You can also order our FREE Rotary Draw Bending Guide wall chart.

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3 A re you looking for the latest techniques on tube & pipe bending? Ask for our FREE Tube and Pipe Bending manual shown here. It answers a lot of questions about bending, with tips and techniques to make better bends and make your work easier and more productive. You can also order our FREE Rotary Draw Bending Guide wall chart. Manual tube bender for prototype or low production. Produces tight radius bends in thin wall tubes with minimal collapse.

4 Look at what TFB can do for you! Since 1965, tube bending companies from around the world have looked to TFB for bending solutions. And for very good reasons! They know that: TFB designs and manufactures (in-house) high-degree-ofdifficulty bending tools. TFB tooling will perform to exacting specifications. TFB quality and expertise ensure longer tool life. TFB can provide tooling for any brand or size of bender. TFB can provide tooling for any size or shape (from 1/8" (3.175 mm) to 12-3/4" ( mm) round, square, rectangular, or extrusion). TFB promises honest delivery dates, not "wish-for" dates. If you re using our tooling, thanks for your trust. If not, please don't let this become a habit. Figure 1-1. TFB President Eric Stange inspects large rectangular mandrel. You can rely on TFB's four decades of experience to provide you with the correct: mandrels - close-pitch or regular wiper dies - square-back or tips clamp and pressure dies - carbide sprayed or serrated our patented Empty-Bending tools squaring and deburring blades - carbide or TL-17 end-forming tools - standard or special Kro-Lon, TFB s proprietary surface treatment For details, look through the following pages. Then call us to discuss your next project or any bending problems you are experiencing with your present tools. We don t create bending problems, we solve them! Figure 1-2. Five-piece, reverse interlocking tool set (2.00 O.D. x wall on 2.00 C.L.R.) for aerospace tube fabrication. 1

5 TFB Mandrels REGULAR (RP): Universal Flexing for standard tube & pipe CLOSE PITCH (CP): Universal Flexing for thinwall tubes Tube bending has come a long way since wet-packed sand cerrobend or cable mandrels. TFB has more than four dozen chrome and Ampro bronze mandrels readyto-ship, in the most common sizes from 3/8" (9.525 mm) to 3" (76.2 mm). In addition to the basic mandrels, TFB has designed many specialty hybrid mandrels, used for hydroforming, wave guide, tube-within-a-tube, bend-on-a-bend, sizing, bullet-nosed, expanding, plastic, sheathed, brute, and ultra-close pitch. Ultra-Close Pitch (UCP): Universal Flexing for very thinwall tubes BRUTE: Single Plane Flexing for large diameter tubes & pipe FORMED END: For standard tube & pipe PLUG: For heavy wall tube Figure 2-1. Types of Mandrels Wall Factor O.D. Wall = W.F. Mandrel Selection There are six common types of mandrels, as shown in Figure 2-1. There are many factors that influence which type to use. The most important considerations include: D of Bend (center line radius/tube O.D.) (see Figure 2-2) Wall Factor (tube O.D./wall) (see Figure 2-2) Ovality and wall thinning requirements Tube material Cosmetic considerations Size and location of weld flash TFB can provide the correct mandrels for any conceivable requirement. The chart on Page 3 shows a wide range of choices. We furnish the H style universal flexing, link mandrels. Our single-plane Brute mandrel has superior strength and straight ball alignment, ideal for high production or larger tubes. Mandrels are available for virtually any size of tube or pipe, as well as any square, rectangular, or extruded shape. All mandrels are available in standard pitch, close pitch, or the ultra-close pitch for extremely thin tubes. "D" of Bend C.L.R. C.L.R. = "D" of Tube O.D. Bend Mandrel materials are Ampco bronze or tool steel. Steel mandrels can be plated with hard-chrome, Kro-Lon, or titanium nitride. How a tube reacts to bending is shown in Figure 2-3. O.D. Figure 2-2. Bending Design Factors Outer Wall Thin Out Inner Wall Build Up Outer Wall Thin Out Inner Wall Build Up Outer Wall Thin Out Inner Wall Build Up Springback Tangent Lines Outer Wall 7 3 Inner Wall Neutral Axis 6 4 Clamp End 5 Neutral Axis (Clamp Die End) Tangent Lines Radial Growth Neutral Axis Clamp End Figure 2-3. Reaction of the tube to bending Tangent Lines Neutral Axis Clamp End 2

