To buy a mechanical pipe bender for a round pipe. How to make a pipe bender for a pipe with your own hands: drawings, diagrams, videos. How to make a rotary pipe bender with your own hands
When performing home construction or plumbing work, it often becomes necessary to bend under a different radius metal pipe.
It is necessary to bend round pipes when laying water supply networks or heating systems. If you try to bend the workpiece on a rectangular stop, a crease will occur, and the pipe may simply burst.
In addition, with improper bending, the internal section decreases, which negatively affects the permeability of the liquid.
It is possible to qualitatively bend a round pipe using a special device - a pipe bender. 
The purchase of an industrial tool is justified only for craftsmen who bend pipes professionally on a commercial scale. The cost of this device is quite high. Therefore, most home craftsmen make for one-time work.
There are not many ways to bend a pipe. Before you decide what type of tool you need, consider their varieties, advantages and disadvantages.
IMPORTANT! When working with such a tool, a lot of effort is applied. Therefore, injury must be avoided.
What are pipe benders according to the principle of operation
Break-in
The beginning of the pipe is fixed close to the fixed template. With the help of a pressure roller, the pipe covers the template and takes its shape.
Advantages - such a device is easy to make, it takes up little space, it is easy to mount on a workbench or just on the garage wall.
The disadvantage is that the bending radius is equal to the diameter of the template. Partially can be solved by changing the central node.
winding
The template is movable, the pressure roller is not.
The workpiece is fixed on the template with a bracket or other device, the template rotates and with the help of a clamp, the pipe bends. In the process of work, the part is wound around the central pulley, hence the name.
Advantages - again, simplicity of design.
Disadvantages - restrictions associated with the size of the template, a powerful lever and a bearing for the drive are needed.
Crossbow
The pipe is mounted on two fixed supports. Strictly in the middle, a shoe (punch) of a certain radius presses on the place of the bend.
Hydraulics or a screw drive is used as a power source. The workpiece bends like a bowstring or crossbow. Hence the name.
Advantages - relative mechanization of the process, less physical effort is required. Easy change of punches makes the tool more versatile.
Disadvantages – Limited bending radius. For large sizes you will need a bulky mechanism and massive shoes. At the points of application of force (both on the supports and on the punch), deformations of the pipe walls occur. A thin-walled workpiece can simply burst.
Rolling (rolling)
The pipe is installed between three rollers, the central one of which can move in height relative to the support ones.
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Disadvantages - large dimensions of the structure, it is inconvenient to work with small radii. In addition to bending methods, it is necessary to know the mechanical limitations for pipes of various diameters and wall thicknesses. As an example, here is a table of material-safe bending radii. This is about steel pipes ah, for aluminum or copper, other standards. If it is necessary to make a bend of a smaller diameter, the pipe must be heated. IN industrial environment, hot rolling is used. In household - gas-burner. IMPORTANT! The use of open flames wooden fixtures and workbenches is unacceptable.
Homemade pipe benders
Simple wooden pipe bender
The design belongs to the break-in type. Only the pinch roller is not used. For manufacturing, you will need boards or thick plywood, self-tapping screws and a jigsaw. A workbench or a massive chipboard (OSB) is used as a bed.
The end of the pipe is fixed with a primitive stop. With the help of muscular strength, the workpiece is given the desired shape. The effort should be applied smoothly, allowing the metal to “rest” after each approach. In this case, damage will be minimal, and the shape will be even and accurate.
To hold the part along the guide, a profile recess can be made at the end of the template. If you have a router - choose a face mill, or simply process with a round rasp.
This method is only suitable for thin-walled pipes.
Stronger blanks will simply destroy the wooden punch. If the metal is too thick and the pipe is short, you can increase the lever by inserting reinforcement into the free end. With thin walls, it would be wise to pour sand inside, plugging the holes with wooden chops.
The lack of functionality of the device is compensated by the ease and low cost of manufacture.
Improved wooden model with pressure roller
A break-in pipe bender with a lever on which the roller is mounted works much more efficiently. Even if it is made of wood. With a modern hand-held woodworking tool, you can easily turn wooden rollers of any size.
Diameters can be the same or different, it all depends on your tasks. The drawing clearly shows the principle of operation of the device, in this case- the pressure roller and the support roller are the same.
If you constantly work with small diameter tubes, you can make a more advanced tool with four bending radii. To do this, a square sheet of plywood is cut at the corners with the required size, a hole is drilled in front of each for a lever with a pressure roller. Changing it to different angles- we get four options for bending.
Perhaps the most common model among homemade products. As blanks, old pulleys from the engine are used, they are ordered at the factory from a familiar turner, they are recruited from washers of various diameters.
