When manufacturing metal structures from profile pipes, the need to bend them often arises. Arched ceilings, greenhouse frames, elements of playgrounds - this is just a small list of objects that require the installation of rounded profiles. In production, special equipment is used to produce pipes with a given radius of curvature. Considering the bulkiness and high cost of such machines, their purchase is impractical for irregular use for domestic purposes. For a home workshop or garage, you can make a profile bender yourself. Everything you need for this can be found in the same workshop or found in the garages of friends and acquaintances. Interested in this design? Then put on work clothes and get down to business!
Roll forming machine. What is it for?
Universal production bending machine
The purpose of the roll forming machine is indicated by its name. This is the bending of metal profile pipes in order to obtain a certain radius of curvature on required area or along the entire length of the workpiece. Using a profile bender, or pipe bender in other words, you can perform several technological operations with rolled metal of various types:
- bending metal rods or reinforcement, including spring steel workpieces;
- bending of profile metal products of square or rectangular type;
- getting knees out round pipes or bending them at the desired angle;
- rounding of parts of any length from rolled products (angles, I-beams, channels).
There are several models of bending machines. Some allow you to apply force only on a certain area of the workpiece. Others roll the pipe between rollers, applying pressure along the entire length. For some reason, it was the latter that received the name “profile benders” from experts, although both of them directly relate to the same type of equipment. By the way, rolling a workpiece allows you to obtain a product of complex configuration without preheating, and bends can be made at an angle from 1° to 360° in arbitrary planes.
Rolling type profile bending
Just like their industrial counterparts, homemade profile benders are electrically driven or powered by muscle traction. Of course, the use of an electric motor not only makes it easier to process workpieces, but also significantly speeds it up.
Classification of profile benders
Depending on the type of drive, which, in turn, directly affects the power and productivity of the machine, profile benders are divided into several types.
Hydraulic machines
Hydraulic driven roll forming machine. Powerful and very expensive
Hydraulic pipe benders are industrial equipment, therefore they have high power and are intended for permanent installation. Such units are used primarily in small-scale and mass production, when it is necessary to produce a large number of blanks of the same type. The hydraulic drive completely removes the load from the operator, giving him the ability to control the machine by pressing buttons.
Advantages of hydraulic machines:
- high speed;
- complete absence of manual labor;
- ease of operation;
- possibility of bending a large cross-section profile.
The disadvantages of devices of this type include high price, stationary design and the complexity caused by the use of hydraulic drive.
Electric profile benders
Electric profile bender with screw drive. Inexpensive and functional
Bending machines using electric motors are also stationary equipment, since they require connection to electrical network. An electric drive is usually combined with a screw drive, which reduces the cost of equipment, but also makes it impossible to bend large cross-section profiles. That is why such machines are found in small enterprises and even in private workshops. By the way, there are designs homemade devices with an electric drive, which function no worse than their factory counterparts.
Advantages of electric profile benders:
- relatively low cost;
- workpiece processing speed;
- simplicity of design;
- high bending accuracy;
- possibility of application digital technologies machine control.
The disadvantages include the same lack of mobility and the inability to bend oversized profiles.
Manual machines
Manual profile bending. Cheap, mobile option
Manual bending equipment is simple, compact and low cost. Thanks to the simple design with drive rollers and a movable roller, working with profile benders of this type does not require any qualifications. If necessary, the machine can be easily moved to the installation site, and affordable price similar devices causes their widespread use in household. Of course, the design is not without its drawbacks:
- there is no way to accurately control the bending radius;
- increased processing time for workpieces;
- high physical exercise per operator;
- processing profiles with little cross section.
The advantages and simplicity of the design of manual profile benders make them attractive for manufacturing in artisanal conditions, which is why such machines have gained immense popularity among home craftsmen. By the way, manual bending devices can be transferred to middle category, if necessary, adding an electric drive to the design.