6 Tooling Selection Guide D of Bend = centerline radius tube outside diameter (2.0 C.L.R. 1.0" O.D. = 2 x D) D of bend 1 x D 1.50 x D 2 x D 2.50 x D 3 x D 3.5 x D Degree of bend Wall Factor = tube outside diameter (2.0" O.D..032 = 62.5 W. F.) wall of tube * 10 Ferrous P P P P Non-Ferrous P P P P P P 20 Ferrous RP-1 RP-1 RP-1 RP-1 RP-1 RP-1 P P Non-Ferrous RP-1 RP-2 RP-2 RP-2 RP-2 RP-2 RP-1 RP-1 P P 30 Ferrous RP-2 RP-2 RP-2 RP-2 RP-2 RP-2 RP-1 RP-1 P P Non-Ferrous RP-3 RP-3 RP-3 RP-3 RP-3 RP-3 RP-2 RP-2 RP-1 RP-1 P P 40 Ferrous RP-3 RP-3 RP-3 RP-3 RP-2 RP-2 RP-2 RP-2 RP-1 RP-1 P P Non-Ferrous CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 RP-3 RP-3 RP-3 RP-3 RP-2 RP-2 50 Ferrous CP-4 CP-4 CP-3 CP-3 RP-3 RP-3 RP-2 RP-2 RP-2 RP-2 P P Non-Ferrous CP-4 CP-4 CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 RP-3 RP-3 RP-2 RP-2 60 Ferrous CP-4 CP-4 CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 RP-3 RP-3 RP-1 RP-1 Non-Ferrous CP-5 CP-5 CP-4 CP-4 CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 RP-1 RP-1 70 Ferrous CP-5 CP-6 CP-5 CP-6 CP-4 CP-5 CP-4 CP-4 RP-3 RP-4 RP-1 RP-1 Non-Ferrous UCP-6 UCP-6 UCP-6 UCP-6 CP-4 CP-4 CP-4 CP-4 CP-4 CP-4 RP-2 RP-2 80 Ferrous CP-5 CP-5 CP-5 CP-6 CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 RP-1 RP-1 Non-Ferrous UCP-6 UCP-8 UCP-6 UCP-8 UCP-5 UCP-6 CP-4 CP-5 CP-4 CP-4 RP-3 RP-3 90 Ferrous UCP-6 UCP-8 UCP-5 UCP-5 CP-4 CP-4 CP-4 CP-4 CP-4 CP-4 RP-3 RP-3 Non-Ferrous UCP-8 UCP-10 UCP-8 UCP-10 UCP-6 UCP-6 UCP-6 UCP-6 CP-4 CP-4 RP-3 RP Ferrous UCP-6 UCP-8 UCP-6 UCP-6 UCP-5 UCP-5 UCP-5 UCP-5 UCP-5 UCP-5 CP-4 CP-4 Non-Ferrous UCP-8 UCP-8 UCP-8 UCP-8 UCP-8 UCP-8 UCP-6 UCP-6 UCP-5 UCP-5 CP-5 CP Ferrous UCP-6 UCP-6 UCP-6 UCP-6 UCP-5 UCP-5 UCP-5 UCP-5 CP-4 CP-4 Non-Ferrous UCP-6 UCP-6 UCP-6 UCP-6 UCP-6 UCP-6 CP-4 CP Ferrous CAUTION: UCP-8 UCP-8 UCP-6 UCP-6 UCP-6 UCP-6 CP-5 CP-5 Non-Ferrous UCP-8 UCP-8 UCP-6 UCP-6 UCP-6 UCP Ferrous BETTER CALL: UCP-6 UCP-6 UCP-6 UCP-6 CP-6 CP-6 Non-Ferrous UCP-8 UCP-8 UCP-8 UCP Ferrous TOOLS FOR BENDING, INC. UCP-6 UCP-6 CP-6 CP-6 Non-Ferrous KEY P-Plug or Empty-Bending RP-Regular Pitch CP-Close Pitch UCP-Ultra Close Pitch No. indicates suggested number of balls NOTE: 1. The Empty-Bending system (without a mandrel or wiper die) is recommended for applications above the dotted line. 2. A wiper die is recommended for applications below the dotted line. 3. H style, brute, chain link mandrel in regular pitch, close pitch, and ultra-close pitch. 4. All mandrels are available with lube holes and grooves and finished in chrome, Kro-Lon AMPCO bronze. 3