Such a device is found in almost every barn or garage of a masterful owner of the house. With its help bend plumbing pipes all running sizes. If necessary, the lever can be reinforced to any length.
When assembling a heating or water supply system from metal pipes, it often becomes necessary to bend them in order to give one shape or another. For these purposes, there is a special tool - a pipe bender, which you can either buy, although it costs quite a lot, or make it yourself. In this material, we will talk about how to make a pipe bender for round pipe, as well as what types of these products are found.
Scope of the tool
It is worth noting that pipe benders for round pipes have a fairly wide scope, and this is far from just plumbing work. By the way, when installing plumbing, the need to modify the contour of the pipe does not always arise. As a rule, swivel fittings and bends are used to create bends in pipelines. Elbows mean sections of pipes bent according to standard templates at the factory.
There are some restrictions for withdrawals:
- standard set of rotation angle options - 45º, 60º, 90º, 180º;
- bending radii can be equal to 1 or 1.5 Du;
- connection - only welded.
In some cases individual system heating or water supply cannot be entered into such a rigid framework, and it is not always acceptable to use the welding method of fastening. Then you will definitely need a homemade pipe bender for a round pipe.
In household and summer cottages, there can be many situations when it becomes necessary to bend pipes. This is the creation of greenhouses and greenhouses with unusual shapes, and setting up frames for vines or weaving flowers, and building summer shower or a small fence, in a word, there are many options. At the heart of all these structures is a frame made of round pipes or a profile, which must be given one form or another. This is where manual pipe benders for a round pipe come in handy.
Note that professional craftsmen do not hesitate to use such a hand tool, because it perfectly meets all the requirements and parameters of the owner. A hand-crafted tool allows you to do quality work, because it is very convenient to use.
Device types
In order to classify products into various categories several features apply:
- Drive type - manual, automatic, hydraulic.
- The installation method is portable or stationary.
- Operating principle.
According to the principle of operation, all pipe benders can be divided into several types:
- Winding. The stop is located at the beginning of the bend. With special clamps, the pipe is pressed against the movable template roller. This roller begins to rotate, passing the pipe between itself and the stop. This is how the bend is made.
- Running in. With this method, the pipe is fixed near a fixed template. The pressure roller begins to rotate around it and gradually bends the pipe to fit the template.
- Rod or crossbow method. A pipe is fixed between two fixed rollers. The pressure on it is made in the center using a template located on the stem. It gradually lowers, bending the pipe in the center between the support posts.
- Rolling (rolling). In this case, pipe rolling assumes that two rotating support rollers placed in one line and one central template are used for bending. The ratio of these elements will depend on the bending radius. As a rule, the pressure on the pipe is exerted by the central roller.
It is worth noting that in the first three methods of work there is one common drawback - in them the radius of the pipe bend directly depends on the template.
Pipe bending by winding, as a rule, is performed only on industrial equipment, since a do-it-yourself pipe bender for a round pipe is not suitable for these purposes. For products subject to the crossbow processing method, weakness– where the top of the template impacts the steel. This area is subjected to strong pressure and becomes brittle, weakens and thins. In some cases, the pipe may even burst - if its walls are thin enough.
But the rolling method is used to form the pipe configuration most often. Moreover, they are used in industrial enterprises for the production of outlets.
In order to properly manufacture a tool, you need to choose its model, taking into account the relationship between the bending radius and the cross section of the pipes. These data can be found in the special recommendations in the form of a table. And, although the figures given there are optimal, the bend radius can still be reduced.
However, for this purpose, you will need a mandrel, which will significantly complicate the work. If we talk about factory conditions, then in addition to the mandrel, hot rolling is often used in production.
However, hot rolling can also be done at home if you have a stationary metal pipe bender with a fixed bed at your disposal. Then, to heat the pipes, blowtorch or gas burner.
DIY pipe bending tools
Because to make makeshift fixture for bending pipes it is possible both from improvised and used components, the cost of such a tool will be quite low (more details: ""). Moreover, for the manufacture of the simplest pipe benders for a round pipe with your own hands, drawings are not required. For example, consider quite simple design of this fixture.
To bend the pipe, one of its ends is fixed between metal elements and begin to exert pressure on the opposite end until it acquires the desired shape. After that, the pipe is left in this position for some more time so that it does not unbend. For this, metal pins are also threaded at the ends of the pipe, which are welded to a temporary jumper.
Actually, this is the simplest type of pipe bender, which is not a problem to make. But there are also more technological products. We will write about them below.
Hand Template Bender
This tool is used for bending. It is made of wood, equipped with a manual drive.
