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Homemade pipe bender for profile pipes. How to make a manual pipe bender for bending a round pipe with your own hands? Manual pipe bender drawings

To carry out construction and installation work, especially when it comes to pipelines, pipes with different bending angles are often required, and the use of fittings may not be justified at all.

Pipe bending in such cases is carried out using pipe benders. These are portable, industrial and for home use.

Contents of the article

Design and principle of operation of a manual pipe bender

A manual pipe bender is quite simple in design and operating principle, so a home craftsman can easily cope with its production yourself. The main elements in any pipe bending device is the pressure plate. Presses on it with a certain amount of force special mechanism, and it transmits force to the pipe being processed.

Both an electric motor or a hydraulic pump, and a spring with clamps are used as a pressing mechanism.

To perform bending, the corrugation is installed between the pressure plate and several shafts, which act as stabilizers. Also, with the help of shafts, you can adjust the bending radius, since their position is adjustable.

So, to bend a pipe along a small radius, the shafts are placed fairly close to each other, and if it is necessary to increase the radius, then they are moved further away from each other.

To bend a round pipe, crescent-shaped shafts are installed on pipe benders.

Manual device

Homemade manual pipe bender, with which bending is carried out round pipes, consists of two machined pulleys, one of which is fixed motionless, and the second rotates around the first at a distance of the diameter of the pipe being processed. The principle of its operation is simple: A pipe is placed between two pulleys and by rotating the movable pulley, the round pipe is bent to the desired angle.

A manual pipe bender in the hands of a skillful owner may be needed at any time, therefore it is worthwhile to approach its manufacture thoroughly, so that it can be used to bend pipes different diameters.

This design will require two triple pulleys instead of single pulleys: one pair will be used for bending 1/2″ pipe, one for bending 3/4″ pipe, and one for inch pipes.

It is unlikely that you will be able to buy such devices on the market, so you will need to order them from a turning workshop. A recess is made at the ends of the shafts, which in size coincides with half the diameter of the corrugation.

Another important point, which must be taken into account when manufacturing shafts - the stationary pulley should be minimal in size, since the minimum possible bending radius of the product depends on this. Optimal size The moving shaft is twice the diameter of the stationary one.

Sequence of manufacturing a pipe bender structure

So, now directly about the stages of work that are performed independently:

• After the shafts are ordered, they begin to manufacture the base for a homemade pipe bender. A thick square metal plate (at least 10 mm) is suitable for it. To attach the base to the table, you need to drill four holes in the corners of the plate, or weld it to metal pole, immured in the floor;
• in the center of the plate, a pin of the same diameter as the small triple shaft is attached by welding;
• next step it is necessary to manufacture a rotating mechanism. To do this, three metal plates are welded in the shape of the letter P (the width of the plates is more than 50 mm), and the height of the structure depends on the diameters of the large and small shaft: this height should accommodate a fully movable pulley and half a stationary one;
• To mount the shafts, you will need to drill several holes. The legs of the letter P are located at a distance from each other, slightly greater than the height of the shafts. A handle about 25 cm long is welded to the top bar of the structure, onto which a lever tube is subsequently placed;
• the large pin is mounted first and secured with cotter pins behind the plate in the shape of the letter P, and the small shaft is put on together with the entire structure;
• to equip the pipe stopper, another pin installed vertically is welded to the frame. It will serve as a stop.

The second method is similar to the previous one, only metal hooks are used as a template, which are fixed on top plywood sheet along the line of the intended bend. The advantage of this design is that the hooks can be rearranged to change the radius of the pipe.

Advantages and disadvantages of manual pipe benders

Main advantages hand-held devices:

1. has small overall dimensions and weight. Pipe bending with their help is possible almost anywhere: in the workshop, on summer cottage, in the garage or on construction site. As a rule, the need for a pipe bender for round pipes arises in those places where they lay engineering systems.
2. Another advantage is that with the help of such devices it is easy to bend pipes made of soft metal or.
3. The manual unit is quite mobile: if necessary, it can be easily moved to any place.
4. Even the most inexperienced user can handle working with a manual pipe bender: the principle of its operation is so simple that it is simply impossible not to understand it.

However, along with the advantages, there are also disadvantages of using such a device. One of the most important: the inability to bend the pipe large diameter. It will also be difficult to bend thick-walled materials.

When setting up a household, sooner or later you are faced with the need to bend a pipe. In a city apartment - less often, but also. The prices for pipe bending tools and accessories, both for sale and for rent, are not exactly exorbitant, but, to put it mildly, they are not encouraging. Therefore, there are more than enough people who want to make a pipe bender with their own hands, and the purpose of this publication is to help them find a design suitable for their specific purpose and give effective practical recommendations for its production.

Amateur craftsmen make a wide variety of installations for bending pipes, from simple devices to real bending machines, see figure:

But a considerable part homemade pipe benders oppression according to the principle “as it happened, so it will be.” At the same time, those who happened to see the insides of an airplane or rocket probably noticed the bundles and intricacies of pipes, bent, sometimes in the most bizarre way, cleanly and evenly “just like it was.” But no “highly cosmic” secrets, respectively. no production equipment. At aerospace factories, pipe bending is done by low-level workers or even apprentices. The secrets lie in the correct proportions of certain features of the manufacture of pipe bending machines and devices and in choosing the type that is suitable for a particular job. In this article, these “secrets” are revealed, with an emphasis on a pipe bender for a profile pipe, since, on the one hand, it is professional pipes that are most needed in private households, and on the other hand, their bending is much more difficult than round ones.

Note: further in the article cold flat production-technological and, in part, decorative-art bending is considered. So, if you are eager to set up mass mechanized production in your own barn, well, say, hyperbolic coils for moonshine stills, then - see somewhere else.

Bending defects

At military councils, it is customary first of all to report on the enemy. So we will begin our debriefing with what needs to be avoided.

Typical pipe bending defects are shown on the left in the figure:

For household and other pipelines general purpose Tightness and wave are acceptable, which together reduce the lumen area of ​​the pipe by no more than 10% at the narrowest point. On pipes for gases and refrigerants, any stretch and, especially, a wave, are undesirable, because There may be microcracks there. A wave, even a small one, is unacceptable in tubular power elements of building structures and mechanisms, since it sharply and unpredictably reduces their load-bearing capacity.

A characteristic defect in bending rectangular corrugated pipes is a “propeller” (in the center in the figure), when the pipe twists along its axis during the bending process. It is most often impossible to fix an arch or semi-arch that is bent with a “propeller” until it is suitable for use. The reason for the “propeller” is the asymmetrical distribution of technological loads during bending, and bending equipment For profile pipes should ensure their proper spreading over the workpiece.

Another characteristic defect, but of round thin-walled pipes made of soft metals (copper, aluminum) is a “bun” (on the right in the figure), an external and/or internal longitudinal scar; Most often, the flattening of the pipe is noticeable to the eye, hence the name. There will definitely be a microcrack in the “bun” somewhere. A chronic leak in the house water supply or an air conditioner losing freon is not a cheap “fix”, but a leak from the fuel pipeline is simply dangerous. Building construction, including tubular elements with a “bun”, are prone to sudden destruction. The reason for the "buns" bent pipes– incorrect selection and/or setting of the pipe bender.

