Types of rollers for a profile pipe - features, purpose, use. Drawings and instructions for making do-it-yourself rollers for a profile pipe Rolls for rolling a profile pipe

Bending profile pipes is a fairly common procedure, for which a special device is used - a pipe bender. You can make a pipe bender for a profile pipe with your own hands, or you can buy it on the construction market or in a store.

One of the simplest types of pipe bender for profiled pipes

Serial devices differ in principle of operation, they can have different types of drives, however, certain experience is required to work on any of these devices. Limits the use of devices manufactured in a production environment, and the fact that they are not cheap. A good way out in all such situations will be the independent manufacture of a device designed for bending profile pipes, for which you can use improvised means.

Required structural elements

The scheme of operation of the pipe bender is very straightforward

To make a pipe bender with your own hands, you can use the drawings of various designs. Their choice is determined mainly by what materials you have. Most often they opt for front-type pipe benders, the design of which includes:

• three rollers (shafts), which must be metal;
• drive chain;
• axes of rotation;
• a mechanism that will set in motion all the elements of the device;
• metal profiles from which the frame of the device will be made.

Very often, a profile pipe bending machine is made with rollers that are made of wood or polyurethane. When choosing such materials, one should take into account the strength characteristics of the pipes that will be bent. If this requirement is neglected, then the working elements of a home-made device may simply not withstand the load and collapse.

Drawing of a pipe bender: the design of the pressure roller attachment is visible in the section

To understand how to bend a profile pipe on a home-made device, it is important to understand what technology this process uses. As a rule, pipe benders use the principle of rolling or rolling, which minimizes the risk of fracture and damage to the pipe.

To make a bend on a profile pipe using such a device, it must be inserted between the pipe bender rollers and turn the handle. The use of such a simple bending device makes it possible to obtain bends on a profile pipe that fully correspond to the specified parameters.

Pipe bender using a jack

To make a simple machine for bending profile pipes, you will need the following structural elements:

• ordinary jack;
• metal profiles and a shelf necessary for the manufacture of the frame;
• springs with high strength;
• shafts in the amount of 3 pieces;
• drive chain;
• a number of other structural elements.

When using such a device, the operation of which can be seen in one of the videos below, the pipe is placed on two side rollers, and the third one is lowered on top of it, creating the required force. To give the pipe the necessary bend, you should turn the handle that drives the chain and, accordingly, the equipment shafts.

Inverted jack option

Pipe bender manufacturing process

To make a device for obtaining a bend of profile pipes, you must perform the following procedures.

• Prepare a reliable frame, the elements of which are connected by welding and bolting.
• According to a previously prepared drawing, install the axis of rotation and the shafts themselves, two of which are placed above the third. The distance at which the axes of such shafts are located determines the bending radius of the profile pipe.
• To drive such a bending mechanism, a chain drive is used. To complete such a transmission, it is equipped with three gears, and the chain itself can be picked up from an old car, motorcycle or other equipment.
• To bring such equipment into action, a handle is needed, which is connected to one of the shafts. It is due to such a handle that the required torsional force is created.

Drawings of a pipe bender for professional pipes

Pipe bender manufacturing instructions

It is not difficult to make a pipe bender for a profile pipe on your own if you follow the following technological sequence.

• Gears, bearings and rings are placed on the pressure shaft, which are connected to it with a key. First, a drawing of such a shaft, a cage for bearings and rollers is developed, then these parts are machined, which is best entrusted to a qualified turner. In total, for this device, it is necessary to make three shafts, one of which is suspended on springs, and the other two are located on the sides.
• Then it is necessary to drill holes in the rings, which are necessary for making grooves and threading.
• Now it is necessary to make a shelf, for which a channel is used, in which holes are also drilled and threads are cut, which are required when mounting the pressure shaft.
• After completing the preparatory measures, the entire structure of the equipment must be assembled, for which welding and bolted connections are used. First of all, the frame is mounted, which also serves as the legs of the pipe bender.
• The next step is to hang the shelf with the pressure shaft attached to it, for which springs are used. After that, it is necessary to install side support shafts on a home-made pipe bender, on one of which a handle is attached.
• The final touch is the installation of a jack on the pipe bender.

Some subtleties of the installation work:

• the pressure shaft, fixed with dowels, is additionally screwed to the shelf;
• installation of the pressure roller is carried out according to the following scheme: the shaft is installed on the shelf, to which the nuts for the springs are preliminarily welded, after the installation work is completed, the shelf is turned over and suspended on the springs;
• chain tension is carried out using a magnetic corner, which is used as a holder;
• when twisting the stars, dowels are used, which are pre-made from the grower;
• the drive handle for the bending machine is made with a turning tube;
• a jack on such a home-made device is installed on a suspended platform, for which bolted connections and welding are used.

Production of a hydraulic pipe bender

On the Internet you can find a lot of photos and videos on how to independently make a device for bending profile pipes with a hydraulic drive. The manufacturing process of such a pipe bender, equipped with a hydraulic cylinder, an injection device and pipe stops, is a rather laborious undertaking.

In the drawing and in the design of such a pipe bender, the following elements can be distinguished:

• hydraulic type jack with a lifting capacity of at least 5 tons;
• shoe;
• rollers in the amount of 2-3 pieces;
• powerful metal channel;
• thick metal plates and other details.

To perform the required bending of the profile pipe using a hydraulic device, it is necessary to insert it into the shoe and fix both ends of it. After that, you need to use the jack, which, with its rising rod, presses on the roller that acts on the pipe and bends it. After the required bending angle is obtained, the process can be stopped and the pipe can be removed from the pipe bender by turning the jack handle several times in the opposite direction.

Pipe bender for profile pipes in finished and painted form

Clamping roller moving platform Shaft installation Chain with tensioner Assembly view

To independently make a hydraulic bending device for profile pipes, a photo of which can be found on the Internet without any problems, you must perform the following procedures.