First, according to the drawing, a wooden template is made, the shape of which will coincide with the bending radius, and the thickness must be greater than the diameter of the pipe. The profiling cut out on the end of the template will simplify further work with the tool. To get the desired profile, you can take two boards, the cut line on which is beveled inward.
The base to which the template will be attached must be fixed. On one side, an emphasis is screwed to the platform, after which the pipe is tried on. If the length of the lever is insufficient, a piece of reinforcement can be inserted into the pipe. There is no need to rush during bending - it is important that the pipe does not move during operation and clearly corresponds to the shape of the template.
Of course, such a primitive mechanism is not something intricate and technically complex. However, for work at home, it is quite acceptable, especially if you need to bend thick pipes.
Roll-in pipe bender made of steel
The most popular among homemade tools is a break-in pipe bender. The templates in it are made from pulleys from engines. Although, some prefer to use washers with different diameters or turn the part on a lathe. It is not necessary to draw a drawing in this case, but it is desirable, for example, so that the turner can correctly machine parts for pipe benders for a round pipe.
Such a break-in type hand tool is made by many diligent hosts who are constantly making and improving something in their home. The advantage of such a pipe bender is that it can work with plumbing pipes of any standard diameter. And to make the applied force more, you can make the lever longer.
Homemade winding machine for bending pipes
According to the principle of operation, such a tool is similar to a break-in tool. However, it can be used to give the pipes the shape of a ring, which is impossible to do on any other device. If we consider in detail the drawing of the fixture, we can see that the cheeks of the template pulley can be dismantled in order to remove the workpiece in the shape of a circle from it.
It is worth noting that a pipe bender of this design can be made from any available materials, including wood, metal or textolite.
How to make a pipe bender for round pipes with hydraulic drive
If we are talking about doing not just some household repair work, but about professional activities, then you should think about making a more complex hydraulic pipe bender. With its help, when bending pipes, it will be possible to reduce the cost of physical forces, because the load will fall on the hydraulic jack.
At the stage of drawing up the drawing of the device, it is necessary to foresee what material the sidewalls will be made of. Optimally suitable for this is a reinforcement bar with a cross section of 18-20 mm, as well as corners with a side of 25 mm. In addition, for the sidewalls you will need 10 mm thick sheet iron with drilled holes for fixing the supports.
A tube of the appropriate diameter is used as a support, into which a bolt with a cross section of 18 mm will need to be welded. A semicircular hole will be located in the center of the support, which also needs to be reflected in the drawing. The workpiece will have to rest against this recess, which will be bent on a hydraulic manual pipe bender.
To create a punch you will need sheet metal 4 mm thick, from which semicircular blanks will need to be cut. The radius of these parts must correspond to the planned bend radius of the pipe. At the next stage, a pipe with a cross section of 32 mm is taken and cut into two parts. One of the parts is bent according to the shape of the blank plates, and then all the parts are welded. For additional strength of the punch in a hydraulic pipe bender, jumpers are welded inside it, providing stiffeners.
A tube is welded in the central part of the platform. Its purpose is an emphasis for a hydraulic drive, which is a jack. All this must be worked out and provided for in the drawing, according to which the hydraulic pipe bender will be assembled. In addition, such a scheme will make it possible to prepare a list of materials and components that have the necessary parameters. In this case, a number of elements for the tool will need to be pre-ordered from the turner.
Thus, it is not so difficult to assemble one or another type of manual pipe bender. Moreover, there are a lot of options and drawings finished products, which can be adopted in order to make independently the necessary tool in the household.
When installing various pipeline systems, they have to have a circular cross section. If you do not use a pipe bender for a round pipe, then an attempt to bend the workpiece to a certain angle can either lead to a crushing of the round section shape with a complete loss of the passage section, or a crack will appear at the bend. Therefore, in order to bend a round pipe, methods were invented and special devices were made.
All pipe benders can be divided according to the method of mechanical action on a round pipe profile. At the same time, it should be taken into account that, despite the external similarity, there are differences in the approach to technology, expressed by differences in the bending technique when exposed to a round pipe profile:
- to the cold
- to hot.
So, the most common models of pipe benders that bend a round pipe to a cold one, that is, without additional heating of the bend, include:
- break-in,
- winding,
- crossbow,
- rolling or rolling.
It is the simplest design and is positioned as a hand-held mobile device. Structurally, it consists of a solid base on which a fixed template of a certain diameter is fixed. A frame lever with a rolling movable roller is attached to the central axis of the template.