Main rules

The rules for choosing the bending radius of the pipe R IZG and the length of the technological shank L are summarized in the table:

The “tail” is needed at the beginning of the bend, i.e. the pipe is fed into the pipe bender with some excess at the outlet. The R values ​​of IZG are calculated for defect-free bending. If the permissible defects (see above) are acceptable, then R IZG can be reduced by one step. way:

• If the difference between the real and the nearest tabulated values ​​of the pipe diameter P is more than 10%, the values ​​of the initial calculated values ​​are calculated by interpolation. Otherwise, we take the nearest one.
• The tabulated R IZG is reduced to the relative value r IZG, i.e. It is expressed in pipe diameters D or heights H.
• For pipes with a diameter of up to 10 mm, 1 is subtracted from r IZG.
• For pipes with a diameter of 11 to 15 mm, 0.85 is subtracted from r IZG.
• For pipes with a diameter of 16 to 24 mm, 0.75 is subtracted from r IZG.
• For pipes with a diameter of 25 to 40 mm, 0.65 is subtracted from r IZG.
• For pipes with a diameter of more than 40 mm, 0.5 is subtracted from r IZG.
• Convert the relative r IZG back to the numerical (millimeter) R IZG.
• From the obtained value of R IZG, take the nearest practically convenient larger one.

Example: need to bend out steel pipe 24x24x1.5, i.e. already classified as thin-walled, complex semi-arches for a flower house or hut. The structure is non-residential, light, complex semi-arch load-bearing structure is not (see below), i.e. "plumbing" wave and taffy are acceptable. We take data for the pipe H=25. According to the table we find r IZG = R IZG /H = 80 mm/25 mm = 3.2. Subtract the correction (for pipe H=25!): 3.2 – 0.65 = 2.55. Convert back to millimeters (again according to the table H=25!): 2.55x25 = 63.75 mm. That is, if we take a new bending radius of 65 mm instead of the “defect-free” 80, then the selection of bending devices and work will be simplified, the possibilities of artistic expression by the shape of the structure will increase, and there will be no visible and/or dangerous defects in the finished structure.

Note: for some types of pipe bending devices, e.g. mandrel and 3-roller, see below, the initial (starting) “tail” does not seem to be needed. But its role in this case is played by the not yet bent remainder of the workpiece, so it is impossible to cut the original pipe in advance exactly to size, otherwise it will be defective. A cut for a single “tailless” product, for example. curl for cold forging, is cut in stock for the “back tail” the same as the “front”. The stock goes to waste, so it is better to bend products without straight sections at the beginning and/or end in batches sequentially from one pipe, then only the very last “tail” will go to waste.

Simple - radius

A specific pipe bender is designed for a bend radius within certain limits. But to select a design prototype, you immediately need to know only its very general meaning:

1. for small radii R IZG<5D (или 5H);
2. for medium radii 5
3. for large radii 20D(H)

How to bend?

This refers to bending quality factors:

• Clean (defect-free) or not – whether acceptable defects are acceptable.
• For pre-installation - distortion of the bending profile is not significant, as long as it fits in the trench/groove/on supports. The “tails” (straight ends) of the curved section are cut to size, i.e. A section of pipe for bending is cut with a reserve that goes to waste.
• True to size - distortion of the profile is also not significant, but the “tails” during installation must fall into place with the specified accuracy. This is how pre-measured parts of pipelines are bent from expensive materials: copper tubes for lowering gas pipelines, parts of split-system air conditioners, tubular parts of production equipment. For example, some exclusive liqueurs are produced in distillers whose vapor-liquid path is silver.
• According to the profile for additional installation - the bending profile is maintained with the specified accuracy; Can be adjusted to fit by hand. Bending is done with technological “tails” for cutting in place. Building structures, decorative details of architectural forms.
• Profile-to-size – parts made of valuable metals of production equipment, instruments, machines and mechanisms, which during installation must fit immediately into place or with minimal adjustment within precisely established limits.

What to bend?

I mean, what kind of curves do you need? This is the second factor that determines the type of pipe bender needed for the job.

In the household sphere, most often there is a need for a trace. types of pipe bends (see also Fig.):

• General purpose – various kinds of distribution pipelines, ventilation devices, wire communications inputs, parts of production equipment, machines, mechanisms, etc. Bending most of all to size or for additional installation in small quantities; less often - along average radii. Acceptable defects in parts of water pipes and inlet devices are acceptable. Bends of parts of gas and steam pipelines, parts of technical devices are defect-free by default, unless otherwise specified in the specifications for the product.
• Building arches are tubular curved parts of building structures that can bear operational loads for a long time without the danger of sudden destruction. Bending almost exclusively according to the profile to size along large radii, occasionally - along medium ones. In private household plots, the most popular type of this kind of parts is arches made of corrugated pipe for greenhouses and other outbuildings. Of the permissible defects, taffy is acceptable in no more than 5% of the cross-sectional area of ​​the pipe lumen.
• Architectural forms - the bending radius is alternating (in one direction or the other) from small to large. Due to the “dips” in the bending profile, the load-bearing capacity is much lower than that of building arches of comparable sizes. For the same reason, sudden destruction of a non-worn part is possible. Bending – according to the profile for pre-installation; rarely - in size. Scope of application: light non-residential structures for landscape design: gazebos, alcoves, flower corridors and tunnels, decorative trellises, fences, etc. In the designs of residential and temporary inhabited structures they are used only in conjunction with additional load-bearing elements. Acceptable defects are acceptable, most often even on 20-25% of the lumen area.

Prototype selection

Based on the entire complex of the above indicators, a pipe bender of a certain design is selected. Among those available or partially available for self-production are devices, tools and machines for bending pipes:

1. manual bending lever– bending round pipes with walls of normal thickness to medium and large radii. Thin-walled pipes flatten and crumple; on profile ones, it gives a “propeller” when the lever is slightly swung to the side. It certainly produces acceptable defects. Bend for additional installation or, with an additional control template, along the profile for additional installation. Simple, cheap, non-volatile. No permanent production area is required for placement. Mobile: can be carried manually over long distances. Low productivity, high bending labor intensity and worker fatigue. Quite high demands on the operator’s physical strength, qualifications, endurance and conscientiousness. Scope of application – single non-standard parts of building structures;
2. bending plate (board)– similar to a lever, but for small and medium radii. Manual mobility is limited to the construction site. Productivity is higher, and labor intensity, fatigue and required worker qualifications are lower than for a lever. Prem. applies. during construction work for the on-site production of parts of pipelines and tubular inlet and/or ventilation devices;
3. bending template (conductor)– has properties similar to those of a bending lever, but is intended for bending thin-walled, soft metal and profile pipes. Defect-free bending according to the profile to size is possible. Very low productivity (especially for steel pipes) due to “sludge” for metal relaxation, see below. If there is no hurry (say, in winter before the summer construction season), a roller pipe bender can replace it. It is also possible to produce multi-radius architectural forms (with a counter-pattern). The required qualification of the worker in metal processing is initial;
4. roller (rolling) pipe benders– manual bending of pipes up to 30-40 mm along a radius profile for pre-installation and to size. Bending radii are small. The complexity and labor intensity of manufacturing are low. A separate production area is not required; operator qualification requirements are minimal. Productivity is low. Defect-free bending of thin-walled soft metal pipes is possible. Mobile manually. Prem. scope of application – general purpose bends (see above) during plumbing and repair and construction work. The complexity and labor intensity of self-production is low;
5. crossbow (crimp) pipe benders– similar in properties to roller ones, but with increased performance for round pipes made of soft metals with walls of medium thickness. Rapid reconfiguration is possible during operation. They are mobile to a limited extent (transported by road) or installed permanently. Self-production is not justified, see below. Most often used in the installation of home and apartment copper and aluminum pipelines. In production conditions - for making general purpose bends on steel pipes with a diameter of up to 60 mm;
6. mandrel (bypass) pipe benders– also similar to roller ones, but bending with a variable radius is possible without a starting shank. The requirements for the employee's physical strength are quite high. The main purpose is the production of small fragments for architectural and decorative purposes and for artistic forging. The complexity and labor intensity of manufacturing on your own is very high.
7. roller (rolling or broaching) pipe bending machines– high-performance bending of any pipes along large and medium radii. Installed permanently in a specially prepared room or on an equipped site; less often, they are transported to the place of work. Bending – defect-free in profile; perhaps - according to the profile in size. The main purpose is the production of radius construction arcs from corrugated pipe up to 80 mm wide.

Description of designs

The material presented above is sufficient for preliminary selection of the design of the pipe bending equipment required for this specific job. To clarify the final solution, we provide more detailed descriptions.

Lever arm

The design of a manual bending lever couldn’t be simpler, see fig. However, such a primitive device for centuries and millennia bent details that sometimes baffled modern technologists. The pipe can also be laid simply on the ground by placing wooden blocks under it and securing it with staples driven into the ground. It is better to work with a lever with an assistant holding the workpiece, checking during bending against a pre-prepared template.

Plate

The bending plate (support-thrust manual pipe bender) has been known for as long as the lever. The design is in some way ingenious: the bending pipe itself is used as a bending lever, and instead of a “hole” (a clamp on the lever), its opposite is a strong support pin or several of them. In general, everything is according to Murphy’s laws: if it doesn’t work out as it should, try doing it the other way around.

The structure of the bending plate is clear from Fig. (left):

Bending plate (support-thrust manual pipe bender) and its “ground” modification for the manufacture of greenhouse frame arcs

The most common variety is 4x4. All common bends can be made on the slab for retrofitting (with acceptable defects). Interfering stops are simply removed; the missing ones are substituted. The installation step of the support pins is taken so that the thickest pipe used fits between them. A concrete slab can be poured directly onto the ground in some inappropriate place on the construction site, for example. where the foundation of the shed will be (inside, not under the tape!) or, say, a cesspool. Brand of ready-made solution – from M250; reinforcement is at least 2-tier. The holes to the pins are formed with wooden sticks, wrapped in film or generously greased with grease (worse). Pins for a concrete slab must be made with shanks as long as the thickness of the slab; You can also use simple round pins from sections of thick-walled pipe or steel rod.

The “earth” modification of the bending plate is shown in the center and on the right in Fig. Supports/stops – pipes or wooden stakes driven into the ground. On such a “machine” you can bend up to 5-6 greenhouse arcs from a pipe up to 16x15x2 at a time. An important feature: the pipe must be passed around the stops slowly, in several steps, otherwise due to the release of voltage, a defect is possible - a reverse wave. The film on it will be wiped all the time, and it is unlikely that it will be possible to install the polycarbonate coating efficiently. The laid arcs are left in the “machine” for a day (preferably up to a week) so that the residual stresses in the metal of the pipe “resolve” (relax) and the profile of the arcs does not “spill” beyond the permissible limits.

Note: based on a bending plate, you can make a universal support-and-thrust manual machine for bending pipes and rods, see video:

Video: homemade universal bending machine

Conductor

An “earth bending slab” is essentially a bending template – a jig. Using solid conductors, pipes are bent to medium and large radii (items A and B in the figure); possibly with variable bend radius. In this case, the ends of the workpiece on the template are pulled together while the metal relaxes with a double bowstring, which is tightly twisted with a piece of rod inserted in the middle.

Bending along a jig is possible without using production space if you hang the template on the wall. Then the workpiece is fixed with a clamp and a hand winch (pos. B). Bending along an alternating radius is possible; for this, the pipe is clamped in the concavities of the profile with counter-templates. For bending pipes by tracing along the conductor, see also the story:

Video: do-it-yourself jig for cold forging from A to Z

Word and rollers and rollers

The heart of all pipe bending tools and accessories described below are profiled rollers and rollers. It is these details that primarily determine the quality of the bend. If a good-looking machine bends a 20x40x2 pipe along a radius of 2 m with a wave and/or a “propeller,” the wrong rollers are 99% to blame.

Profiles, dimensional parameters and installation relationships for rollers and rollers of pipe bending devices are shown in the figure:

Grooves and ridges in the grooves (working grooves) of rollers/rollers for profile pipes are needed to disperse process stresses in such a way as to eliminate the “bun” on the bending sides and the general “propeller”. The width of the grooves and ridges in the roller grooves for wide pipes (on the right in the figure) is within 5-10 mm. This is still not enough for a guarantee from the “propeller”, see below. Below in Fig. The device of the lever-handle for manual roller pipe benders is also shown. The rollers are secured with nuts to prevent them from falling out by the threaded shanks of the axles, but pressing the axle into the oblique groove when turning the lever greatly reduces the ability of the roller to “make a wave.” If you make grooves with a pitch of 20 mm (for reasons of strength), then, having 2-4 replaceable small rollers of different diameters, you can quickly reconfigure the tool to R IZG somewhere in the range of 20-120 mm with a step of 10 mm, which for practical purposes the goals are quite enough. Numerically expressed dimensions in Fig. are given in the table:

But what is not necessary for the rollers of a pipe bender for arcs made of corrugated pipe is “cosmic” precision - in work they are rolled to the mirror, like rails under the wheels of a train. Therefore, firstly, the rollers of a pipe bending machine for small profiles with large radii (mostly for greenhouse arcs) can be assembled from plywood disks (see figure). Then the radius of the rollers along the stream R must be at least (0.2-0.25) R IZG, otherwise the pipe may “lick” the stream, and the machine will jam, and the workpiece will be “screwed up”.

Secondly, durable steel rollers/rollers for small and large radii can be made without turning:

Video: rollers for pipe bender without lathe

and even without welding and turning:

and the rollers of a simple pipe bender for greenhouse arcs in manual broaching are made of bearings:

Roller

Manual rolling pipe benders come in 3-roller (with a pressure roller) and 2-roller (with a sliding pipe stop). Rollers here and there need to be turned according to the profile (precision is normal machine-building), therefore, of course, a 3-roller pipe bender (see figure below) will cost more, but if you do not tear the lever sharply, at the minimum R for a given pipe, the bend will give a clean defect-free bending. The working force on the lever of a 3-roller pipe bender is less than on the lever of a tool with a stop, but 3-roller bending to size is impossible - the pipe noticeably stretches behind the bypass roller, so pre-measured valuable workpieces are bent into bends and rolls by a 2-roller.