• According to the drawing or photo, a structure is made for mounting the shoe and rollers, as well as the frame of the equipment.
• A metal plate is attached to the lower platform, on which the jack will be installed. After that, such a device is fixed with bolts and a drive handle is installed on it.
• The most important thing is to find suitable rollers for the profile pipe, which should tightly wrap around with their working part. If desired, rollers for a profile pipe, which are installed on a channel at the same height, can be made by hand. The shoe is installed below the rollers, and their relative position is determined by the required bending radius.
• To fix the rollers and the shoe, bolts are used, the holes for which are made according to the dimensions indicated in the drawing.

Drawing of another version of the pipe bender

Pipe bending methods using a homemade machine

The question of how to bend a profile pipe with a homemade pipe bender is unlikely to confuse you if you read a few more recommendations. On hydraulic machines, it is possible to successfully bend profile pipes from different materials, as well as thick-walled products. Such an operation can be performed both by cold and hot methods, which involve preheating the pipe section.

Thus, a manual hydraulic bending machine can be used to act on a pipe in two ways:

Another variation with a jack

Cold bending is the simplest bending method and is used for pipes made from ductile materials. The subtlety of such a process is the filling of the pipe before the flexible sand, salt, oil or cold water. This allows you to get a better bend without significant deformation of the pipe.

If you are interested in the question of how to properly bend a profile pipe with thick walls or made of materials of increased rigidity, then the answer to it will be the use of the hot bending method.

To the question of how to bend a profile pipe as accurately as possible and without unnecessary labor, some useful tips from qualified specialists will answer.

Removable rollers of various shapes will allow you to comfortably work not only with profile pipes, but also with round ones.

• In manual pipe benders for bending profile pipes, you can not use sprockets, but assemble a structure based on a single drive roller. Instead of a clamping screw, a jack is often used in such pipe benders.
• If you are bending according to a template, then so that the pipe does not slip off it, you can use metal hooks as stops.
• If it is necessary to bend a profile pipe under a large radius, it is best to use a pipe bender with three rollers.
• To get a more versatile bending machine, you can make its thrust rollers movable. So you can change the bending radius of the pipe.

In order to strictly observe the dimensions of the required pipe bend, it is best to perform such an operation using a template that is made of wood. Even the simplest manual pipe bender using such a template will allow you to bend a profile pipe with exact observance of the specified parameters. By the way, such templates are mainly made to implement the simplest manual bending methods.

Do-it-yourself pipe bender for a profile pipe - diagram, drawings, video

We make a pipe bender for a profile pipe with our own hands. Stages of work, diagram, design drawings and tips for working with a homemade pipe bender.

Homemade pipe bender for a profile pipe: device and manufacturing nuances

The need for a reliable and simple device for bending profile pipes arises when the home craftsman begins to work seriously with metal. Pergola frame, carport, garden bench, workbench…

These and many other designs turn out to be strong and beautiful if the profile metal for them is carefully bent on a special profile bender.

There is always an economical alternative to buying a ready-made machine, since you can make a pipe bender for a profile pipe with your own hands in your home workshop. Before the first workpiece is clamped in a vice, we suggest that you get acquainted with the principle of operation and the existing varieties of homemade pipe benders.

How does a pipe bender work?

The principle of operation of this device is simple: a profile pipe is placed between three support shafts. The central shaft creates pressure that bends the metal at the desired angle.

To bend the pipe in one local area, a point machine is used.

If you need to get an arched profile, then a rolling bending machine is used that combines the bending of the metal with the broach.

Varieties of pipe bending machines

Depending on the drive that transmits force to the profile metal, there are three types of pipe benders:

• mechanical (pressure is created manually using a central screw or lever);
• hydraulic (a hydraulic jack is used);
• electrical (bending force creates an electric motor);
• electro-hydraulic (hydraulic cylinder is driven by an electric motor).

It should be noted that a rolling pipe bender with a manual profile drawing is designed for a pipe with a small section (maximum 40x40 mm). It is impossible to stretch a large profile manually. For its bending, powerful machines with an electric broaching mechanism are used.

How to make a bending machine with your own hands?

The basic principle that should be followed when developing a drawing of a home-made pipe bender is the maximum simplicity of design and reliability.

The spot bending machine can be assembled from two pieces of channel, four corners and two scraps of pins from tractor tracks.

The bending of the pipe in it is performed by a standard hydraulic jack with a force of at least 5 tons. A steel "shoe" is installed on its working rod. It can be ordered from a turner or made yourself from an old pulley, the width of the “stream” of which is equal to the width of the profile pipe. By cutting off a half from the pulley and drilling a seat for the jack rod in it, a hydraulic drive mechanism is obtained.

The frame of the homemade device consists of four corners (shelf 60-80 mm) welded to a steel plate. Two channels are welded parallel to the upper ends of the corners. Holes are symmetrically drilled in their walls to control the angle of bending of the workpiece.

The manual pipe bending machine is brought into working position very simply:

• Two steel fingers are inserted into the holes on the channel and the stop rollers are mounted on them.
• The jack with the shoe is raised so that a profile pipe passes between it and the stops.
• Having installed the pipe, they work with the jack handle, creating a bending force.

It is also quite possible to build a rolling manual pipe bender for a profile pipe on your own. For its manufacture, 2 linear meters of a channel will be required (wall height 15-20 cm), from which the base and racks are cut.

For the manufacture of rollers, six short pieces of steel pipe are taken. It will act as a holder for the bearings. Therefore, its inner diameter must be equal to the outer diameter of the bearing. Having ordered three shafts from the turner for mounting the bending rollers, they begin to weld the frame.

For the machine under consideration, the extreme right support plays the role of a guide that sets the profile bending angle. It is mounted on a channel hinged to the main frame using conventional door hinges. The jack rests against the turntable with its working rod and raises it.

By rotating the handle, mounted on the shaft of the intermediate stop, the profile is pulled through the machine.