Design and principle of operation of bending units
Design of the simplest rolling type profile bender
The main elements of a roll forming machine are shafts mounted on a strong metal frame. In this case, a pair of rolling rollers is responsible for the longitudinal movement of the workpiece, and a movable roller provides pressure on the part. Depending on the design of the unit, the clamping force is adjusted over a wide range using a screw pair, a jack or a hydraulic mechanism. The rolling rollers are driven by an electric motor or manually. The latter option is used on small devices and is most often repeated by craftsmen at home.
In addition, there are other designs of profile benders:
- units with a left movable roller are used to produce spirals. Most often, such machines are equipped with CNC and allow you to bend parts, precisely controlling the bending gradient;
- machines with movable lower shafts bend large workpieces, therefore they are equipped with a hydraulic drive. The presence of a position controller for each shaft allows you to obtain parts complex shape, up to twisting the workpieces into a spiral;
- models in which all rollers are movable represent the elite of roll forming equipment and can work with parts of any configuration and thickness.
The main difference between profile bending machines and other pipe bending equipment is that the configuration of the workpiece is changed not by bending around a stationary roller, but by cold rolling. This allows you to change the configuration of workpieces of any section and length. Similar design and will serve as the basis for homemade machine, which we propose to do yourself.
A diagram that shows the operating principle of a rolling pipe bender
Required tools and materials
To manufacture a machine for bending profile pipes, you will need a fairly large number of parts, but this does not mean that you will have to buy all the items on the list. Predominant number necessary materials can be found in any garage or workshop. Here's what you'll need during the process:
Every craftsman will have the tools that he will need during the work process:
- angle grinder;
- electric drill;
- set of metal drills;
- hammer;
- welding machine;
- set of open-end and socket wrenches.
The only difficulty you will have to face is making the drive rollers and the pressure roller. The ability to turn them from a workpiece to lathe Only the lucky owners of such equipment have it. However, do not despair - in any organization there is a turner who will inexpensively produce parts according to the submitted drawings. The remaining elements of the machine can be used used.
Everything you need to make a profile bender
Mechanism chain transmission can be borrowed from the gas distribution mechanism drive of automobile engines, and the bearing housings (and the bearings themselves) can be borrowed from old agricultural machinery.
Options for manufacturing manual roll forming machines
To make a roll forming machine, it is not necessary to repeat exactly existing structure. It is much easier to create a device according to your own drawings, based on what you have at hand. This will save time and money and make it possible to design a device that is ideal both for its purpose and for its installation location. That is why you can find many devices on the Internet that use the same principle, but differ in execution.
Drawing of a pipe bender with radial action on the workpiece
One of the designs allows radial bending of rectangular profile pipes due to the use of two rollers, one of which is movable and the other is a support (guide). The workpiece is deformed to the desired radius by pressing and moving the working roller around the guide. The device body is made from steel sheet up to 8 mm thick and metal corners. To avoid involuntary displacement of the workpiece, before bending it is clamped between a stationary roller and a specially installed stop.
Homemade rolling bending machine for profile pipes
More universal is a rolling type machine, the design of which is described above.
Besides, there are other truly simple designs allowing pipes to be bent according to a template. Unfortunately, the quality and accuracy of the deformation performed leaves much to be desired, and to obtain a different radius, a new template will have to be made.
Devices for bending pipes according to a template
During production manual machine Some points to consider:
- so that when bending large workpieces the profile bender does not tip over, its bed is made stable and massive. The best material a channel or I-beam can be considered for manufacturing;
- The machine rollers must have low roughness and increased hardness. It is better if their configuration follows the shape of the profiles of the most used sizes;
- the housing design must ensure a change in the distance between the axes of the drive shafts. The increased distance will make it possible to roll workpieces with a large cross-section, then, with a decrease in the interaxial distance, it will be possible to obtain bends of small radius;
- The drive lever must ensure ease of rotation during operation, so it should not be made too short.
Most connections in the manufacture of profile benders are made using welding machine. However, you can completely dispense with bolted connections It won’t be possible - the moving structural elements are attached in exactly this way.
Making a rolling structure with your own hands
For self-made We recommend using the most common design of a roll forming machine with two lower shafts and a pressure roller. Easiest to install on the unit manual drive, which, if necessary, can be easily converted into electric.