The device of a 2-roller pipe bender is shown on the left in the following. Fig., and in the center and on the right there are drawings of 2 of its options for metalwork, household and installation and repair work: tabletop and removable for installation in a vice. Please note: using a removable pipe bender with a horizontal plate is much more convenient. Therefore, many amateurs attach corners from 60x60x3 to the underside of the slab in a T-shape and clamp the device in a vice. But - only if their jaws are made of steel or gray or white tool cast iron. And now the sale is full of beautiful, chocolate-like vices made of raw cast iron. With a relatively small force, the sponges break off very well.

Note: Additionally, how to make a roller pipe bender for profile pipes without turning yourself, see the video:

Video: a simple pipe bender in 2 hours without lathe

Crossbow

A crossbow-type pipe bender is essentially a bending press, operating on the principle of pushing a workpiece between a pair of turned profiled rollers, which in this case are the press matrix. Therefore, hand-held crossbow pipe benders with a rack-and-pinion ratchet drive are rare: after the 3-4th bend of a dozen copper pipe, the hand already gets tired. Most crossbow pipe benders are equipped with a hydraulic drive with pumping by hand or an electric pump. Let’s say right away: there is no particular point in making a crossbow pipe bender yourself. The reason is not the turned rollers and/or hydraulics, but its main part: the punch (shoe). It is completely unrealistic to place the equipment necessary for its manufacture at home or in a garage and power it from a household electrical network. If you find an old worn-out shoe (and you need several of them), then instead of a more or less decent bend there will be tatters and rubble. Therefore, the purpose of this section is to help the reader choose a suitable crossbow pipe bender from those available for sale or for rent.

It can only be justified to independently manufacture a stationary crossbow pipe bender (item 1 in the figure) at the start of a micro-enterprise, respectively. profile. A set of shoes and a car jack from 10 tf for it will cost several times less than a finished piece of equipment, especially since the jack can be removed for its intended use. In such a case, the approximate dimensions of the installation frame are shown in pos. 2; its metal must withstand a breaking force of 10 tf, and a shear force of approx. up to 7 ts. But keep in mind: you can only do relatively small details. To bend the 6th pipe in the middle at 90 degrees, the entire machine will need to be raised above the floor by more than 1.7 m. Which means: a high ceiling, a strong supporting structure and a scaffold for the operator. And from the point of view of supervisory authorities, work at heights, which requires special licensing.

If you intend to buy a bending crossbow (trade name option), then it is better to buy one with a double corner frame and in a complete set (item 3): then purchasing additional shoes/rollers/rules individually will cost 2-4 times more. It is undesirable to take a tool with a straight frame (item 4), as this gives a taffy, which is noticeable in the advertising photo. The rows of roller mounting holes must be arranged with an angle of approx. at 150°, the top of which should fall on the center of curvature of the shoe at its working outlet. Then bending at 90° will be clean, and if the acceptable defects are acceptable, then the roll can also be bent.

As for the “cheap” tools with a single frame and sliding stops (item 5), this is frankly commercial hack. The bending force is hundreds of kgfs or tons, and the deviation of the bend from the plane (“whisker lifting”) due to frame misalignment can reach 3-5 mm/m, and there is a wave along the edges of the bend. This is not so scary; at first the tool bends satisfactorily. But soon the coating of the sliding jaws wears out, their metal becomes copper-plated, and there are burrs on the bend, or even a “bun” with visible cracks. In general, such a tool is for sale, but not for long-term regular use.

Dornovye

A mandrel is a bending template (conductor) to which the workpiece is not pressed, but is traced along its groove. Mandrel (bypass) pipe benders are used, firstly, if the bend of a small radius must be as clean and accurate as possible. For this purpose, the manual drive is made ratchet with reduction gear or electro-hydraulic. Manual lever mandrel pipe benders are used, secondly, if you need an inexpensive tool for quick bending of more than 90 o with satisfactory quality (staple blanks, rolls, coils).

The design and principle of operation of a manual mandrel pipe bender with a rotary jig and a gear-ratchet mechanism are shown on the left in the figure:

Roller

Rolling (broaching, roller) pipe bending machines are also known in 2 variants for a specific purpose: with a fixed and breaking table. Both, manual and machine-driven, are installed permanently or carried by vehicles for use at the place of work. They are usually used for bending profile pipes of rectangular cross-section along large radii, but round pipes can also be bent. The round timber arcs come out slightly bent with a screw (in a gentle spiral), but this defect in this case (round pipe) can be completely corrected during installation. But the “screw” of the professional pipe will definitely go with a “propeller”, which is simply invisible on a round pipe.

With fixed table

Roller pipe benders with a fixed table bend corrugated pipes over large radii without defects, exactly along the profile. Technological “tails” of the workpiece are not needed at the start and end of the process, i.e. It is possible to bend the profile to size. However, there is only one profile: a circular (single-radius) arc. In general, such bending machines are optimal for mass production of load-bearing arches of greenhouses, sheds, garages and other outbuildings, incl. at the customer's location.

The structure of a roller pipe bender is shown in the figure:

At the top left is its operating principle: the workpiece is placed on the lower rollers and pressed to the desired bending radius by the upper one, then the rollers are rotated until the “rear tail” comes out. The lower rollers are identical, this will ensure symmetrical spreading of technological stresses and, accordingly, clean, defect-free bending. The upper roller is usually made with a diameter 1.5-2.5 times larger than the lower ones; this speeds up rolling without significantly increasing the working force. When purchasing or designing a homemade pipe bender of this type, make sure that it has a bending radius scale, and that the installation grooves of the lower rollers are oblique in a “reverse herringbone” pattern (shown by green arrows). Without a radius scale, several workpieces will have to be damaged, and rollers in straight grooves, transverse or longitudinal (see below), can “shoot a wave” due to beating or displacement. During work, beware of asymmetrical installation or displacement of the rollers, then no amount of correct profiling will save them from the “propeller”. Drawings of a roller pipe bender for corrugated pipes up to 45 mm on the wide side are given in the figure:

The disadvantage of this design is that the lower rollers are installed in straight longitudinal grooves; it would be better to provide oblique ones, as shown in the inset there. The efficiency of reconfiguring the machine will not noticeably decrease, but asymmetry and adjustment failures in operation are excluded.

More about the drive

The symmetry of the drive force is also important primarily “from the propeller”. The symmetrical arrangement of the rollers in this case is not yet a completely sufficient measure.

For symmetrical spreading of process stresses, the drive roller must also be located symmetrically relative to the driven ones, i.e. The machine drive is needed on the central (upper) roller. If, for example, for ergonomic reasons, the drive is simply transferred to the lower roller (on the left in the figure), then the machine will sooner or later (or immediately) produce a “propeller” and, possibly, a wave at large radii.