You can adjust the bending radius of the profile not only by tilting the rotary channel, but also by the outer rollers. To do this, they are not welded tightly to the frame, but are made movable (holes are drilled in the channel and base plates).

Instead of a hydraulic jack, a screw car jack can be used to lift the outer roller.

Do-it-yourself pipe bender for a profile pipe - device diagrams, photos and videos

Learn how to make a pipe bender for a profile pipe with your own hands. Design options, description of manufacturing features, photo and video materials.

How to make a profile bender with your own hands

When arranging a site or in preparation for the summer and garden season, there is a need for arcs from a profile pipe. They are needed when constructing a greenhouse, assembling a gazebo or a canopy. It is unprofitable to buy already bent arcs - the price is two times higher than for the same flat rolled product. The way out is to do it yourself, and in order to facilitate the process (it’s very difficult with your hands), you need to make a pipe bender for a profile pipe. You will need a channel or corners, rolling rollers and some more details. Of the tools - a grinder with a disk for metal, a welding machine, a ruler.

Profile bending design

The machine for bending a profile pipe is structurally different from the usual one. This is due, firstly, to the greater resistance of the profile to bending loads, and secondly, to the fact that the bending radius is usually required to be large. Therefore, there are three rollers in the design. Two of them are installed permanently, one remains mobile. With the help of a movable roller, the radius of curvature changes. In general, there are two types of pipe bender for a profile pipe: with an average movable roller and with an extreme one (right or left - as desired).

Do-it-yourself pipe bender for a profile pipe can be made in different sizes

Pipe bender with middle movable roller

Two extreme rollers are fixed on the body. They are raised above the base plane. For the middle roller, a special U-shaped frame is brewed. In the middle of its jumper, a long clamping screw of large diameter is installed. A third roller is attached to the lower end of this screw (can be welded). By rotating this screw, the roller lowers and rises, changing the bending radius of the profile pipe.

Design of a pipe bender for a profile pipe with a movable middle roller

A cloud is welded to one of the fixed rollers, with the help of which the pipe is rolled through the machine. In order to be able to apply less effort for rolling, two fixed rollers are connected by a chain. For efficient transmission of torque, sprockets are welded to the rollers (possible from a bicycle), a chain is selected for them. Such a simple mechanism makes bending a profile pipe much easier.

With extreme movable roller

In this design, the right or left roller is made movable. It moves along with part of the base. This part is connected to the rest of the frame with powerful metal loops.

Drawing of a bending machine for a profile pipe with a lifting platform

You can change the height using a jack, as shown in the drawing. The height of the platform in this case is selected depending on the height of the jack. The bending radius is changed by lifting the movable part of the table.

Pipe bender for a profile pipe with a lifting platform

Unlike the previous design, this pipe bender for a profile pipe is driven from a central roller - a handle is welded to it. To reduce the force required, it is also possible to weld the sprocket to two fixed rollers and transmit the torque using a chain.

What materials and design nuances are needed

The base of the pipe bender is made from a channel or two welded corners. The thickness of the shelves is at least 3 mm, select the width of the shelves and the back of the channel according to the available parts. One rule - the base must be massive and reliable.

Several holes can be made along the edges of the platform. Through them, you can fix the machine to some kind of heavy base using large-diameter self-tapping screws. Fixation is necessary, since when bending pipes with a thick wall, considerable effort has to be applied and it is more convenient to work if the machine is firmly fixed.

This is how the bed looks like in welded racks for attaching a movable roller

A few words about rollers. They should be made of good quality, preferably hardened steel. It is on the rollers and on the axles that hold them that most of the load falls.

It is necessary to say about the form of rollers. They should not be smooth - there should be rollers along the edges that will not allow the pipe to “walk” during rolling. Only under such conditions will the arc from the profile pipe be even, and not twisted. Ideally, each pipe size needs its own rollers. But then the design becomes more complicated - they must be made removable, a reliable method of fastening should be thought out. The second option is to make rollers of complex shape, such as in the photo. Carve several steps for different sizes of pipes.

Rollers for bending profile pipes of different widths

The same photo shows that the upper part of the bed is uneven, but notched. With the help of such teeth, it is possible to rearrange the rollers at different distances and thus also adjust the bending radius.

In general, they assemble home-made bending machines for shaped pipes from what is at hand or what they find / buy inexpensive. Who has the opportunity - grinds rollers, inserts bearings. Those who do not have such an opportunity use what they have - up to the bushings from bicycle wheels. In general, it is necessary to understand the design and

Tricks to make pipe bending easier

Bearings are used to make the rollers move better. But, in principle, for a homemade pipe bender, which will be used only occasionally, you can simply make holders from a corner or channel. Make a hole in them, which is slightly larger than the axis on which the roller will be mounted. Pass this axle with a roller put on through the holes of the holders and somehow fix them (at least weld a couple of points that will be stoppers). During operation, for a better move, lubricate the friction points with a thick grease such as Litol. This is not suitable for industrial and semi-industrial production, but for making arcs for a greenhouse or a gazebo with your own hands - just right.

Example of turned rollers

There is another trick that helps to reduce the required force when bending a profile pipe. You can use the principle of increasing transmission as in a bicycle. By the way, you can use sprockets from a bicycle. In this case, the handle that drives the rollers is welded to a small asterisk. It is installed somewhere on the body. Larger sprockets are welded on the shaft axis (but the teeth with the same pitch). All this is connected by a suitable chain.

With such a torque transmission device, an electric drive is not needed - it will be easy to work

And one more improvement - with the constant use of a pipe bender for a profile pipe, it makes sense to mechanize it. In this case, they put a motor that runs at low speeds.

The procedure for bending a profile pipe on homemade machines

You are unlikely to be able to get the required bending radius at a time - too much effort is required for this. It is impossible to create it manually. Get the required bend in several passes:

• First, the rollers are set so as to obtain a slight bend, the pipe is rolled in one direction, then it is removed from the rolls, unfolded and inserted with the other side. It is necessary to unfold to get an evenly curved pipe.
• With the same position of the rollers, it is pulled several times until the curvature is no longer added.
• If the required bending radius is not reached, change the position of the roller and repeat the steps again.