Device drawings
As already mentioned, it is better to design a profile bender yourself, based on your own conditions and preferences. In your work, you can rely on the drawings of the machines, which the craftsmen who made them are happy to share.
Assembly instructions
- Manufacturing of drive (support) shafts and rollers. It is better to entrust this work to a turner, after which the parts must be hardened.
The manufacture of shafts and support rings will have to be entrusted to a turner
It is possible to produce cylindrical rollers without grooves under profile pipes. In this case, two restrictive rings are made for each shaft. Such cylindrical attachments are installed taking into account the width of the workpiece and secured with bolts.
- Bearings are installed in cages. If it is not possible to use factory parts, they can also be turned on a lathe.
Shaft supports with installed bearings
- Sprockets are fitted onto the shafts and the location of the keyways is determined. The grooves for the key can be cut using a drill and file or a Dremel.
The keyway can be made with a drill
- Holes are drilled in the restrictive nozzles and threads are cut for the clamping bolts.
Thread for fixing restrictor rings
- A platform is made for installing the pressure roller. To do this, take a thick metal plate or channel, in which two pairs of holes are drilled for attaching cages with bearings. In addition, on back side will be installed hydraulic jack, so in some cases you will have to cut off one flange of the channel.
Upper roller support
- Screw the pressure shaft and weld eyes made of M8 nuts to the platform for attaching the springs.
- Using welding equipment, the supporting legs and frame are made. Special attention should be given to the part of the body in which it will be located support platform top roller. The corners that will form it must be even, and when installing them, the geometry must be carefully observed using measuring equipment.
Bed with installed top roller platform
- The platform with the installed roller is suspended on springs to the upper cross member of the frame.
Rotation on drive shaft band press transmitted from an electric motor, which is connected to it using a belt drive. The speed of movement of the belt mechanism can be adjusted, thereby changing the processing modes of parts. Tape flat grinding machine can be positioned horizontally or vertically, as well as at a certain angle, which is allowed by some equipment models in this category.
When choosing a belt sanding machine model for processing a particular part, it is important to consider the length of the surface that needs to be sanded. It is much more convenient to process parts on such machines whose surface length is shorter than the length of the abrasive belt and work table. If such conditions are met, the quality of processing will be much higher.
The belt sanding machine can have different design: with movable and fixed work table, with free tape. A separate category includes wide-belt equipment, the peculiarity of which is that their work table, which is also a feed element, is made in the shape of a caterpillar. In those equipment models that include a work table, abrasive belt located in a horizontal plane, and in equipment with a free belt, in which there is no work table, it can have a different spatial position.
Compulsory structural element any belt sander, including tabletop ones, is exhaust device, which is necessary to remove dust, in large quantities formed during processing. Both a professional and any homemade grinding machine used in a home workshop or garage are powered by an electric motor.
Principle of operation
The main operating parameters of a belt sanding machine include the feed speed and the force with which the belt is pressed against the workpiece. Parameters such as the degree of grain size of the abrasive belt should be selected depending on the material from which the workpiece is made, as well as the degree of roughness that the surface of the machined product should have.
The characteristics of the material being processed, in particular its hardness, primarily influence the grit size of the abrasive belt to be selected. Processing modes that are directly related to each other are feed speed and tape clamping force. So, if grinding is carried out at high speed, but with insignificant pressing force of the abrasive tape, then some areas of the surface of the part may turn out to be untreated. If, on the contrary, you increase the clamping force and reduce the feed speed, then you may encounter the fact that separate areas burns and blackening of the material may appear on the treated surface.
Another variation of the machine - side view work surface tapes
The results of grinding are also influenced by how well the abrasive tape is glued together. To obtain high quality To avoid problems with the belt machine, do not use abrasive belts that are not glued correctly or have torn edges. When putting the tape on the equipment shafts, it should be positioned so that the overlapping end of the seam does not ride up against the surface of the workpiece, but slides along it. Learn more about gluing tape in the video below.