In this case, both lower rollers need to be driven, synchronizing them with a rigid secondary drive, for example. chain, in the center. And it is best to make all the rollers the same and synchronize all 3. Rolling will slow down somewhat, but its fatal defects will be eliminated. If you replace the lever gate with a steering wheel, as in Fig. at the beginning of the section, and it’s heavier so that it works like a flywheel, then bending will work - “even for a rocket.”

With a breaking table

The working table of a roller pipe bender of this type consists of 2 parts: fixed and suspended on a hinge. The “hanging” part is supported by a jack, and the outgoing lower roller is installed on it. In this way, the bending radius of the pipe is precisely and smoothly set. The design is quite bulky and heavy, so it can only be installed permanently.

The distribution of technological stresses of the workpiece in a pipe bender with a breaking table is initially slightly asymmetrical. A simple measure to combat this is the only one, organizational: do not turn the drive too quickly, squeezing out productivity. But, firstly, you can bend not only to large, but also to medium radii: the adjustment limits R of the bend in a pipe bender with a breaking table are much wider. This circumstance is also significant when the table is stationary, so some master mechanics make roller pipe benders with a non-movable upper roller, and the installation of R IZG is carried out by lifting the outgoing rack and pinion mechanism, see fig.:

Secondly, having a qualified assistant, you can bend, for example, pointed semi-arches with a smoothly variable radius: one turns the drive (or adjusts the electric one), and the second pumps up the jack. Why extra beauty? True beauty is never in excess. For example, greenhouses on pointed arches are more than relevant in northern regions, where the Sun does not rise high even in summer. Note +15-20% increase in yield and 10-12% savings on lighting is already economic beauty, materially very tangible.

The structure, approximate dimensions and some design features of a roller pipe bending machine with a breaking table are shown in the figure:

Installing driven rollers sliding in longitudinal grooves is quite a valuable find. Expanding the range of adjustment of R IZG is, as they say, still seeds: by moving the lower rollers asymmetrically from the upper one, you can compensate for the asymmetry of stress spreading. In principle, after spending a lot of time and material on experiments, you can build a setting curve or table for different R IZGs, according to which the machine is adjusted for defect-free bending. True, the possibility of manufacturing semi-arches of variable radius will most likely disappear or be significantly narrowed. Which, of course, is not good.

The construction of greenhouses and sheds, the laying of utilities - all this requires a bent metal profile. But buying pipes bent to order is expensive, and purchasing a ready-made pipe bender is also not a cheap pleasure. So modern craftsmen use devices and self-made mechanisms to create metal arcs of the required radius.

In this article we will consider the following questions:

• Types of homemade pipe benders and their features.
• The design of the simplest device for bending square pipes.
• Design of a three-roll machine for bending round and square pipes.
• Technology for bending pipes using a three-roll homemade pipe bender.

Types of pipe bending devices and mechanisms

Nowadays, you can find examples of pipe bending equipment that have different designs: from relatively simple devices for manual bending to homemade machines with manual or electric drive.

According to their purpose, pipe benders are divided into two types.

The first type is angular (they allow you to give the desired radius to a certain area of ​​the workpiece).

The second type is three-roll pipe benders - machines and devices that allow you to form a given bending radius along the entire length of the workpiece.

Depending on the method of adjusting the radius, pipe benders are mechanical.

And hydraulic.

The support shaft drive can be either manual or electric.

A simple device for bending metal pipes

The design of a homemade pipe bender depends on the volume and complexity of the work that is planned to be performed with its help. If the device is needed for one-time use (for example, for building a home greenhouse), then there is no need to create a complex three-roll mechanism with hydraulic adjustment of the bend radius.

belor44 User FORUMHOUSE

We urgently need to install a greenhouse. I want an arched one, but neither one based on metals nor my friends have a pipe bender. Build a pipe bender on shafts and rollers? There is neither time nor need for this. I think that a device for manual bending is suitable for one construction.

Yes, indeed, the simpler the pipe bender, the less hassle there is in its manufacture. The main thing is to correctly determine the dimensions of the device, which will directly depend on the bending radius.

Introducing a user-made device moning. It is designed to work exclusively with thin-walled pipes, because bending pipes by hand is hard physical labor.

Moning User FORUMHOUSE

I made this thing for a 30*30 square pipe. The radius that was obtained was approximately 1 meter. You can weld something like spacers or legs on the sides of the device so that it doesn’t throw from side to side when you press on the pipe. Regarding the jumpers at the bottom of the pipe bender: first, the pipe is placed under the top jumper (for the initial bend), then the pipe is placed under the next jumper (for further advancement).

Consistent bending is necessary so that if there is a sharp bend, the pipe does not break.

Calculating the dimensions of the device is very simple: to do this, it is enough to know the bending radius that needs to be obtained on the finished part. The strip (40 mm wide), which serves as a mandrel for the workpiece to be bent, initially has a curvature that provides a given bending radius (R).

Taking into account the presence of elastic deformations, the radius of the mandrel should be slightly smaller than the required bending radius of the workpiece.

Knowing how to use welding, a grinder and auxiliary tools, this device can be made in less than 1 day.

Each metal pipe has its own elastic limit, therefore, the bending radius cannot be reduced below certain values. Permissible minimum radii can be taken from the corresponding tables.

We present an example of a table of permissible radii for round pipes.

Minimum bending radii of pipes in a cold state

Pipe outer diameter, mm	Bend radius, min
	45	35	20	10
	R bend, min
18	74	62	56	43
24	95	79	65	55
32	115	96	79	67
38	156	131	107	91
50	197	165	136	115
60	238	199	165	139
75	280	260	194	173
80	324	270	224	190
90	362	302	250	213

Manufacturing of electromechanical pipe bender

In the design of an electromechanical pipe bender, three main working parts can be distinguished: one pressure and two support (drive) shafts. Hence the name of the machine – three-roll rolling pipe bender.

Such a device has a rather complex design, so if you were unable to get the drawings of a homemade pipe bender, we recommend that you first draw each of its elements on paper (at least as a sketch). And we will tell you step by step what dimensions and characteristics the main components of the future product should have.

So, the main function of a pipe bender is to bend parts to a given bending radius. The bending radius depends on the distance between the support rollers (shafts) and is adjusted by the pressure roller. The distance between the support rollers is a constant value. This is what should be taken into account when starting to design a machine.

Alli58ru User FORUMHOUSE

The distance between the lower rollers depends on the minimum bending radius. When determining it, keep in mind that the smaller the distance between the rollers, the harder it is to lower the pressure roller and the harder it is to pass the workpiece between the shafts. And vice versa: the greater the distance, the easier it is to twist. For me, if memory serves, the distance is about 35-40 cm. The shafts rotate quite easily: I bent a minimum radius of about 50 cm, but less is possible.

The bend radius (arc radius) is calculated using a simple geometric formula.

Guided by it in relation to your equipment, you can quickly adjust the machine to the specified parameters.