Electric tube bender

The change in the bending radius is obtained gradually, otherwise you cannot make an arc from a profile pipe on a home-made pipe bender. What if you need to repeat the same bend? Make a graduation - note to what height the roller moved, how many times it was rolled in each position. When repeated, the differences, if any, are insignificant.

The complexity of bending lies in the fact that there is no scale and it is difficult to get the intended bending radius without experience. Sooner or later you will get it, but a lot of material can be spoiled.

How to bend a profile pipe without a machine

There are two ways to get an arc from a profile pipe without a profile bender - using welding and a template. Let's start with welding.

Get an arc by welding

The profile pipe is cut with a grinder on one side. They are made after 15-30 cm, depending on the required radius, section and wall thickness. The cuts should not touch one side - the one that will be outside.

The result of bending by welding

The spare part prepared in this way is bent, giving the desired bend. For reliability, the edges of the arc can be fixed by welding a rod to them. Then they pass through all the cuts by welding, welding them. And the last stage is the grinding of the welding spots and the treatment with anti-corrosion compounds.

Using a template

Thin-walled profiled pipes can be bent by hand using templates. If you need some special shape, it can be cut from a piece of thick plywood or chipboard, fixed to the table with clamps. On the workbench, where we will bend the pipes, we make 8-10 holes. The template is placed near these holes.

The process of obtaining an arc from a profile pipe using a template

At one end of the pipe, the holes are repeated; with their help, the pipe is attached to the workbench. Now the free end of the pipe begins to be pulled smoothly, forming a bend that repeats the shape. You need to pull smoothly, without jerking.

The template can also be made on the ground. Pipe-pegs are driven into the ground (at least half a meter deep). They form the required arc. For emphasis, two additional stakes are hammered, which are located away from the arc. The distance that you need to step back to the side is slightly more than the width of the pipe.

Pattern on the ground

Having inserted the pipe, it is pulled towards the arc. Great effort is needed, hard work. It can only be obtained with a thin-walled seamless pipe. The seam has too much resistance in the seam area. It is very difficult to overcome it manually.

Do-it-yourself pipe bender for a profile pipe

Home craftsmen often use a profile pipe. You can expand your creative possibilities with the help of a pipe bender, which you can do yourself

How to make a pipe bender for a profile pipe with your own hands

If you like to create unique building structures, engineering structures, good equipment for a home workshop will come in handy. When selecting specific types of equipment, it is necessary to pay attention to the mechanisms discussed in this article. To make a pipe bender for a profile pipe with your own hands - study the detailed instructions, videos, photos, drawings. With the help of these materials, it is not difficult to implement the corresponding project.

Electric pipe bender

Do-it-yourself pipe bender for a profile pipe: basic data

Before studying the working documentation and algorithms of installation operations, it is necessary to accurately determine the intended purpose of the product. A do-it-yourself pipe bender for a profile pipe must be designed for certain efforts, workpiece sizes, and materials. It is easier to establish meaningful criteria after familiarizing yourself with the parameters of fixtures tested in practice.

What are these devices for?

Elements of building structures of complex shape are created using different techniques:

• Fastening with bolts and screws is not always able to provide the necessary reliability. Such connections are destroyed by vibration, additional loads are formed.
• Welding has an excessive thermal effect, which destroys the original structure of the materials. To make the connection reliable and durable, a good qualification of the performer of the work is required. Special equipment consumes a lot of electricity. In some technological processes, expensive consumables are used and special conditions are created.
• Adhesive joints are limited resistance to loads and influences of various nature.

The disadvantages listed above are completely or partially eliminated if the workpiece is bent in the right way. In order to avoid damage, accurate dosing of loads and speeds is required. In some places, it is necessary to maintain the integrity of the walls with external supports.

To reproduce such techniques without errors, special devices, machines are used.

What engineering solutions will be applied in practice

With a relatively low strength of materials, it will be enough to use a suitable stencil.

The workpiece is wound on a roller, forming the required angle

To create the necessary force, a lever mechanism is installed here. A metal pin is used to fix the free section of the pipe. It is installed in suitable grooves of the "comb" before performing work operations.

Machine "crossbow" type

Using the example of this factory sample, it is easier to study the design features:

• The handle (1) regulates the automatic stroke of the piston in the opposite direction. This solution reduces the burden on the user.
• A hydraulic system is installed inside the body. When moving the handle up and down, a force of up to 150 kN is transmitted to the working piston (8). This is quite enough for fast bending of workpieces made of durable metals.
• The support rollers (3, 4) are installed in the required holes of the open frame (5, 9). They do not damage the surface of the pipe, but provide a secure fit.
• This removable segment (6) is designed to be bent at an angle of 90°. But with the appropriate configuration, you can install on a similar product of a different shape.
• The robust housing (10) is mounted on three supports (7). Rubber pads prevent the machine from moving during work.
• In addition to cleaning from dirt, occasionally check the condition of the oil filter (11). No other regulatory procedures are required.

For rolling, a mechanism with three rollers is used, which are movably fixed

Running in

In this technique, a workpiece of the desired shape is used. A pipe is pressed against it using a rotating roller and a lever.

With the right choice of technology, a straight pipe can be bent as follows
With the help of appropriate equipment create such decorative products

Important! Before bending a workpiece using a certain radius, you should study specialized reference books. They provide data on the permissible deformations of pipes made of different materials, with different wall thicknesses. If these instructions are violated, visible or hidden defects are formed in the finished products.

Relatively small mechanical loads on working tools are created by levers and manual force. To work with durable metals, the equipment is equipped with hydraulics, electric drives.