The principle of operation of such a mechanism is simple. To begin with, the workpiece is firmly fixed on a fixed template. Further, with the help of a lever and a crimping roller, the pipe is tightly rolled around the template so that, as a result, it completely repeats the bending radius of the template.
The disadvantage of such devices is that the bending radius corresponds to the diameter of the fixed template. This can be partially solved by changing the size of the diameters, by replacing the fixed template and the swaging roller, so it is possible to bend pipes with a nominal diameter of 15 to 32 mm.
Factory models are produced that have in their design three templates of different diameters at once and, accordingly, three running rollers designed for bending gas pipes of the main sizes.
The advantage of a running-in manual pipe bender is its versatility in use due to the simplicity of the design, which does not take up much space and allows its installation as a locksmith's workbench, and to almost any temporary surface in a construction site. Therefore, a running-in pipe bender for a round pipe is most often made by hand than other types of fixtures.
Winding type pipe bender
According to the principle of operation, it is similar to the break-in one, only its design provides for a movable template. The workpiece is fixed using a bracket fixed directly on the template itself, but instead of a crimping roller, a fixed thrust shaft is made.
The winding pipe bender works by rotating the template, which bends the pipe, as if winding it around the central pulley, which corresponds to the name of the device.
Such devices are manufactured mainly in the factory, while the device is provided for mechanical bending of the central pulley electric drive through the gear motor.
The disadvantage is also a limitation, which is associated with the diameter of the central pulley. And in the case of a manual drive, a more powerful lever and a large bearing for the central pulley shaft will be required.
The advantages include a simple design and relatively small size.
Crossbow type pipe benders
They are a base with two spaced fixed roller bearings, on which it is laid pipe billet. The bending process occurs due to the fact that exactly in the middle between the rollers, a punch with a certain radius size presses on the workpiece at the place of the future bend. The punch is similar in shape to the template, only it represents only a part of it, no larger than half a circle in size. The workpiece is bent, like an onion arc, from two sides at once, which allows least deform the section of the pipe at the bend. 
To transfer force to the punch, as a rule, a hydraulic drive is used, hence the crossbow-type device has a second name -.
Although, along with hydraulics, manual screw-driven pipe benders are produced, as a rule, such devices are significantly inferior in performance to the latter and have a more bulky design.
The advantage of the crossbow hydraulic pipe bender is, first of all, the mechanization of the bending process, which practically does not require physical strength for its work, and simple replacement punches makes the fixture also versatile, allowing you to bend almost any small-sized metal.
The disadvantages include the limitation of the bend radius. And also, for large sizes of workpieces at the stops, a slight curvature of the diameter of the pipe section may occur, but when working with a thin-walled pipe, it can be significantly wrinkled.
Rolling or rolling pipe benders
They are a structure with three rollers, two of which are fixed, and one, installed in the middle, is able to move up and down relative to the other two. Such an arrangement of the rolling rollers during the translational movement of the pipe allows it to be bent in an arc. For several rolling you can get the required. 
The disadvantages of the rolling method include the low productivity of manual devices.
The advantage is the ability to bend almost all types of profiles, including thin-walled sizes.
It should be noted that the rolling bending method has proven itself well on industrial universal bending machines, where mechanical rolling of the workpiece is used with the help of an electric drive, and the number of rolling rollers is determined by the technological map.
The main difference when bending a rectangular profile from a round pipe is the large bending radii. With a further attempt to reduce the bending radius, a certain deformation of the straight lines of the profile walls begins to occur, which significantly reduces the flow area and reduces the structural properties.
How to bend a pipe without a pipe bender
If, nevertheless, you have a need to bend a round pipe, and there is no manual pipe bender, then how to bend the pipe correctly, you can recommend several completely working methods. So:
- It is necessary to fill the pipe with sand, at the same time, so that the sand does not spill out, we temporarily caulk the ends with rags. Having found a rounded surface so that one end of the pipe can be firmly fixed with a nozzle in the form of a pipe of a larger diameter, sufficient length for the lever, we gradually bend our workpiece to the required angle.
- In exactly the same way, you can bend a metal pipe of small diameter, using ice crumbs instead of sand or stuffing it tightly with snow.
- To bend in your arms metal-plastic pipe and not break, it is necessary to put a spring of a slightly smaller diameter inside the pipe. At the end of the bending process, it should easily exit the pipe.
If you know another way to bend a round pipe without a pipe bender, then share your experience in the comment block.
For 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 both portable, industrial and for home use.
Article content
The device and principle of operation of a manual pipe bender
A manual pipe bender is quite simple in design and principle of operation, so a home craftsman may well handle it yourself. The main elements in any pipe bending device are the pressure plate. A special mechanism presses on it with a certain force, and it transfers the force to the pipe being processed.