Manufacturing of rollers

To make rollers, you should look for reliable materials that have already passed the strength test. Some use rotors from electric motors of old washing machines or kingpins from a KamAZ vehicle, others use carbon steel circles. In fact, there are many options, the main thing is not to forget that the chosen material must be strong enough. User Dva11, for example, used wheel hubs from an old sprinkler installation.

Dva11 User FORUMHOUSE

Hub diameter – 75 mm, length – 110 mm, bearings were selected according to the hub (205 fit). I had to buy 5 bearings and 1 pulley, and made the rest of the parts from scrap metal.

Smooth cylindrical shafts are a universal option. They are used to bend pipes of various sections. If the profile of the shafts is brought into line with the profile of the pipes being bent, the quality of bending will noticeably improve.

You can also use blanks designed for different profiles of bent workpieces.

Ideally, removable nozzles or ring clamps (limiters) are installed on the shafts, with the help of which the profile of the rollers is adjusted to the width of the pipe.

rusi45 User FORUMHOUSE

I made some improvements to the design of the rollers: I made attachments for the pipe on the outer shafts, where the stops are located. Tests were carried out on a 1-inch pipe. The attachments are easy to replace. To do this, I made one side of the bearings sliding. The nozzle is made of steel 65G (plus hardening). There is virtually no wear, and the file does not take hardness.

The internal radius of the roller or nozzle for a round pipe should be made with a margin: the radius of the pipe plus 1-2 mm. For example, if the pipe diameter is 24 mm, then the internal radius of the roller will be 13-14 mm. Only in this case the pipe will not jam during rolling.

This is the size we are talking about.

If a pressure roller designed for bending rectangular pipes has a slight convexity in the middle, this will help maintain the geometry of the profile being bent. The roller will press the upper wall of the pipe inward, preventing the workpiece from spreading out to the sides.

Frame design

Having decided on the center distance and the design of the rollers, you can mark the blank parts for the frame. Based on the experience of FORUMHOUSE users, it should be concluded that the strongest frames are made from steel channels (at least 80 mm wide). This material is easy to get, so you can safely take note of it.

The photo shows the machine at the manufacturing stage. And here is the drawing that is taken as a basis.

Human User FORUMHOUSE

During the work, some changes were made to the original drawings.

The presented drawing is not a mandatory guide to action, but provides an objective understanding of how a rolling pipe bending machine works.

Clamping mechanism

Many craftsmen make a clamp from a regular car jack (mechanical or hydraulic). The forces that it is capable of creating are quite sufficient to give the metal workpiece the desired configuration.

It’s not that difficult to make a homemade or even a professional pipe bender with your own hands in order to be able to bend pipes at a given angle and, importantly, with a given bending radius.

Contrary to popular belief that this device is most often used when performing plumbing work, in such cases various fittings and elbows are usually used - pre-bent sections of pipes manufactured in industrial conditions. However, there are restrictions on the use of bends, which are determined by their standard characteristics:

• rotation angles (can be 45, 60, 90 and 180 degrees);
• bending radii (bends with bending radii of 1.0 DN and 1.5 DN are available);
• use of welding.

Not in all situations such parameters can satisfy those who need to give a pipe structure the required shape. It is in such cases that a mechanical pipe bender (or manual pipe bender) comes to the rescue.

Those owners of dachas and private houses who are going to independently produce various arched structures, greenhouses, custom-shaped fences and much more cannot do without a machine for bending steel pipes.

In this article we will thoroughly examine how to make a pipe bender with your own hands. After all, a homemade pipe bender can be used not only at home, but also in semi-professional activities, since its design is not sky-high in complexity, and commercial devices for bending pipes are quite expensive. Therefore, by making a manual pipe bender with your own hands, you will save a lot of money.

Classification of pipe bending devices

Devices for bending steel pipes are classified:

• by degree of mobility (stationary and portable);
• by type of drive (manual, electric, hydraulic, electrohydraulic);
• according to the method of influence (running in (roller), winding, impact with a rod (crossbow), rolling).

The essence of how a pipe bender influences a pipe is as follows.

Run-in

With this method, one end of the pipe is clamped, and a stationary template is used to give it the required bend. Pressure rollers are used to roll the product around the template.

Winding

In such a device, the pipe is pressed against a movable template (roller), on which it is wound, stretching between a rotating roller and a special stop installed at the beginning of the bending point.

Crossbow pipe benders

In such a pipe bender, the pipe rests on two stationary rollers, and bending is performed by a template, which is attached to a movable rod. The template presses on the middle of the fixed section of the pipe, thereby giving it the required bending angle.

Diagram of a crossbow pipe bender: 2 - jack, 3 - shoe (punch)

Rolling or rolling

The required bending radius is obtained using a three-roll device, the basis of which is two support rollers and one central roller. The central roller exerts pressure on the pipe, the position of which determines the radius of its bend. is more universal; in all other machines the bending radius depends on the template used.

The manufacture of a pipe bender operating on the winding principle is not simple, so such a device is made mainly in an industrial way. The crossbow method has another significant drawback: the pressure from the rod with a template attached to it, called a shoe, is concentrated in its upper part. This method of acting on the pipe leads to its significant stretching along the outer radius of the bend, which may be accompanied by a decrease in wall thickness and even its rupture. It is especially not recommended to use the crossbow method for bending thin-walled products.

An example of a homemade rolling (rolling) type pipe bender

A machine operating on the principle of rolling (rolling) practically does not have all of the above-mentioned disadvantages; this technology is used in the production of bends in the factory.

A DIY pipe bending machine can have a different design. You should choose its type based on what radius you need. There is a list of recommendations, in accordance with which the choice of a specific model of device for bending steel pipes is made. Important parameters that need to be taken into account are the thickness of the pipe walls and its overall diameter. Before starting to work with a pipe bender, it would not hurt to familiarize yourself with the data in the table showing the maximum possible radii for bending steel pipes.

To obtain a bend radius smaller than that specified in such recommendations, it is necessary to use hot rolling, which is used mainly in production conditions. A device with a mandrel is more difficult to create at home, so they are much less likely to be made independently, giving preference to rolling ones.

In order to independently hot-roll a pipe, you can resort to using a home-made pipe bender, but provided that it is made entirely of metal and its frame is highly reliable. To perform such a technological operation, you will additionally need a blowtorch or gas burner.

Making a simple template-type pipe bender

A simple rolling pipe bending machine can even be made from wood. Naturally, this will be a manual pipe bender, the design of which may not even include a pressure roller if it is used for thin-walled products. The template for such a device is made from a wooden board, the thickness of which should be such that it exceeds the diameter of the pipe itself.

For ease of work, it makes sense to consider profiling the template from its end in order to avoid the pipe jumping off during bending. For these purposes, you can fold two boards, first sawing one edge at a time, thus creating a kind of gutter. A pre-drawn drawing will help avoid mistakes.

When using such a pipe bender, the template is attached to a reliable base, and a stop is attached to the left side of it (for right-handers). The pipe that needs to be bent to the required radius is inserted between the template and the stop and carefully bent, making sure that it does not jump off the template.