A stationary machine is useful for quickly completing large-scale tasks
The manual device is mobility, the ability to perform work in a limited space

Creating a do-it-yourself pipe bender for a profile pipe: drawings and other preparatory operations

A simple fixture for bending aluminum and plastic blanks is shown in this figure.

Such a device is not difficult to assemble quickly using improvised means.

For the manufacture of such a structure, a solid board is needed. After marking, a round profile is cut out of it with an electric jigsaw. The rest is used to make the support element. The created parts are rigidly attached to the supporting surface. For the strength of the joints, in addition to screws, clamps are used. Next, the pipe is bent by hand until the desired shape is formed.

Before creating this simple pipe bender for a profile pipe with your own hands, it is recommended to make an elementary drawing with dimensions. A template made of thick paper, cardboard, on which markings will be applied, will come in handy. It is clear that for the manufacture of more complex structures, it is necessary to prepare full-fledged design documentation.

Assembly drawing
Pipe bender with screw drive of the working shaft
The design is not difficult for self-manufacturing Professional drawing indicating the steel grade and other parameters
Such a simple device can be done quickly with your own hands.

It is not necessary to strictly adhere to engineering standards in order to make a pipe bender for a profile pipe with your own hands, a schematic image is quite enough. It is only necessary to specify all the dimensions, decide on the materials, the technological process and the components. The project will help solve several practical problems:

• In the process of preparation, it will become clear whether it is necessary to use welding and other special equipment.
• A complete list of necessary components will be needed for targeted visits to certain stores.
• We must not forget that the machine must be protected from adverse external influences using wood impregnation, metal painting.
• Some parts will be too difficult to make on your own. Appropriate orders should be placed with specialized workshops.

Important! When bending strong metal pipes, great efforts are needed. In order not to take unnecessary risks, you can use drawings of a proven design, or copies of an industrial design.

How to make a pipe bender for a profile pipe with your own hands

To make a pipe bender for a profile pipe with your own hands - study the detailed instructions, videos, photos, drawings. With the help of these materials, it is not difficult to implement the corresponding project.

Standard profile pipes of square or rectangular section are widely used in construction due to their high bending strength and low weight. In cases where the permissible load values ​​are exceeded, which occur during strong bending, the products are deformed and torn. To eliminate the negative consequences allows the use of pipes with a reinforced profile.

Profile pipe strengthening machine

Reinforcement means the formation of ribs at the corners of a square or rectangular profile during rolling on specially shaped rollers.

Pipes with a reinforced profile are characterized by high bending strength and are used to create curved structures of any complexity.

Strengthening the profile is carried out on specialized equipment.

Application area

To obtain the desired configuration, profile pipes are sequentially processed on machines for strengthening the profile, a forging block and a pipe bender.

The pipe bender allows you to bend profile pipes in a longitudinal section along a given radius. Such products are used in the installation of canopies, gazebos, visors.

Strengthening is a necessary step in preparing a profile pipe for making a curl by cold forging. The forging block allows you to create decorative elements from pipes with a square or rectangular section, curved in the most bizarre way. The resulting products are distinguished by volume, lightness, low price.

Design

The machine for reinforcing the profile by the principle of operation and design is in many ways reminiscent of a conventional rolling machine.

In addition to the frame and the motion drive, the main components of the machine for strengthening the profile pipe are:

1. Lower (support) shaft - 1 pc. It is leading, with its help the pipes move.
2. The upper shaft is clamping. Carries out the deformation of the profile - presses the pipe to the lower shaft.

The feed and take-up shafts are securely mounted on a massive base (case), which must ensure the stability of the installation during operation. The feed mechanism ensures the rotation of the shafts around its axis.

Process technology

The amplification process on the simplest machine is performed sequentially, with two pipe installations:

• The first step is to install the pipe on the rollers.
• 2nd step - rolling the first 2 symmetrical sides.
• 3rd step - reinstallation of the pipe (turn 90 0).
• 4th stage - rolling of the second 2 symmetrical sides of the profile.

Profile strengthening machine

Profile reinforcement is performed on a cold forging machine equipped with rollers for squeezing the profile pipe before bending it into a curl.

profile pipe

The rolling process depends on the wall thickness of the profile pipes and the grade of the material from which they are made.

Drive mechanism

According to the principle of operation, there are different types of wire mechanisms:

• manual;
• electric;
• hydraulic.

The machine with a manual drive is characterized by a simple design, compactness, and is designed for small amounts of work. Only a physically developed person can work on it. You will have to deform the metal with the help of muscle strength.

The machine with an electric drive for strengthening the profile pipe also does not take up much space. It works from an electric motor, the performance is high.

Hydraulic equipment is too bulky. Allows you to roll profile products with maximum dimensions. Designed for large volumes of work.

Functionality

Increased interest is enjoyed by multifunctional modules of a stationary type, which are equipped with:

• rollers to strengthen the profile pipe;
• rollers for rolling out the ends of blanks in the form of artistic elements;
• forging block for cold forging.

All operations are performed without readjusting equipment and changing tools. Modules allow you to make various decorative forged elements of different sizes and the required shape.

An example of a multi-purpose plant is a commercially available crow's foot (PGL) amplification unit adapted for several operations:

• reinforcement of the "crow's feet" type (crimping, squeezing);
• rolling the ends of the workpiece.

After such processing, the pipe is completely ready for the manufacture of a decorative curl on the forging block.

Making a machine with your own hands

It does not always make sense to purchase a professional machine. For one-time work, the simplest do-it-yourself installations are more suitable. The main thing is to have drawings, carefully study the principle of the device and the operation of the machine, select high-quality materials for workpieces and the necessary tools for assembly.

Scheme

Schematic diagram of a machine for rolling 2 types of profile sections in a section. Based on it, you can get an idea about the design and interface of the main components and the principle of pipe processing. In this case, the top shaft is the driving one.

Machine diagram

Accessories

The components of the rolling mill must not have chips, potholes, have a decent margin of safety, and be made of certain steel grades.