Any, including a manual grinding machine, must provide the ability to adjust the belt tension, which is ensured by moving a movable shaft that is not driven. Belt tension is very important parameter, when choosing which you should be guided by the “golden mean” rule. If the sanding machine belt is pulled too tightly, this can lead to its rupture during operation, and if its tension is too weak, it causes slipping and, as a result, its excessive heat. The main characteristic for determining the degree of tension of the tape is its deflection, which is measured by lightly pressing on its surface in a tense state.
A manual belt grinding machine can be serviced by one operator, who moves the work table with the workpiece and rotates it so as to bring all areas of its surface under the abrasive belt.
How to make a belt sander
Many home craftsmen and professionals are wondering how to make a grinding machine with their own hands. The reason for this question is quite simple: the high cost of serial grinding equipment, which not everyone can pay off if not used regularly. In order to make such equipment, you will need several main components: an electric motor, rollers and a reliable frame. Naturally, drawings of such a device or a photo of it would not be superfluous. Also at the end of the article you can watch videos on assembling a tape machine on your own.
The motor for belt grinding equipment is not difficult to find; it can be removed from an old one. washing machine. You will have to make the frame yourself; for this you can use a sheet of metal with dimensions 500x180x20 mm. One side of the frame should be cut very evenly, since it will be necessary to attach the platform on which the electric motor will be mounted to it. The platform for the electric motor should also be made of a sheet of metal with dimensions 180x160x10 mm. Such a platform must be secured to the frame very securely using several bolts.
Another version of the bed
The efficiency of a belt sanding machine directly depends on the characteristics of the electric motor that is installed on it. If you are planning to make a grinding machine with your own hands, then an electric motor with a power of 2.5–3 kW, developing about 1500 rpm, is quite suitable for you. In order for the sanding belt to move at a speed of 20 m/s when using such a motor, the drums must have a diameter of about 200 mm. What’s convenient is that if you choose an engine with these characteristics, you won’t need to make a gearbox for your grinding machine.
The drive shaft is connected directly to the electric motor shaft, and the second - driven - must rotate freely on an axis, which is installed in bearing units. In order for the abrasive belt to touch the surface of the workpiece more smoothly, the section of the frame on which the driven shaft is installed should be made with a slight bevel.
Make shafts for a belt sander with minimal financial costs possible from chipboards. Simply cut square blanks of 200x200 mm in size from such a plate, drill central holes in them and place them on the axle with a package with a total thickness of 240 mm. After this, all you have to do is grind the resulting package and make it into a round shaft with a diameter of about 200 mm.
Drawings and detailed analysis some parts of a machine made of wood.
Wood belt sander (click to enlarge)
Table tilt adjustment mechanism Plate block Belt tensioner
The technique of making a machine for the embroidery process is very simple and easy. To independently create such a device to facilitate creative process possible with a minimum of effort and time. You will only need about an hour of free time from embroidery and about three hundred rubles.
Even the most inept girl can build such simple equipment. The proposed technique for manufacturing the device will allow you to easily see the wrong side of the product, since the machine has a rotating frame part for a full turn of 360 degrees. In addition, such a machine is quite convenient for fixing hoop frames or for installing a frame made by yourself from polyvinyl chloride pipes.
So, for this model of the machine you will need to purchase polyvinyl chloride pipes intended for laying electrical lines. They are freely available in any specialized electrical products store. Polyvinyl chloride pipes, which are used to create water supply systems, are unacceptable in in this case, since they are connected using special equipment, and the pipes for electrical wiring are perfectly fixed in the grooves of the connecting part.
Necessary materials:
1. Saw for metal products;
2. Wing bolt 5 cm long, 2 pieces;
3. PVC pipe with a diameter of 2 cm;
4. Corner connections and tees;
5. Fasteners for plastic products in the form of half rings;
6. Rubber seals, 2 pieces;
7. And, of course, the main thing is desire and perseverance.
You need to understand that the parameters of the machine directly depend on the initial size of the hoop frame. Therefore, it is first necessary to make a frame design. To do this, you need to saw off four pieces of pipe, which are connected together with four corner connecting elements.
Next, you need fasteners for plastic pipes assemble into one fixing device; to do this, you need to fasten two fasteners with a bolt, and fix the rubber seal between them.