7 TFB Wiper Dies It's not the price of the wiper die itself that makes it costly or inexpensive. It's how the wiper die performs. A precisely machined TFB wiper die, one that can be positioned quickly and is properly supported by the Figure 4-1. With moderate thumb nail pressure, the bend die, will produce good wiper s leading edge must deflect evenly all around, bends, have a longer tool life, often to (0.13 mm to 0.26 mm). and will be the most cost efficient. Conversely, the most expensive wiper die is the one that takes longer to position, produces marginal bends, requires frequent operator repairs, and has more down time than running time. And it may even cost more. Figure 4-2. To prevent tube scratches and prolong tool life, the new TFB wiper die finishing process provides extraordinary polished tube grooves and C.L.R. machined surface. TFB wiper dies are available for round, square, and rectangular tubes and for shapes and extrusions. You can choose either Ampco bronze or steel, with optional Kro-Lon surface. Figure 4-3. Replaceable, round back, wiper die tips, available in aluminum bronze or alloy steel. Inventoried sizes range from 1 (25.4 mm) to 3 (76.2 mm). Figure 4-4. The ultimate wiper die, with Kro-Lon on special steel and lube holes on both tube groove and C.L.R. surfaces. 4 Figure 4-5. Conventional, square back, wiper die and wiper die tips, with standard and offset holders to clear collet and reduce drop length.

8 TFB Bend Dies, Pressure Dies, and Clamp Dies With four decades experience, TFB knows what combination of tooling is needed to exactly meet your specifications. For the proper bend die, factors such as tube O.D., C.L.R., bender size, degree of bend, and machine tool clearances are carefully considered. Dies may be hardened, at Rockwell C, with a penetration of 0.015" to 0.020". See Figure 5-1. Three types of pressure dies are shown in Figure 5-2. Pressure dies for benders with pressure die assist can benefit from grit blast or carbide spray tube grooves. This allows more advancing force without slippage. The length of the pressure die equals the arc length of the largest bend die, plus 2 x O.D. or the minimum length required to mount on the bender. Pressure dies with worn, slick, or oversized tube grooves prolong setup time, allow wrinkles, and cause excessive collapsed bends. Two types of clamp dies are shown in Figure 5-2. Clamp die length generally equals 3 x tube O.D. Without a sufficiently long, straight clamp area, special tube groove surfaces can be used, such as carbide spray, serrations, grit blast, or knurl. Less than 2 x O.D. for grip sections may require a compound clamp die and matching bend die clamp inserts. For multiple bend die machines, TFB can furnish stacked tooling from your bent tube print. Figure 5-1. Types of Bend Dies Figure 5-2. Pressure Dies and Clamp Dies 5