Shafts, axles are machined on a lathe. Some components can be bought at the store or removed from other mechanisms, for example:

• self-centering rolling bearings (4 pcs.);
• stars (4 pcs.);
• chain from a bicycle, moped.

To assemble the frame (base), you will need rolled metal (channel, pipes), sheets 5-10 mm thick. The base ensures the stability of the unit during operation.

Frame assembly

Rollers (2 pieces of each type) to reinforce the profile are best machined from alloy steel, for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.

The rollers and axles must be many times stronger than the pipes being processed. Otherwise, the rollers will often have to be replaced with new ones. The hardness of rollers on professional installations is at least 52 HRC.

Instruments

When assembling the machine, you will need the skills (as well as the appropriate equipment):

• turner;
• welder;
• locksmith.

Fastening by welding in some places can be replaced by threaded connections.

Required tools:

• drill, with a set of drills;
• wrenches of different sizes;
• level for setting the horizon line;
• caliper, tape measure.

Construction of incoming parts

Along the edges of the rollers, special rollers are machined, which securely fix the position of the pipe during rolling.

rollers

You can get the dimensions of the rollers for profile broaching from a kit from professional installations. Drawings of rollers and axles according to the obtained dimensions are not difficult to develop on your own. Below is an example drawing.

Roll drawing

Rolling of each profile size is carried out by rollers of the corresponding sizes. It is not easy to make a model with removable elements; for this reason, it is recommended to make rollers for strengthening the profile pipe when assembling the machine with your own hands in multi-stage. This will allow processing pipes of different sizes without reinstalling the rollers.

Both axles have the same dimensions but different lengths. On a longer axis (leading) fix the handle of the movement. Below is a drawing of the axis with a seat under the handle.

Drawing of an axis with a seat under the handle

Assembly work

The frame is created gradually, as the rest of the parts are assembled. The individual elements of the base are interconnected by welding or large-sized bolts.

The distance between the upper and lower axle depends on the diameters of the rollers. In the absence of accurate assembly drawings, the dimensions between the axles are determined empirically:

• install rollers on the axis;
• measure the distance between the axles;
• drill holes on the side walls of the frame for the installation of bearings;
• then the axles are removed to the side, they are engaged in the installation of bearings.

The connection of the axle and rollers is carried out in several ways:

• using a dowel, about 8x8 mm in size;
• welding through pre-drilled blind blind holes made with a large diameter drill.

The second method is available if there is a machine for manual arc welding or semi-automatic welding.

Next, the axis is inserted into the bearing, which is pre-fixed in the box, pre-welded to the wall of the frame from the inside. Reliability of fastening - maximum. First of all, axles with rollers are installed in the side wall of the frame where the chain drive is supposed to be located. Then the axles are inserted into the bearings fixed on the 2nd side wall of the frame.

After installing the main elements, the frame is strengthened:

• welding seams;
• threaded connections.

The assembly of the chain mechanism in practice also occurs with the determination of dimensions in place:

• the 1st sprocket is installed on the lower axle;
• on the upper axis - the 2nd sprocket;
• try on the chain, outline the location of 2 more stars.

Chain Assembly

The rollers should rotate without difficulty with the chain tensioned. The handle is welded to the drive axle last.

chain mechanism

For the movement feed mechanism in the form of a worm gear, you need to stock up on gears of the right size.

Movement feed mechanism

Special requirements are imposed on the coaxiality of the rollers: they must be located in the same vertical plane and be strictly parallel. Any misalignment will lead to uneven compression of the profile, which will significantly reduce the quality of the rolled product.

A machine made at home specifically for strengthening shaped pipes should not pose a danger to humans during operation. When assembling, you should:

1. Secure all moving parts as securely as possible. Eliminate their rebound during operation.
2. Provide protective shutters.

Properly assembled home-made installations are not inferior to professional models in terms of the quality of manufactured products.

What are the ways to give a square or rectangular profiled pipe the shape of a regular arc? How can home-made rollers for a profile pipe be arranged? And what solutions does modern industry offer? Let's try to answer these questions.

Why is it needed

Let's give some examples.

• The arched canopy is not only beautiful, but also practical: snow will never accumulate on it.
• A curved canopy over the porch looks much better than a simple one-slope design.
• The arched greenhouse is exceptionally durable, perfectly resists snow and wind loads.

By the way: assembling greenhouses from profile pipes is a good business, requiring only the notorious pipe bending rollers and a welding machine.

Types of rollers

What are they actually like?

Mechanical

The simplest design is mechanical three-roll rollers. It is these machines that can most often be found on sale; their price starts from about 15 - 20 thousand rubles. How are they arranged?

In full accordance with the name, the design is based on the drawing of a professional pipe with three rolls. One of them can be displaced relative to the other two in the direction perpendicular to the plane that unites them; a screw mechanism is used for displacement, which allows even a person with quite ordinary physical abilities to develop significant effort.

One of the rolls is equipped with a handle that allows it to be rotated and thereby pull the bent pipe.

Several modifications are possible to slightly improve the performance of the pipe bender:

• Combining the rolls with a common chain will ensure their synchronous rotation thereby preventing pipe slippage.
• A gear train can be used instead of a chain.
• The use of hardened rolls increases their resource several times.
• In addition, the rolls can be interchangeable, which will allow bending both profiled and round pipes without jamming.

Electrical

In this case, part of the manual work is transferred to the electric motor.

On sale you can find two versions of electric pipe benders:

• In simpler solutions, the electric motor is only responsible for pulling the pipe. The positioning of the bending roll is done manually.

• Advanced models of rollers use electricity both for pulling and for shifting the roller (of course, through a gearbox that multiplies the force).

hydraulic

This category includes both powerful industrial machines weighing tens of tons and relatively compact devices. Their common feature is the use of a hydraulic cylinder: by pumping up oil pressure in it, you can develop a huge force on the deforming roll.

bending radius

Regardless of the device of the pipe bender, a general pattern applies: the greater the thickness of the pipe (its section parallel to the bending radius), the greater the minimum bending radius. Here are the values ​​declared for their machines by one of the domestic manufacturers - they are quite typical.

