pics of the next bend and see if you guys can see anything wrong in the pics. Thanks for the ideas and help!

[LAME]

I imagine you are running manual with the die, but I know I can make thin wall tube distort very similar to that if I abruptly start the bend with the hydro.

Here is how .120 looks with the same die
http://www.rock-heads.com/forum/uploads/post-4-1102302624.jpg

[Trick-Tools.com]

I am not sure where you got your bender and die, but I'd be glad to help you! You should have no problems with that wall thickness!! I wonder if they shipped you the wrong die or if your inserts in the follow bar are in backwards. There is a taper to one of the inserts that must be on the correct side of the follow bar. Email, PM, or call if I can help!

[fabcam]

I am not sure where you got your bender and die, but I'd be glad to help you! You should have no problems with that wall thickness!! I wonder if they shipped you the wrong die or if your inserts in the follow bar are in backwards. There is a taper to one of the inserts that must be on the correct side of the follow bar. Email, PM, or call if I can help!

Once you guys find the problem, post up and tell us what happened.
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[jjmat3]

I am not sure where you got your bender and die, but I'd be glad to help you! You should have no problems with that wall thickness!! I wonder if they shipped you the wrong die or if your inserts in the follow bar are in backwards. There is a taper to one of the inserts that must be on the correct side of the follow bar. Email, PM, or call if I can help!

PM sent! Thanks! Nice to see the Gentler/Softer side of PBB! :laughing:

[jjmat3]

Update:
What I found last night is that one of the inserts was loose and after tightening it and cleaning the tubing of All coating, the bends came out much better. I'm still getting a little deformation, but expected and useable. I also made sure the tube clamp bolt was nice and snug, think that may have helped too.
Anyhow, Thanks to all for the help! Hope to get started on the rack this weekend.

[fabcam]

Update:
What I found last night is that one of the inserts was loose and after tightening it and cleaning the tubing of All coating, the bends came out much better. I'm still getting a little deformation, but expected and useable. I also made sure the tube clamp bolt was nice and snug, think that may have helped too.
Anyhow, Thanks to all for the help! Hope to get started on the rack this weekend.

Thanks for the update. Glad you got it working. Have a great time this weekend.

Some people may disagree, but I thought this was some good tech and I think many of us learned something.
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