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The die-cut process lends itself to a clean, burr-free end condition. If a two blade cutoff is used (one blade scarfs the top of the tube and the second vertical blade comes down and cuts the tube) a burr-free, dimple-free end cut will result.
Cold saw cutting equipment can be the most economical dedicated cutting system available. A cold saw is a self-contained system requiring a minimum of set-up and operator expertise, utilizing a spinning blade to cut a clamped tube. The quality of a cold saw cut is dimple-free and usually burr-free. The length of the cut can be controlled to ± .010".
Band saw cutting utilizes a continuous ribbon blade in either a horizontal or vertical plane to cut a clamped tube or tubes. This method of cutting provides the ability to cut multiple pieces of tubing of the same or different diameters to the same length at the same time. For example, a bundle of tubing can be cut to a pre-determined length without breaking the bundle and cutting each piece individually. This is a self-contained dedicated cutting system requiring minimum operator skill. Length tolerances are dependent on the number of tubes being cut simultaneously. Generally, band saws can meet a length tolerance of ± 1/16".
Different shapes and sizes of perforations can be punched into a tube depending on the design of the perforator. Some examples are elongated holes, square, diamond, rectangular, and star-shaped. Punching units can be used in an arbor press, punch press, press brake, air or hydraulic press, or in a self-contained system.
TUBE END FORMING & END FINISHING
Expanding is increasing the OD dimension at the end of a tube. Like swaging, many options are available. The length, shape, and final OD depend upon the method, capacity, tooling, and tube characteristics.
Flaring is an operation that forms the tube end at a specific angle, OD, and depth to meet application demand. This method can be achieved by band (thin wall tubing), punch press (short lengths), and primarily a dedicated end finishing machine.
Beading means to expand the tube, internally or externally, a specific radius or diameter. A punch press and die assembly is required for each OD. Short lengths can be formed on a punch press, but long lengths require a dedicated end forming machine.
Doming is simply closing the end of a tube. The tube end is rolled or pressed to the application requirements. This operation is typically performed with a dedicated end forming machine, but short lengths can be formed on a press.
Press bending. A ram die with the desired radius of bend is fitted to the press arm. The arm forces the tubing down against the opposing two wing dies. The wing dies, with resisting pressure, pivot up, forcing the tube to bend around the ram. Press bending is very fast and may bend more miles of tubing than any other method. Since the tubing cannot be internally supported, considerable distortion can occur.
Rotary draw bending. Rotary draw bending may be the most versatile, precision system of bending. It certainly produces high quality bends on the tightest radius within thin wall tubes. With a heavy walled tube on a generous radius, only a three piece family of tools is required. The work piece is locked to the bend die by the clamp die. As the bend die rotates the follower type pressure die advances with the tube. As the wall of the tube becomes thinner and/or the radius of bend is reduced, a mandrel and a wiper are required.
Contact one of our Sonco Tube professionals at 888-766-2613. We are standing by to provide additional information or to provide a free quotation for your next tubing project.
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