Without pipe bender

It is technically possible, but the result is likely to be unsatisfactory.

The bending instruction is not so much complicated as it requires a large amount of preparatory work.

1. A template is made from wood or plywood with a surface shape that matches the arc you need.
2. A loop is attached to the template - a latch into which one of the ends of the pipe is inserted.
3. Further work, in fact, comes down to the application of brute force at its second end. Various levers can be used to increase the force.

crazy hands

A variety of schemes and drawings of rollers for a profile pipe with their own hands in recent years have literally flooded the Internet.

We will immediately disappoint the most economical readers: some of the parts will have to be ordered.

What exactly?

• The rolls themselves. They can be cylindrical, or with grooves for bending round pipes.
• Cages for bearings.
• When using a chain drive - sprockets.

Of course, without reference to a specific design, giving advice on assembling rollers is a thankless task.

• The drive handle must have a rotating handle. Otherwise, the first calluses on the hands will appear after a few meters of the stretched pipe.
• Bearings are better to take self-centering. Mounting both bearings of each roll exactly on the same axis at home is an unrealistic task; the slightest misalignment will increase the pulling force.

Rollers for a profile pipe are a tool that is not known to everyone. What is it and what is it for?

A little about the profile pipe

Traditional round tubular products are more familiar to the layman. They are used for water supply systems, drainage systems, as a cable sheath and much more. The profile pipe has an unusual shape.

The profile of a tubular product can have a different shape, but the following types are most popular:

• Oval. Products of this profile are found in radiator systems and as elements of decorative structures.
• Square or rectangle. This profile is used in the construction of load-bearing structures. This is explained by the high strength of the products under transverse load. The weight at which a conventional pipe is bent, a rectangular or square profile pipe can withstand without changing shape.

Mounting methods for load-bearing structures

When mounting load-bearing structures, the joining of elements is carried out in two ways:

• By Welding. Connection of elements by welding differ in durability and durability. This is especially important in places where there is a lot of pressure on the connection.
• With bolts. Such a connection is more profitable, since not everyone has a welding machine. Elements of greenhouses, canopies and racks can be connected with bolts.

Bearing parts, on which a large load is planned, are best done using I-beams or channels. These elements are not so beautiful, but they have high strength compared to a profile pipe.

Creating curved surfaces

In load-bearing structures, the profile pipe plays the role of a horizontal, vertical or inclined support for balconies, ceilings or roofs. But for canopies, canopies or greenhouses, you need to create a curved surface.

This is explained by several reasons:

• Aesthetic perception. Rounded shapes have a calming effect on the vision and psyche of a person.
• Wind and precipitation. The streamlined shape does not interfere with the wind, so with strong gusts of a rounded surface, practically nothing threatens. In addition, precipitation in the form of rain and snow does not linger on round shapes.

To create a curved surface, you need to bend the material. You can perform this action when heating individual sections with a gas burner.

This is the easiest way to bend, but it has some disadvantages:

• First of all, its implementation requires a large lever, a strong stop of the tubular product and great physical effort.
• Secondly, in this way it is impossible to achieve uniform bending.

You can create an even sector of the circle using rollers.

Types of rollers

For the production of a profile pipe and its bending at home and in a factory, completely different tools are required.

factory production

rolling- this is the main technological operation in the process of manufacturing profiled tubular products.

The whole loop looks like this:

• Flat blanks are rolled into a cylinder, the joint is welded.
• The resulting product is rolled through rollers, where the desired profile is formed under high pressure.
• The quality of the seams is checked.
• Products are calcined to relieve residual stresses from deformation.

For the production of large volumes, factories use the appropriate equipment. For example, at a full-fledged rolling mill of a large enterprise, pipe bender rolls weigh several tens of tons, and the force applied to them can reach several hundred tons. In this case, not a manual drive is used here, but equipment with an electric drive.

home production

Do-it-yourself rolls for a pipe bender must meet completely different requirements:

• Ease. The equipment should move without much effort.
• compactness. In a small room, the large dimensions of the machine will only complicate the workflow.
• economy. Powerful electric motors can be used to quickly roll workpieces. However, such consumption of electricity requires large expenditures for its payment. In addition, to work on such equipment, it is necessary to have appropriate wiring that can withstand high power.

At home, two types of rollers are used: electric (with motors up to 1.5 kW) and manual.

Manual rolls for a profile pipe are the easiest option. Such a device consists of three steel rollers, two of which are located on the same horizontal, and the third roller is lowered between them according to the principle of a clamp using a screw mechanism. A handle is attached to one of the rollers lying on the same line, which sets it in motion. The principle of operation of such a mechanism is as simple as its device: a profile pipe is laid on two rollers, it is pressed from above by a third roller, which bends the pipe under pressure. By turning the handle on one of the rollers, the pipe is rolled through the rollers. As a result, a smooth bend is obtained along the entire length.

If transverse grooves are made on home-made rollers for a profile pipe, then it will be possible to bend a round non-profiled pipe.

Do-it-yourself rollers for a profile pipe can be used for the manufacture of elements of greenhouses and canopies in a small volume. For the production of a large number of structures, such a device is not suitable.

It is much easier to bend a profile pipe on electric rollers. A simple mechanism consisting of a low-power electric motor and a gearbox is engaged in broaching and deformation of the pipe. A large gear ratio on the gearbox ensures the operation of the mechanism with a low power motor.

Using various drawings of rollers for a profile pipe, you can not look for suitable equipment, but make it yourself.

A profile pipe is an element of many building structures and frames. It is used in the construction of industrial and residential buildings. The main characteristic that distinguishes it from other types of pipes is not a round cut shape. A profile pipe is produced from a sheet welded and bent along in the desired shape. If necessary, you can make rollers for a profile pipe with your own hands - you will find drawings and explanations in this article.