As a mechanism for pressing, both an electric motor or a hydraulic pump, as well as a spring with latches, are used.
To perform bending, the corrugation is installed between the pressure plate and several shafts that act as stabilizers. Also, with the help of shafts, you can adjust the bending radius, since their position is adjustable.
So, to bend the pipe along a small radius, the shafts are located close enough to each other, and if it is necessary to increase the radius, then they are moved away from each other.
To bend a round pipe, crescent-shaped shafts are installed on the pipe benders.
Hand device
A home-made manual pipe bender, with which round pipes are bent, 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 work is simple: a pipe is laid 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 skilled owner may be needed at any time, therefore it is worthwhile to approach its manufacture thoroughly, so that they can bend pipes of various diameters.
This design would require two triple sheaves instead of single sheaves: one pair would be used for bending 1/2″ pipe, one for 3/4″ pipe, and one for inch pipe.
It is unlikely that you will be able to buy such devices on the market, so you will need to order them in a turning workshop. At the ends of the shafts, a groove is made, which in size coincides with the half diameter of the corrugation.
Another important point, which must be taken into account in the manufacture of shafts - the stationary pulley should be minimal in size, since the minimum possible bending radius of the product depends on this. Optimal size the movable shaft is twice the diameter of the stationary one.
The sequence of manufacturing the design of the pipe bender
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 home-made pipe bender. A thick metal plate (at least 10 mm) of a square shape is suitable for it. To attach the base to the table, it is necessary 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 fixed by welding;
- next step it is necessary to make a rotary mechanism. To do this, three metal plates are welded in the form 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 shafts: a fully movable pulley and half of the stationary one should fit in this height;
- to mount the shafts, you will need to drill several holes. The legs of the letter P are at a distance from each other, slightly greater than the height of the shafts. A handle, about 25 cm long, is welded to the upper bar of the structure, on which a lever tube is subsequently put on;
- the large pin is mounted first and secured with cotter pins behind the plate in the form of the letter P, and the small shaft is put on together with the entire structure;
- to equip the pipe stopper, another pin is welded to the frame, installed vertically. It will serve as a stop.
The second method is similar to the previous one, only used as a template metal hooks, which are fixed over the plywood sheet along the line of the intended bend. The advantage of this design is that the hooks can be repositioned to change the radius of the pipe.
Advantages and disadvantages of manual pipe benders
Main advantages handheld devices:
- has small overall dimensions and weight. Bending pipes with their help is possible almost anywhere: in the workshop, on suburban area, in a garage or on a construction site. As a rule, the need for a pipe bender for round pipes arises in those places where engineering systems are laid.
- Another advantage is that with the help of such devices it is easy to bend pipes made of soft metal or.
- The manual unit is quite mobile: if necessary, it can be easily moved to any place.
- Even the most inexperienced user will cope with work on 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 a large diameter pipe. Thick-walled bending will also be difficult.
While working on the site or in the garage, it is often necessary to bend several pipes along one or another circle. Or, alternatively, make flat steel strips semicircular. For this, a device such as a pipe bender is used, but to acquire factory model to perform a couple of operations - the pleasure is not cheap. It is easier to make a simple do-it-yourself pipe bender that can bend the pipe to the required dimensions. With the simplest and most popular options for this design, we will get acquainted today.
What are tube benders used for?
Profile pipes with various cuts are considered the most popular today. metal products and are used in the construction of greenhouses, sheds, garages, to create fences, during the laying of pipelines, and so on. And in the manufacture of most of these products, the pipes must be bent at one angle or another, and without special equipment this cannot be done.
So, a pipe bender is a special device through which, in most cases, pipes are bent, and the bending angle can be different (within 0-180 degrees). The drive of a modern pipe bender is often electromechanical or hydraulic.
Note! Using the device described in the article, you can bend products of any configuration (boiler rooms, gas and water pipes; moreover, pipes can be either steel or copper, aluminum or metal-plastic).
The scope of the pipe bender is quite wide - it can be found on construction sites, when creating heating / plumbing networks, at industrial facilities, etc. A pipe bender made by hand is an indispensable thing in the household that can be used for the most various works. If you, for example, intend to install an air conditioner with your own hands, equip a ventilation or heating system, then it will not be easy to do without this unit.
How is a pipe bender arranged?
The specific design of the device depends, first of all, on its purpose, however, without fail, the pipe bender includes:
- frame;
- a pair of pipe stops;
- hydraulic cylinder;
- straps (upper/lower).
Note also that the frame can be either open or closed. As for the hydraulic cylinder, it is main part device that performs a power function.