The third stage is the process of fixing the frame-hoop into fasteners, the diameter of which is 2 cm and 2.5 cm. The hoop itself in the form of a frame must be made of polyvinyl chloride pipes, the diameter of which is 2 cm. But the frame needs to be fixed into a fastener, the diametric parameter which is 2.5 cm. A fastening element with a diameter of 2 cm is suitable for the design of the machine.
So, focusing on the frame, it is necessary to cut a pipe for the installation of a machine tool. You need to be careful and remember to maintain the required step of 15 mm, which is equal to the thickness of two fasteners. Subsequently, the cut pieces of pipe must be connected using adapters - triple and corner. Any available metal rod it is necessary to heat it up and use it to drill two holes through for subsequent fixation of the frame using screws and fasteners. Then, you need to fix all the workpieces and connect them with a bolt.
The configuration of machine equipment can be very diverse. It all depends on the location of the machine, desire, design abilities and expected dimensions. The machine device can be built for embroidering on a table, on a sofa or on the floor. All this affects the height of the machine. In addition, if necessary, additional storage areas for all “inventory” can be made. These can be additional shelves for drawings, cases for needles and threads, as well as drawers for fabrics.
Such a simple machine is quite easy to use and does not require special effort when setting it up, and also has a non-bulky design, which is very practical in small room.
As a result, after recreating the entire action plan, you should get an embroidery machine of the following sizes:
1. Hoop in the form of a frame measuring 45 cm in length and 30 cm in width;
2. The base of the machine is in the form of a frame for desktop version the length is 55 cm and the width is 35 cm. If you want to make a machine that will stand on the floor, it is recommended to make the base of the machine a little wider, preferably 55 cm long and 45 cm wide. This will ensure better stability;
3. The elements on which they are fixed are 45 cm long;
4. The bar for placing additional storage places must correspond to the length of the machine base pipe, it has a length of 55 cm;
5. The pipe, which is designed to hold various cases, should have a length of about 15 cm and connect the base of the machine and the bar for extra space storage;
6. The height of the machine for the table should be about 25 cm, if manufactured floor structure, its height should be 75 cm;
7. Holders for lighting fixtures and cases for drawings should have a length of about 20 cm, their quantity is determined purely individually, but as a standard they are made in the amount of 4 pieces.
Standing device for various additional elements, like organizers for sets of needles and threads, can be made completely separately from the machine. During embroidery separate design can be placed near the machine. This is quite convenient, since there are no unnecessary cluttering parts on the machine, and you can reach the right tool easy and fast. Pipe fixing fasteners are attached to the holes made with inside additional details. If it is necessary to have several cases or organizers, it is necessary to secure several pipes horizontally using fasteners. One of the three pipes, namely the top one, must be secured using an angle fitting that has an angle of 45 degrees. If desired, you can fix two or more additional parts on one horizontal pipe, taking into account the length of each part. That is, if it is necessary to fix two cases on one mount, the length of each of them is 28 cm, then the length of the required pipe should be 56 cm long.
This machine design is for those who want to quickly make a small drilling machine, but has no desire or ability to work with hardware.
A drilling machine made of plastic pipes has a number of advantages compared to a machine made of iron:
- Easy to make.
- Easy.
- Easily repeatable without any drawings.
Pictured are the parts you will need. Almost all of them can be purchased at plumbing and hardware stores.
Please note that in addition to the plastic parts, the design also contains two wooden ones. This is the base of the frame and the mounting base for the drill itself.
The parts are as they will be soldered.
What pipe diameter should I use? - You decide. It all depends on the size of your drill. I took the diameter 25 mm.
Let's start assembling the drilling machine.
A movable unit that is attached to the lowering and raising handles. The middle crosspiece is larger in diameter so that it moves smoothly along the pipe. She doesn't get drunk, she just gets ready. Next, we solder the central unit on which the drill will be attached. The crosspieces are taken of the same diameter as the tubes on which it will ride. You cannot take it with a larger diameter - there will be too much play, and in order for it to move along the pipe without problems, the pipe must be ground down with sandpaper.
We assemble the entire structure with the base of the machine.
Springs have been purchased. You can try to find similar springs in an old mattress.
