gg nn mm ii About the Book rr oo This book discusses the techniques and processes of TT F F tube, pipe, and extruded-shape fabrication. Guidelines uu ee for round, square, rectangular, and other shapes are bb bb written about in detail. This text is a reference and in- ee uu formation guide for tube and pipe fabricators serious TT s about attaining competitive positions in the industry. FF e Some of the topics covered are: oo s s rr • process planning; mm e (cid:127) basic cut-to-length methods; c (cid:127) methods of bending; inin r o s i v e (cid:127) justification and selection of equipment; gg P e n (cid:127) end-forming methods and designs; e h (cid:127) tube branching methods; PP p r rr m (cid:127) brazing and joining techniques; oo o (cid:127) lubrication requirements; and cc C (cid:127) inspection techniques. ee A ss e d Reference data is included that details the plasticity ss u i theory of bending and forming, mechanical behavior of ee G ss metals, and mechanics of bending and end forming. The :: book is adapted from Cold Bending and Forming Tube AA and Other Sections (1966). C C oo mm About the Author pp rr ee Greg Miller is currently president and CEO of Tubu- hh lar Solutions in Medina, Ohio, where he takes an active ee nn role in all company operations and sales activities. He ss has written multiple articles for various trade publica- iviv ee tions over the last 10 years. As a speaker, Miller has G G participated in tube fabrication seminars throughout the uu U.S. In addition, he has served for three years as chair- idid person of the Small Diameter Tube Conference spon- ee GREG G. sored by the Society of Manufacturing Engineers. MILLER Society of Society of Manufacturing Manufacturing Engineers Engineers MILLER www.sme.org www.sme.org Association for Forming & Fabricating Association for Technologies/SME Forming & Fabricating www.sme.org/afft Technologies/SME www.sme.org/afft Tube Forming Processes: A Comprehensive Guide i prepages.pmd 1 9/20/02, 9:53 AM prepages.pmd 2 9/5/02, 11:51 AM Tube Forming Processes: A Comprehensive Guide Gregory Miller Society of Association for Manufacturing Forming & Fabricating Engineers Technologies/SME Dearborn, Michigan prepages.pmd 3 9/5/02, 11:51 AM Copyright © 2003 by the Society of Manufacturing Engineers 987654321 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, including photocopying, recording or microfilming, or by any information storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of informa- tion contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not consti- tute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: 2002112342 International Standard Book Number: 0-87263-633-X Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Cheryl Zupan, Staff Editor Walter Kelly, Editorial Consultant Rosemary Csizmadia, Production Supervisor Frances Kania, Production Assistant Kathye Quirk, Graphic Designer/Cover Design Jon Newberg, Production Editor Printed in the United States of America prepages.pmd 4 9/5/02, 11:51 AM For the “tubologist” in all of us—this book is dedicated to the hard work, perseverance, and tenacity of the men and women who work on our factory floors. prepages.pmd 5 9/5/02, 11:51 AM Tube Forming Processes: A Comprehensive Guide vi prepages.pmd 6 9/5/02, 11:51 AM Acknowledgments Attempting to be accurate in all subject areas of this book re- quired the help of many industry professionals. Without their in- put, this book would not have been possible. There is no substitute for the first-hand experience and knowledge reflected by the fol- lowing contributors: • Michael B. Cone, Advanced Tubular Technologies, Inc., Water- ford, MI; (cid:127) Ron Duval, SMT Industries, Inc., Sidney, OH; (cid:127) Bill Holyoak, T-Drill Industries, Inc., Norcross, GA; (cid:127) Joe Ivaska, Tower Oil & Technology, Chicago, IL; (cid:127) Wally Jenson, Engelhard Joining Systems, Daytona Beach, FL; (cid:127) Jeff Johnson, Finn-Power USA, Inc., Schaumburg, IL; (cid:127) Dale Miller, Manchester Tool and Die, North Manchester, IN; (cid:127) Todd Smith, J & S Machine, Inc., Ellsworth, WI; (cid:127) Ron Stange, Tools for Bending, Denver, CO; and (cid:127) Bob Want, Tools for Bending, Denver, CO. Organizing the vast amount of information in this text was a difficult task. Without the help of Carolyn Ghiglione, it would have been another 34 years before the book went to print. I thank her for bringing her supreme effort and many skills to this project. vii prepages.pmd 7 9/5/02, 11:51 AM Tube Forming Processes: A Comprehensive Guide viii prepages.pmd 8 9/5/02, 11:51 AM Table of Contents Preface..........................................................................................xiii Process Planning.............................................................................1 Materials Suitable for Bending.......................................................1 Copper and Copper Alloys............................................................9 Magnesium and Magnesium Alloys...........................................10 Titanium and Titanium Alloys....................................................... 11 Nickel and High-nickel Alloys ......................................................12 Cold-bending Suitability ...............................................................13 Material Shapes and Finishes......................................................15 Designing Bends..........................................................................20 Dimensioning Drawings of Bent Parts.........................................41 References ...................................................................................44 2 Basic Tube Cut-to-length Methods.........................................47 Saw Cutting..................................................................................47 Lathe Cutting................................................................................54 Rotary Cutting ..............................................................................54 Dual-blade Shear Cutting............................................................58 Supported Shear Cutting.............................................................63 Laser Cutting................................................................................64 Bibliography.................................................................................67 3 Basic Bending Methods..........................................................69 Rotary-draw bending..................................................................72 Compression bending................................................................138 Ram Bending ..............................................................................143 Press Bending.............................................................................145 Roll Bending................................................................................150 ix prepages.pmd 9 9/5/02, 11:51 AM