With the help of such a pipe bender, made from scrap materials, you can bend along a large bend radius. You can avoid making a wooden template and simplify the device by replacing it with metal hooks fixed to the base, located in a circle with the required bend radius. This device is convenient in that the dimensions of the bend can be changed at any time by placing the stop hooks around a circle with a different radius.

Armed with a manual winch, you can significantly expand the range of work performed due to a noticeable increase in traction force for bending pipes.

Pipe benders with pressure roller

A more complex design is a manual pipe bender, which uses a pressure roller. To make such a device, you can use both wood and metal.

For pipes made of soft materials (for example, copper), wood rollers are the best option, since they do not cause metal deformation. It’s not at all difficult to make such videos at home if you use photos or drawings of similar devices, which are posted in large numbers on the Internet. The manufacturing material can be thick boards or several layers of plywood.

A homemade pipe bender of a similar design, which is based on rollers - movable (pressing) and stationary - allows you to bend round pipes that even have a significant diameter.

In order to understand that such a device is simple in design and use, just look at its photo or drawing. Depending on what loads are expected for a pipe bender of this type, the base for it is made of metal or durable plywood. The U-shaped holder on which the central and pressure rollers will be placed is made of metal.

Relative to the axis of the central roller, securely fixed to the base, such a holder must be able to rotate. On the reverse side of the central roller, a handle is attached to the holder, which is a lever, so the force created directly depends on its length. This lever pipe bender allows you to perform operations with different bending radii of pipes.

Many people wonder whether it is possible to make a winding-type pipe bender with your own hands. Naturally, it is first advisable to study a drawing or photo of such a device, which does not have a stop on the base. The design of this type of pipe bender is based on two pulleys, a frame with a lever and a pressure roller, and a reliable base. Bending using such a device is carried out due to the fact that the pipe, placed in the groove of a stationary pulley and clamped with a clamp, is wrapped around a template using a lever and a movable roller.

Pipe bender for soft pipes with two different bend radii

For small and soft products (aluminum or copper), a homemade pipe bender is suitable, allowing bending with two different radii. Photos of such a device are easy to find on the Internet. This pipe bender uses one pressure roller and the template is made with two radii at the same time on one plate. Naturally, for each bending option, the pipe bender handle must be reinstalled, for which two holes are provided on its base.

Winding type pipe benders

Examples of such devices are hydraulic pipe benders, which are used to bend round pipes. The design of such a device has a powerful pulley to which the pipe is attached at the bending point. This pulley is fixed on a reliable frame, and at its base there is a rod, which is driven by a jack. A significant force is created on the rod using a jack, which is transmitted to a lever that rotates the pulley and winds the pipe onto it. The lever can rotate freely around the axis of the pulley and is connected to it using holes located around its circumference.

A working example of such a pipe bender can be seen in the video below:

You can also make a similar mechanical pipe bender yourself using a rack-and-pinion jack. More physical effort is required when using this device.

Example of work on video:

Examples of devices of this type include homemade pipe benders, the rollers of which are made of wood. When working with such devices for bending round pipes, it is necessary to apply significant physical effort, which is reduced by a movable rotating roller.

An example in the video below:

Crossbow type pipe benders

These pipe benders got their name because of their resemblance to a crossbow. The basis of the design of such a device is a frame made by welding from corners and channels. Inside such a frame, on which two movable rollers are mounted, there is a jack, which, using a special shoe, creates a force directed at the pipe. Pipe benders with movable rollers and a pressure shoe are used primarily for bending round pipes, since they can simply deform any other type of product.

A rugged, no-frills crossbow pipe bender

The most popular options for homemade pipe benders

The most technologically advanced and versatile are pipe benders that operate on the rolling principle. It is these devices, often equipped with an electric drive, that are used by professionals who are constantly faced with the need to bend pipes made of various materials, including stainless steel.

The design of such a device is based on three rotating rollers, one of which is a pressure roller. Thanks to the gradually increasing pressure of the pressure roller and rolling repeated for each new position of the roller, bending of the pipe is carried out in the most gentle way, its walls are subjected to tensile manipulations very evenly.

Computer model of a pipe bender Drawing of a pressure screw Drawings of shafts
Ring drawing Pipe bender components Assembly process
Motor driven

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Application of bent pipes

You can bend it using a special device -. By performing this procedure, you can obtain good quality products that are used in many areas of our lives.

Bent profile pipes are used for the manufacture of building structures, arches, greenhouses, fences, and gates. They are a decoration for elegant outdoor furniture: benches, chairs, tables. Bent profiles are used for the production of school desks, chairs, furniture for medicine, offices, and other institutions.

Features of hydraulic pipe benders

A hydraulic pipe bender, made by yourself according to your own sketches or drawings, or taken from the Internet, is a special device that can be used to bend pipes or rolled products at different bending angles, ranging from 0 to 180⁰.

You can buy a good hydraulic pipe bender in stores, or you can try to make it yourself, which in terms of quality of operation will be in no way inferior to factory products.

And since improvised means and materials are used for self-production, the cost of such a bending structure will be much cheaper than serial devices. And the financial side of the manufacture of such a device, you see, is of great importance for most of us. Taking this into account, many craftsmen make universal structures with their own hands, with the help of which profile and round pipes with any bend radius can be easily and efficiently bent. And the Internet helps them, where you can choose not only the hydraulic pipe bender you like to make with your own hands, but also watch ready-made drawings, videos, listen to or read advice from experienced craftsmen.

Among factory analogues, the Stalex hydraulic manual pipe bender is very popular, with which it is easy to bend, as well as. It is convenient for professionals to work with such a tool, since pipes can be bent directly on the construction site, and very smoothly and accurately. The design of a mass-produced manual pipe bender is such that when using it, flattening or breaking is completely eliminated.

Peculiarities:

• creates a force equal to 12 tons;
• equipped with a hydraulic drive;
• equipped with a set of replaceable shoes;
• can operate in horizontal or vertical position;
• provided with automatic return of the slider;
• during operation, the entire working stroke of the cylinder is involved;
• The bending radius is adjusted by vertical or horizontal supports (depending on the model).

Advantages

Among the many manual pipe benders, hydraulic type machines are considered the most popular and in demand. There are good reasons for this.

Hydraulic devices are capable of efficiently bending even a 3-inch round pipe. They are successfully used both by professionals to perform large volumes of work, and by novice amateurs who want to bend one or two profile or round pipes.

In addition to such advantages as:

• ease of manufacture;
• reliability;
• strength;
• low cost,

They are also valued for their impact power, thanks to which it is possible to process not only thick-walled ones, but also to work with fairly large products made of other metals: aluminum, brass, bronze.

In addition, a special installation (jack) greatly facilitates the work of the operator, who makes a minimum of effort to obtain a large force of pressure on steel or other materials pipes.

Important! You cannot bend the pipe more than is provided for by the design of such a device, although there may be opportunities for this. This is due to possible invisible damage to the finished part, which will certainly appear a little later, during operation.