Production of a profile pipe by rolling

Assortment of profile pipes

In the factory, two methods are used for the production of profile pipes from a metal sheet:

• hot method, in which a longitudinally welded round pipe is heated;
• cold method, in which rollers for a profile pipe are rolled over unheated metal.

The basis for the production is carbon, low-alloy, less often stainless steel. Modern factory equipment will make it possible to obtain a profile with high accuracy of seams and bends, since the process is controlled by transmitting data from a computer and receiving them from sensors that take readings with an accuracy of thousandths of a millimeter. Home-made rollers for a profile pipe cannot provide such detail, but they cope with the task of producing elements for home construction and household work. In this technique, consumables are made for fences and canopies, greenhouses and technical buildings, gutters and cable channels. It is not recommended to make a profile pipe for large-scale buildings at home. Factory equipment makes it possible to subject each manufactured element to test tests and check both the quality of the seam and the accuracy of profile calibration. The absence of such equipment does not give the master the opportunity to guarantee the quality of a homemade product.

Assembly of a machine for the production of a profile

The use of curved profile pipes

Do-it-yourself rolling machine for a profile pipe looks like a design for bending pipes. It consists of the following elements:

• carrier frame;
• roller system;
• pressing form:
• stop and levers for actuating the rolling mechanism.

In fact, these are two different mechanisms and only the frame can be similar. All structural elements are assembled from durable elements and welded: any flaws and negligence can result in an industrial injury. The machine itself is firmly fixed on the surface.

It is practically impossible to provide the required pressure manually: it is desirable to equip the press for creating a profile pipe with an electric drive.

In the machine for giving a rounded profile, the main thing is a press that twists a sheet of metal. Only a solid construction gives such pressure: the entire period of welding must be kept motionless. To simplify the work, the metal is heated and then rolled. After welding, the already round pipe is checked for the quality of the connection: an insufficiently even and clean seam will disperse when the rolling of the profile pipe from a round shape to a rectangular or square one begins.

Workpiece processing process

The finished straight-seam pipe is rolled hot or cold. At home, it is difficult to organize hot rolling, so the process is often carried out on already cooled metal.

The pipe is placed under a press of rollers that form the required shape.

Rolling is carried out gradually with a decrease in the distance between the upper and lower rollers. Sudden pressure leads to internal folds in the metal, which will affect the strength of the knees. The last rolling achieves the planned diameter and contour of the cut.

The pipe is checked for cracks and deformation of the metal in the bend area after each rolling. The area of ​​special attention is the seam area, it is the most vulnerable.

After processing with rollers, the pipe is calcined: this measure eliminates the stress of the metal layers and increases the strength of the structure as a whole.

Profile pipe bending

Masters rarely decide to independently manufacture a profile pipe, preferring to purchase ready-made factory-made material. The profile pipe is an inexpensive consumable item, so there is no need for bending with your own hands. A machine for bending profile pipes with your own hands is a more demanded equipment, since the element is sold in direct form, and ordering bending according to your own drawings is an expensive service. A curved or rounded profile is used for the construction and erection of decorative elements as it is more aesthetic. Frames and cornices, arcs of greenhouses and arches of gates can be made with your own hands. The simplest rollers for bending a profile pipe are assembled in a few hours. They will not provide industrial volumes and accuracy, but they will reduce the cost of production of individual elements.

Bending quality requirements

The simplest way to bend shaped pipes is incandescence and pressure. In this way, you can even create an acute angle, but you should not count on the accuracy and strength of the knot. Folds on the inner surface of the knee and cracks on the outer are guaranteed. Bending without defects is achieved only by gradually rolling the pipe on rollers and calculating the minimum diameter. The maximum bend angle is not standardized, the minimum is limited by safety requirements. A standard factory machine for bending a profile pipe sets the minimum diameters of a rounded bend, you can also focus on the same indicators when creating a home-made machine:

• pipes 20x20x2, 25x25x2, 15x15x1.5 - 56 cm;
• pipes 30x30x2 - 65 cm
• pipes 40x20x2 - 65 cm;
• pipes 40x40x2 - 180 cm;
• pipes 50x25x2 - 80 cm.

Machine drawings for home use

The simplest deforming structure can be assembled right in the yard or technical room, fixing all the elements on a dense shield or directly on the fence. Elementary models will help out if you need to bend several pipes in a single shape, for example, for mounting the upper arches of a greenhouse. Regardless of the selected bend diameter and the dimensions of the pipe itself, you will need:

1. A frame that follows the contour of the required arch. It is cut from a single piece of wood or assembled from a number of planks. According to this stencil, the pipe will bend.
2. An emphasis on one side of the frame. The gap between the stop and the stencil is made corresponding to the diameter of the processed pipe. The smaller one will make it difficult to install the element into the device, the larger one will not fix the knee firmly.
3. A block with which the pipe is manually pressed against the template.

Working with such a pipe bender is difficult: all efforts will have to be done manually. But the design will ensure accuracy when bending: it is possible to make several elements with an identical deformation angle on it.

The pipe bender for permanent use is assembled on a durable U-shaped frame. The following elements are required in his system:

• two rotating shafts fixed on the rail, along which the profile will pass during rolling;
• an extrusion shaft located above them, during the rolling of a profile;
• clamp or jack providing pressure;
• a chain with which a set of rollers will move.

To assemble rollers for a profile pipe with your own hands, you will need a welding machine and engineering skills. Inaccuracies in calculating the diameter of the functional shafts will make the device inoperable.

Video: working with a manual profile bender

Assembling a bending device with your own hands is a complex, time-consuming and expensive process. Against the backdrop of moderate prices for equipment, it is worth thinking about the rationality of the acquisition. Perhaps, for bending several elements, it is more profitable to contact the workshop, and for permanent work, purchase a factory model with a quality guarantee.