Also in the do-it-yourself pipe bender circuit there is an injection device, which is located on the back of the case; in the same place is the bypass valve screw, the handle. But on top of the cylinder there is a plug, through which oil is poured inside and its level is checked. The unit bar located at the bottom is screwed onto the thread located in front of the housing, and then pressed with a special fixing nut. Additionally, the bar is fastened with a lock and a pair of screws.
For manual reinforcement, a retractable rod is used, which returns back thanks to a spring located in the cylinder. The pipe bender bars are made as a welded structure. On the transverse plates there are holes through which the stops are installed. In the lower part of the body there are also threaded holes for mounting bolts, adjustable in height.
Note! The emphasis is made in the form of a trunnion, and the stops located at its ends are inserted into the holes on the slats. The bent product will rest on the stream located in the middle of the stop. The bending elements are made of precision cast steel.
Considering a do-it-yourself pipe bender, one cannot fail to note the fact that thin-walled profile pipes have become increasingly popular in recent years, moreover, they make it possible to create durable and attractive designs, as well as save on construction work. It is from such pipes that greenhouses and various sheds are made today. What is the difference between a profile pipe and an ordinary one? First of all, the cross section, which in this case is not round, but oval, rectangular or square. This is what explains design features pipe bender for of this type pipes - rollers must be of the same cross section as the products being bent, otherwise the cross section of the latter may be deformed.
Types of pipe benders
With a manual pipe bender, you can bend rings and arcs. Such a device weighs relatively little (about 65 kg), so it can be transported to the place of work with small metal structures (the same greenhouses, gates, sheds). Here are the main characteristics of materials that can be processed with a manual fixture: a round pipe with a cross section of 3 centimeters, a square - 4x4 centimeters, a rod - 1.6 centimeters, a strip - 4x1 centimeters and, finally, a square - 1.6x1.6 centimeters.
Thanks to various types of mandrels, the range of processed products can be expanded, and the pipe bender, in turn, can be turned into a profile bender. Price hand tool is such that it can be purchased or made with your own hands, even for minor industries.
As for electric pipe benders, they are used in industrial scale when working with products of various sections. Similar units very productive, which is due, first of all, additional features, among which the rotation of the rollers in two directions at once, the use of foot pedals, adjustment using the control panel.
The possibilities of electric pipe benders include bending arcs from square (8x4 centimeters) and round (3 centimeters) pipes. In order to match the configuration of the section and the diameter of the products, the devices are equipped with special interchangeable mandrels for each specific case.
A hydraulic manual pipe bender is considered more modern, the strength of which is such that it allows processing fairly large steel products. It is this option that is desirable to use for water or gas pipelines. In this pipe bender, the drive is equipped with a special hydraulic installation, which distinguishes it from a conventional device (the operator's work is noticeably facilitated).
Hydraulic devices can be of several types at once and can be used for various pipes and fittings. So, a portable pipe bender (TPG) can be used for solid steel pipes, as well as for round products (we are talking about the bulldozer method, when the pipes are not filled with sand or other fillers). There is also a manual unit (RGU), with the help of which water and gas pipes, fittings or, again, rolled steel are bent.
Note! From the point of view of operating conditions, a pipe bender (including with your own hands) can be manual and stationary. Representatives of the first group are more suitable for domestic use, while representatives of the second group are at enterprises that require bending pipes or other products.
The principle of operation of the pipe bender
At first it may seem that there is nothing super complicated in bending pipes, but in reality this is not entirely true. If handled incorrectly, you may encounter all sorts of defects, including crushing (may cause a change in diameter) or stretching of the thickness at the bend (due to this, strength characteristics pipeline). For this reason, the device must be selected correctly, knowing the principle of its operation - this is how you minimize possible defects.
The very principle of operation is as follows. At the beginning required size a semicircle is drawn on folded boards or pieces of chipboard, after which they are cut along the line and fixed with nails on the floor, wall or fence. At the same time, it must be remembered that this shield should be somewhat thicker than the product being bent (by about two to three centimeters). An emphasis is fixed from the edge of the board in the side part. The edge of the pipe is inserted between the latter and the template, and then, in accordance with this template, smooth bending is performed (you need to take hold of the second end of the product for this).
Important information! If we are talking about a short pipe or a small bar, then the second end is extended by cutting a pipe that is suitable in diameter.
Also note that there are enough complex decisions problems with bending large diameter pipes, however, they require plumbing skills and the use of professional equipment. To make such a pipe bender yourself is not only difficult, but also expensive - it is much easier to purchase a manual unit that has already been used.