9 GENERIC TOOL HOUSES AND GARAGES HAVE ATTEMPTED TO FURNISH LOOK-ALIKE EMPTY-BENDING TOOLS... WITH DISASTROUS RESULTS. ALWAYS DEMAND THE PATENTED EMPTY-BENDING TOOLING MADE ONLY BY TOOLS FOR BENDING, INC. TFB Empty-Bending (Patent No ) After years of research, TFB developed and patented a tube/pipe bending system that: requires fewer tools (only bend die, pressure & clamp, see Figure 6-1) lowers tooling costs improves production produces high quality bends has faster setup time needs no lubrication (or removal of lube) less wall thinning Figure 6-2. Cross-section illustration of bent tube, showing compression of inner wall and stretching of outer wall. By eliminating the cost of a mandrel and wiper die, Empty-Bending not only reduces initial startup costs, but also provides ongoing production savings, quicker setups, drop-on-tooling, and no internal tube scratches. Figure 6-3. Empty- Bending tool sets for onepiece fittings on conventional bender. Figure 6-1. Empty-Bending Dies Figure 6-4. Tool set for 4.5 (114.3 mm) O.D. x 6 (152.4 mm) C.L.R. plastic-lined pipe. Gauge on left shows true radius groove tube. Gauge on right shows multiple radius tube groove. 6 1

10 Figure 7-1. Kro-Lon plated mandrel and wiper die. Note: when the Kro-Lon surface wears out, it can be re-surfaced. TFB Kro-Lon Surfacing Kro-Lon is TFB s patented process for surface treatment of TFB bending tools that dramatically extends the tool life and prevents tube scratches. Results from testing and customer reports show a typical Kro-Lon mandrel, on average, will outlast a steel mandrel with hard chrome by 2:1. Kro-Lon will out produce aluminum bronze by more than 250% The Kro-Lon process impregnates the tool with a surface of approximately 60% hard chrome and 40% Teflon. First the tool is heat treated, ground, and polished. Then controlled captivation of the plating, to a sample, showing micropores. Figure 7-2. Cross-section of Kro-Lon test thickness of 0.002", produces thousands of microscopic openings and fissures (micropores) that penetrate the entire thickness of the plating. Using a capillary thermal-mechanical process, these micro-pores are literally packed with Teflon (10 microns or less) to achieve a clear surface of physically bonded Teflon and chrome. Figure 7-3. Kro-Lon test sample showing Teflon impregnation throughout the sample. 7

11 Figure 8-1. Squaring and Deburring Blades CB-12 1/8" Thick Carbide Squaring and Deburring Blades TFB Squaring and Deburring Blades and End Forming Tools TL17-2 Tri-Life Coated Deburring Blades You can chose from four squaring and deburring blades, to match the materials you are processing. Our TL17-2 Tri-Life (see Figure 8-1) is a sub-micron carbide blade with a coating that exceeds titanium nitride by 3:1. Ideal for all ferrous and non-ferrous tubing from 1/4" (6.35 mm) to 3" (76.2 mm) O.D., it's superior surface significantly extends blade life compared to carbide and tool steel. TL17-2 blades produce the finest cuts and a high luster mirrored surface. The TFB B-1 and B-12 blades are made from tool steel for use on copper, aluminum, brass, and mild steel. B-1 blades are 1/16" (1.588 mm) thick. The stronger, more durable B-12 blades are 1/8" (3.175 mm) thick. Before Our CB-1 blades are carbide steel, for use on titanium, stainless steel, and other abrasive and hardened materials. These 1/16" (1.588 mm) blades will last ten times longer that tangtung. We also have all the end forming tools you might need for flaring and beading (see Figure 8-2). These tools are custom designed by TFB for better performance and longer life. After Flaring Dies Deburring Head Figure 8-2. End Forming Tools 8 1

12 Tools For Bending Our Only Business Is Tooling Your Business All the players on your TFB team - engineering, estimating, accounting, management personnel - are experienced tube benders. Sales staff, both in-house and in-the-field representatives, are trained to solve your bending challenges. This team's knowledge and dedicated skills ensure that we meet our goal of - Quality Bending Products Shipped On Time All TFB tube and pipe bending tools are manufactured in-house, everything from design and machining to heat treating and plating. This same facility warehouses a large inventory of ready-to-ship tools, in a wide range of sizes. We even have a drive-up window to handle rush orders. If you are using bending tools, you need to check out all the benefits you can receive when you work with TFB. So call us or visit our web site today.

13 Tools For Bending, Inc. 194 West Dakota Ave. Denver, CO Phone: Fax: Form number: HT-08/02