Drill assembly.
The machine is ready. The base is wooden, pre-cut and painted. In the center there is a hole for the free movement of the drill.
The drill is secured with plastic clamps. You can also use a drill with a pistol grip, after holding the trigger.
When soldering the machine, be especially careful: use gloves to avoid getting burned.
This is the small machine I came up with, which is well suited for drilling electronic circuit boards and small metal or plastic products.
IN general use You will definitely find it in everyday life.
When installing indoor water supply, sewerage and heating pipelines, plastic pipes have to be cut in large quantities. It is not recommended to use improvised means for this due to many potential problems in the future.
Needed for slicing professional tool. And it’s better to take a special pipe cutter for polypropylene pipes, the use of which guarantees an even cut without burrs.
We will tell you how to choose equipment for cutting polypropylene pipes, describe the device and principle of operation, and also outline the main criteria for choosing pipe cutters.
In stores, tools for cutting polypropylene (PP) pipes are offered in a variety of ways. These are both manual mechanical and electrical devices.
Each of them has its own merits. The most suitable equipment should be selected based on the volume of work and its complexity.
Polypropylene pipes can be cut using scissors or a roller tool - the first option is cheaper, and the second is more efficient in operation
When choosing equipment for cutting polypropylene pipes, the main attention should be paid to two points:
- The blade must be made of alloy steel.
- Each pipe cutter model has two indicators - minimum and maximum size pipes. This range should be selected so that it is sufficient to complete the work.
The body material of such equipment is usually made of metal. And it's best when it's aluminum, not steel. A pipe cutter with aluminum handles is light in weight and requires less effort to operate. Soft polypropylene pipes do not require excessive effort when cutting. An aluminum tool will cope with the resulting loads without problems.
A pipe cutter can have replaceable or non-replaceable cutters. Sooner or later they will wear out. In the second case, the tools will have to be purchased again. However, if the cutting apparatus is needed for a one-time job, then it is better to take more cheap model with permanent equipment.
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Due to inexperience, the slightest tilt in the hands leads to the formation of a crooked end, which then has to be sharpened. And if the pipe is also wrinkled, then it will need to be straightened from the inside with a calibrator.
Pistol pipe cutters with a ratchet mechanism also belong to this type. They are much easier to work with. You have to apply very little effort for cutting, and the cut is more even.
The return of the knife to its original position occurs entirely as a result of pressing a button due to a spring. This best option for cutting polypropylene pipes with thicker and harder walls.
Option #3 – roller
The next type of pipe cutter is a roller cutter. It has one or more rollers in its design. This tool looks like a hook. Inside this hook there are movable wheels on which the pipe being cut rests.
The cut itself is made by another cutting roller-knife, which is pulled out from the handle on a telescopic extension.
Due to the presence of a telescopically extendable cutter in the design of the roller pipe cutter, it can cut pipes of a wide variety of diameters - they just need to be of a sufficient cross-section to fit into the hook
Cutting polypropylene occurs as a result of turning the roller pipe cutter around the pipe clamped in it. Here it is important to rotate it so that the cutting line in the plastic does not go away from the starting point.
The cutting roller should end the circle in the same place where it started. If you have to cut thick pipe walls, you will need to make a revolution around the pipe several times, gradually pressing the cutter deeper into the plastic by turning the screw on the handle.
This type of pipe cutter also includes a roller rotary tool with several cutting rollers on a circular clamp, but it is more intended for cutting products made of steel and cast iron
At correct use and accurately holding the knife along the line, the cut as a result of using a roller pipe cutter turns out to be perfectly even. In this regard, it is comparable to a guillotine.
But it cuts pipes much faster, but also costs more. Plus, the slightest accidental shift of the knife to the side leads to the appearance of burrs at the cut site, which must be subsequently removed.
When cutting polypropylene with a roller pipe cutter, do not over-tighten the handle, pressing the blade disc too hard against the surface being cut. Microcracks may form in the plastic, which will reduce the strength of the pipe and may lead to chips at the end.
Everything should be done smoothly and slowly. This is especially true when working with thick-walled and large-diameter sewer pipelines.
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