Video - Do-it-yourself pipe bender for profile pipes
A simple do-it-yourself pipe bender for ordinary pipes
To assemble a simple pipe bender with your own hands, you only need what can be found at any summer cottage. More specifically, you will need:
- wooden shield;
- two small bars;
- large hooks;
- several sturdy boards.
Draw on finished shield semicircle, according to which the pipe will bend. If the unit will be used several times, draw a couple of semicircles at once. Next, nail bars or boards vertically from below (they can help with the pipe and fixing its ends). After that, fasten large hooks along the semicircle. This unit is quite convenient, but its minus is that the hooks will have to be outweighed each time in order to receive various angles bending.
Making a pipe bender designed to work with shaped pipes with your own hands
For this kind of pipes, the design described above is no longer suitable. For this reason, you will need a special do-it-yourself roller pipe bender. If you familiarize yourself with the drawings and step-by-step instructions, you will be able to make such a machine with your own hands.
From the materials you will need:
- pre-made frame made of steel profile;
- rollers;
- jack;
- three rollers.
After preparing everything you need, you can proceed directly to the manufacturing process.
Step one. fabricate metal carcass. Below you can additionally weld fasteners for fixing on the table top. After that, place a pair of vertical supports: on the side and in the center. WITH opposite side(where there is no support) the profile will rise, and therefore it needs to be bolted. This part will be lifted with a jack.
step two. Weld the shafts to the finished frame. Two on the sides, while under the third it is required to prepare supports in advance. The shaft will be attached to the latter.
Step Three. Weld a handle made of steel pipe to the central shaft. With the help of this handle, the product will be bent.
Step Four. Fix two shafts between the shafts on the sides and the central one, as well as a roller, so that the product being bent does not move. The fact is that in this way the pipe will not move much, and therefore the work will be done with maximum accuracy.
Step five. At the end, place the jack under the movable part of the profile (the one with the roller). The jack, by the way, can be either a simple rack or a bottle jack. If necessary, fix it on the structure.
Note! Take careful measurements before starting work. Draw a diagram, check how well the parts are welded together. In addition, we recommend that you watch the video below.
Video - Making a simple pipe bender on your own
Manufacturing of a compact snail pipe bender
To make a pipe bender with your own hands, you can use ready-made design drawings. Familiarize yourself with several options, proportion their complexity and your capabilities, the availability of the required skills and equipment. So you will be able to choose the most optimal design. So, check out a few more options for pipe benders that you can assemble with your own hands.
Let's start with the fact that for the correct bending of profile pipes, it is necessary to clearly understand what physics is this process. As a rule, in hand tools the so-called circular bend is used, due to which the risks of damage to the product, the appearance of cracks or creases are minimized. To bend the pipe in such a unit, it is necessary to fix the pipe in it, and then press the lever. The product will flex as it rolls over the roller, which in turn presses it against the main wheel.
As for the necessary equipment and materials, you will need:
- a sheet of metal 6 mm thick;
- ruler / tape measure;
- Working wheel;
- hammer;
- pressure roller;
- corners made of steel, with dimensions of 5x5x0.25 centimeters;
- welding machine (and skills to work with it, of course);
- a piece of thick pipe with a diameter of 2.5 centimeters;
- Bulgarian;
- axes of rotation;
- washers, nuts;
- a piece of metal rod with a square section (2x2x4 centimeters).
Note! When building a pipe bender with your own hands, be sure to follow the safety requirements! In particular, this applies to welding and metal cutting!
How to calculate the design. Drawing
Before you start making a pipe bender with your own hands, determine under what radius you will need to bend the pipes most often. It is on this that the dimensions of the impeller will depend (they must be the same as the inner radius of the finished elbow).
The drawing presented above was created for profile pipes whose diameter does not exceed one inch. Using this unit, it will be possible to obtain a bending radius of up to 12.5 centimeters (this is 1/2 the diameter of the impeller). But if you require other bending parameters, apply the appropriate calculation method.
So, the main size of the fork is the distance between the axes of the roller and the impeller (here a = 200 millimeters). This gap is chosen in this case, taking into account the fact that the limiting diameter profile pipe will be 25 millimeters, but we recommend adding a few more "reserve" millimeters.
Here is the formula for calculating the distance between the axles:
d + r1 + r2 + 2= a, in which:
- d is the exact diameter of the product;
- r1-2 is the roller/impeller radius.
Note! If the design of the future unit provides for a kind of brook pulley, then measure, starting solely from bottom point this element.
To determine the size of the fork, take 10 millimeters as the gap between its base and the roller, and then add another 30 "spare" millimeters. But to determine the internal clearance, add one or two millimeters to the wheel thickness.