Preparation for production

Before making a manual pipe bender, you need to decide on the type of device. To do this, you need to familiarize yourself with the drawings and photos, as well as diagrams of possible designs made by yourself, watch a video, remember what materials and available tools you have, and only then begin the manufacturing process. And most importantly: for what purpose and for what work will you need a structure with which you can bend the risers. Plus, it would be a good idea to consult with a more experienced neighbor or friend who has already dealt with the manufacture of this or a similar device. And if you are ready, then you can start making a device for bending profiles.

Manufacturing process

Before you start making a machine for bending a round pipe, you need to stock up on everything you need:

• a hydraulic jack from a car or tractor (more powerful ones can be used, if possible);
• channel (about 3 meters);
• 3 rollers with axes;
• metal plates.

When making a manual pipe bender, you should follow a simple algorithm:

1. Using a tape measure, measure the required length of the channel for the base and use a grinder to saw off 2 equal pieces, thanks to which the base of the future hydraulic pipe bender, and with it the frame (1), will be more stable.
2. Place the cut pieces of the channel tightly to each other, weld from below and above along the joint line. Such a platform will be the basis of a pipe bending machine.
3. Weld side channels on both sides of the base at an angle of 110⁰.
4. Weld longer pieces to the top of the side channels, in which it is first necessary to drill several (from 2 to 8) holes, placed symmetrically on both sides of the future pipe bending machine. They are designed to install axles with pressure rollers, by rearranging which you can adjust the bending radius of the risers.
5. Secure the jack (3) to the base with plates with holes for bolts (2) with a diameter of 10-12 mm so that it does not move when working with steel or other pipes. To do this, you need to drill the base in certain places and secure the hydraulic device with strips and bolts.
6. Securely fasten the shoe (4) to the jack rod so that, if necessary, it can be easily removed and replaced with another one.

Scheme for making a manual pipe bender

That's it, the structure is ready for work, and the required dimensions are indicated on the drawing of a pipe bender made by yourself, although in the photo, no holes are drilled in the upper channels (there are 2 of them, one on each side of the side channels). Therefore, the manual hydraulic pipe bender shown is designed to bend parts with only one bend radius.

The height of the bending machine is determined by the parameters of the jack and the distance “a”. This means that to bend a half-inch steel pipe, this length should be approximately 2 cm (if the jack is not in use).

It should be noted that all the force from the punch is directed to the upper part of the manual pipe bender. Therefore, there may be cases where the outer part of the bending part is subjected to too much stretch, which will contribute to a significant thinning of the wall of the round pipe. There are even tears in the riser. Therefore, it is not always possible to use the unit to bend thin-walled pipes.

As you can see, there is nothing complicated, and the design for bending a round pipe is reliable, durable and will last for decades. And most importantly, only available materials were used for its manufacture, which greatly reduced the cost of such a device.

Rolling version of a pipe bender with a rotating platform

The device is used for profile pipes. The principle of operation of this design is as follows: the rotary platform, driven by a jack and through which the bending angle is set, is connected to the main frame using a hinge. The profile is pulled as a result of rotation of the handle, which is attached to the intermediate shaft of the bending machine.

Bending machine

The base for a manual pipe bender and the stand are made of channels with a wall height of 125-200 mm. Bearing cages, the basis of the rollers, can be made from a steel pipe, and its diameter must match the diameter of the bearings.

The bending parameters can be adjusted in two ways: using a turntable and using rollers located on the edge.

For this purpose, it is necessary to drill the support plates and channel, which will ensure the mobility of the elements of the bending machine.

Both platforms of such a device are also made of channels. To raise the outer platform of a manual pipe bender, use a conventional automobile or tractor hydraulic jack.

To weld a vertical stand from a channel, it is necessary to retreat approximately 45-50 cm from the edge of one side of the base of the hydraulic pipe bender. To strengthen it, it is advisable to pair two pieces.

Using a building level, it is necessary to achieve strict horizontality of the stationary platform of a homemade bending machine, and then weld a stand to the back of it. Using profile pieces, build up the limiters to a height at least equal to or greater than the thickness of the profile or round pipes that will be bendable.

Using the door hinges, connect the main frame of the manual pipe bender to the guide platform. Mount bearings on the edges of moving and stationary platforms, as well as on the limiters of such a device, using welding.

To strengthen the entire structure of the hydraulic pipe bender, it is necessary to use corners that are welded in separate places. Attach a handle to the middle shaft of the bending machine, and install bearings on the outer ones.

Place the jack from below under the guide platform, securely fasten it to the base using bolts, and the homemade pipe bender is ready for work.

By the way, you can also do the repair of a hydraulic pipe bender made by yourself, and here’s why: no one except you knows the features of its structure and operating principle. Therefore, only you yourself can make high-quality pipe bender repairs at home.

Bending technology

The bending process looks like this: first you need to install the steel pipe into the shoe and secure it on both sides. After this, you need to use a jack, thanks to which such a device (rod together with the shoe) will rise up. The force created by the hydraulic drive is instantly transferred to the rollers, after which the riser will begin to bend under the preset bending radius. After finishing the bending process, the device must be lowered and the finished product pulled out. The main thing is that such a bending machine can be stopped at any time, which eliminates the possibility of injury.

Important! If it is necessary to bend a very short profile pipe, and the distance between the rollers does not allow this, then both ends of the riser must be extended with scraps of pipes of the appropriate diameter.

Methods for bending pipes with a hydraulic machine

Before bending a profile or round pipe, it is advisable to listen to the advice of people experienced in this matter.

Firstly, homemade hydraulic pipe benders bend pipes made from any materials quite efficiently. It is very important that with the help of the device thick-walled products are bent without any kind of defects, which is beyond the capabilities of pipe benders of other structures made independently at home.

Secondly, the procedure can be carried out using hot and cold methods, which also makes such devices more popular and in demand.

The highlight of cold bending is that a steel or other metal pipe must be filled with something before performing the operation. Sand, salt, oil or oil refinery, and water are well suited for this. Thanks to such fillers, the quality of bending of steel pipes or pipes is significantly improved, and the occurrence of all kinds of unnecessary deformations is eliminated.

With the hot method, you need to preheat a certain section of the steel pipe, and then bend it in the same way as a cold workpiece, but without filler.

Thirdly, to obtain a high-quality product, thick-walled structures are bent using a homemade hydraulic pipe bender using the hot bending method.

Inexperienced operators think that bending with a DIY metal bending machine is a fairly simple operation. But it is not so.

If you handle a manual pipe bender incorrectly, you may experience unwanted defects:

• a change in the diameter of a round pipe, which is caused by the so-called crushing;
• the appearance of thinning of the original samples at the point of bending of a round pipe or profile analogue, which can lead to a deterioration in the strength characteristics of the part.

In order to minimize possible defects, it is necessary to be able to choose the right device and become thoroughly familiar with the principle of its operation.

If you need to perform bending identically to the template, then in order to prevent the profile or round pipe from slipping, which means that there is no difference between the template and the bent part in terms of size and configuration, it is necessary to replace the stops with metal hooks.

Typically, a homemade pipe bender with two rollers is used when bending structures of small radii, and with three – large ones.

In order to improve the design, it is necessary to make a pipe bender with your own hands so that the thrust rollers can move, which will allow you to instantly change the radii of bends.