TPT September 2008

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September 2008 172 ›
Tube B ending & E ndforming T echnology
The electric axes automatically adjust
position, which enhances accuracy and
repeatability, while components are not
only produced ‘right first time’, but are
repeatable batch-to-batch without undue
reliance on operator expertise. And, since
all axis movements are set automatically, a
job changeover can typically be completed
within two to three minutes.
This multi-tool stack tube bender brings
with it fewer bend tool changes and less
downtime. The VGP 3D software allows
checking on-screen, providing a reliable
guide to component cycle times and
identifying any possible collision risk.
Because the PC-based control selects the
correct parameters, the guesswork is taken
out of tube bending and the most complex
of tubular components can be completed in
one cycle.
This new machine is also extremely
environmentally friendly since power is
only required during axis movements.
This means power consumption can be as
little as 10 per cent of previous generation
machines.
BLM Group UK Ltd – UK
Fax: +44 1525 402 312
Email:
Website:
BLM SpA – Italy
Fax: +39 031 715911
Email:
Website:
pipes used on a V8 twin-turbo, high-
performance petrol engine.
On conventional hydraulically-powered tube
bending machines, setups can take up to
two hours to complete and depend heavily
on individual operator skill and know-
how. In contrast, the BLM E-Turn uses
‘stacked’ pre-set tooling on each of its two
heads, thereby accommodating Freeman
& Proctor’s six sizes of tube and specific
bending requirements without incurring
significant setup time penalties.
A further advantage is that a repeat order
merely requires the operator to call up
the relevant program with the confidence
of knowing that there will be no material
wastage during setup and every finished
part will be correct to specification.
Complex components requiring radii of less
than 1 x diameter can be produced on the
E-Turn using the ‘bend boost’ device, which
can have its power modulated during the
bending process to avoid unsightly stress
marks on high-value components. X, Y,
Q, Z and R axis speeds are, respectively,
2,000/1,000mm/sec (depending on ‘boost
power’); 250º/sec; 1300mm/sec; 900mm/
sec; and 200º/sec.
These performance figures, combined with
precise control of the E-Turn’s 12 axes
of movement courtesy of Visual Graphic
Programming (VGP) software, significantly
reduces setup times. All parameters can
be stored and recalled without further
mechanical adjustment being necessary.
Freeman & Proctor Ltd, UK, is an ISO
9001:2000-accredited specialist in the
manufacture of high quality, fabricated,
tubular assemblies for aerospace and
automotive applications. The company’s
range includes high-pressure fuel pipes
(including double skin dual fuel and
hydraulic pipes), electrical conduits and
hydraulic pipes, and small bore fabricated
pipe assemblies.
In order to further improve its capabilities,
the company has installed the latest BLM
E-Turn ET52 all-electric CNC tube-bending
machine. This new machine is the largest in
the four-model E-Turn range and bends tube
from 6-52mm maximum OD. The machine
can accommodate a range of ferrous and
non-ferrous materials, including stainless
steels, nimonics and titanium alloys.
Because the complete head of the E-Turn can
rotate through 180°, it is capable of left- and
right-hand bending in automatic cycles with an
X axis accuracy of ±0.05mm, and Y and Z axis
accuracies of ±0.05°. However, in its primary
market of aerospace components Freeman &
Proctor has a limited demand for this mirror
image capability – components are, typically,
complex configurations in difficult materials
and called off in small batch quantities.
Typical aerospace components range from
engine pipe assemblies to complex fuel
by-pass manifolds used on jet engine after-
burners. Automotive components include
fabricated suspension struts used on a
high-performance sports car to air injection
All-electric tube bending for complex
aerospace tubular parts
 Fabricated tubular assemblies produced by
Freeman & Proctor Ltd for aerospace and
automotive applications
 The BLM E-Turn tube bender installed in the UK factory of Freeman & Proctor Ltd will bend tube up to 52mm
maximum OD