Case of Innovative solutions

2012.08.20

Machine model : CNC Pipe bender MS-80R (delivered in 1988)
*Bending of fuel in-let tube for vehicles

 
≪Point of solution≫

For pipe bending, bending tools are normally composed of the followings

　①Bending roll ②Clamp die ③Pressure die ④Mandrel ⑤Wiper die ⑥Chuck jaw 

　　Wiper die is designed to free from possible inner wrinkles of pipe during bending process,
    and needs to be made of softer material than that of pipe to keep if from surface defect.
    The wiper with too soft material would meet, however,
    heavy abrasion that may end up with shorter life to be replace at working as many as 3000 work pieces.
    Running cost would then stay high and frequent time-consuming re-installation and calibration become unavoidable.

 

 

≪For better bending tools≫

 

Advantages of roll wiper
　　　
・Most popular material of wiper die is cupper/aluminum alloy. This will cause shorter life of the die comparing to other type of material.
・Same material ( normally die steel) is used for roll wiper as that of wiper die,
and TiC-coated surface treatment is given for longer service life of molds.
　This will turn the service life loner with smaller abrasion..
・By bend-roll and wiper die mechanically incorporated, set-up time of tooling is saved with no calibratio

 

≪Advantages of roll wiper≫

 ・Roll wiper would normally need the machine no special modification to mount thus this new installation is rather easier.
・Most existing tools at client shop are still workable except bend-roll and wiper die. This will lead to tool-cost reduction

 

≪Expected benefit by roll wiper≫

 

Increase of quality stability, decrease of deficiency and running cost

・Wiper section that works for no wrinkle generation is incorporated in the bend roll and with surface treatment.
  This remarkably enhance anti-abrasion performance of the tooling.
・If in case of tooling surface coating removed after long years service,
  retreatment can be given yet with no skilled calibration needed when remounting.
・It is noted as a difference from standard tooling, that ,in this tooling,
  so-called clamp die section is designed in similarity as that of wiper die.
　This tooling is heat-treated on the hard die-steel, and no abrasion is observed as those seen with standard wiper.
・Frequency of die change or re-treatment as followings

　① Conventional type  ： 3000work   pieces／per die
  ② Roll wiper type    ： 100000work pieces／per die　

　Thus the roll-wiper brings clear differences over conventional type of wiper in terms of remarkable reduction of re-setting frequency and running cost.

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