Important information! For a more versatile design, make a few holes on the sides of the fork. When you move the axis of the roller, you will change the distance between the surfaces of the rotating elements.
How to make such a pipe bender - a detailed guide
As you can see from the diagram above, the design consists of:
- iron thick plate (base);
- forks;
- impeller;
- and finally the roller.
To make a pipe bender with your own hands, follow the sequence of actions below.
Step one. First, make a roller and an impeller. If you have lathe, this is very good, however, in the absence of such equipment, these elements can also be manufactured without any difficulties. For a moderate fee, a specialist will quickly turn your pulleys for you.
Note! Do not skimp on the creation of movable parts! They must have a groove for the maximum diameter pipe, in addition, the roller must have a seat for a rolling bearing.
If necessary, you can make adjustments to the design of the surface of the knee; the roller/wheel chute is shaped. When the roller rolls, it will leave a mark on the outside of the knee, while the wheel will leave it on the inside. To facilitate work and reduce the cost of the total cost of the structure, you can install two ball bearings of the required dimensions instead of a roller.
step two. Using the same machine, it is necessary to make an axis for the roller and the impeller. It is important that the thickness of the elements matches the inner diameter of the bearing you are using. As for the length of the axle, it should be the same as the outer width of the fork. The length of the axis of rotation of the wheel will be slightly longer, since the thickness of the base plate of the unit will also be taken into account. If you refuse to install bearings, you can thereby significantly reduce the cost of the process, and in this case, long bolts with nuts will act as axles. Be that as it may, remember that working on such a device will be much more difficult.
Step Three. After that, take a sheet of metal, cut out the back wall and side surfaces of the fork from it; in addition, you will need a piece of pipe with thick walls, which will serve as a lever.
Step Four. Make holes in the fork for the roller/wheel according to the diagram.
Step five. Weld the elements of the fork. At the same time, make sure that exactly the right angles of this product are made with especially high quality.
Note! It is better not to fasten the lever butt to the fork, as this kind of fastening will be unreliable due to the large applied forces. The best option- drill a hole in the back wall, where the end of the pipe will subsequently enter. If you weld such a joint using welding machine, you will get an extremely strong joint as a result.
Step Six. We continue to assemble a pipe bender with our own hands. So, now arm yourself with a grinder and cut out the frame with it. After that, drill a hole of the appropriate size in it for the stationary wheel axle.
step seven. If necessary, press the bearing into the roller.
Step eight. Place the roller in the fork, and then secure with nuts or a welding machine.
Step nine. Install the assembled fork on the base, fixing the wheel axle in the same way as when installing the roller.
Step ten. Weld a piece of square section - this will be a kind of retainer for the workpiece.
At the end, make holes in the corners of the base to install the unit to the workbench. Do not forget to clean up the welding spots so that the design looks more attractive in the end. Also paint the pipe bender with enamel to prevent rusting.
Another design of the bending machine
Here, as you can see, the roller is pressed by means of a threaded gear. IN this example a hydraulic jack and a manual drive will be used, in which there will be elements of a gas distribution mechanism (we are talking about those in automobile engines). And one more thing: do not forget about personal safety! Always use personal protective equipment when working!
Now - directly to the process of making a pipe bender with your own hands
Step one. First, make a pressure shaft and support shafts. If you do not know how to work with a lathe, then you will need the help of a professional. At the same time, it is important that the rollers have shanks necessary for mounting sprockets.
Note! The chain, as well as sprockets, can be any.
step two. Attach bearings to the shafts, fasten the gears to the keys.
Step Three. Weld the frame of the future pipe bender. First of all, make a square frame on which there are support legs, and then install a structure on it, through which the plate with the roller will move.
Step Four. The plate in this case will serve as a channel (H- or U-shaped). To install the pressure shaft, make holes on the edges of the plate, taking into account the dimensions of the bearing supports.
Step five. Hang a piece of channel with a roller on four springs on top of the frame (pre-weld nuts in the corners that will serve you as mounting loops). Then, finally install the hydraulic jack.
Step Six. Fix the drive shafts on the lower frame.
step seven. Put a chain on the sprockets, push it down to determine the place where the tensioner will be located. Install the latter on the construction frame.
Step eight. Install a handle to rotate the shafts of the structure. We recommend using a handle with a rotating tube to make it easier to work and to avoid blisters on your hands.
Step nine. You can process a finished pipe bender with your own hands with a special rust converter, and then paint it.
In the end, it remains only to check the resulting design for operability. That's all, we hope that you, following our instructions, will definitely get the desired result! And at the end - another thematic video.
Good luck with your work!
Video - Making a simple pipe bender
