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.

A

Manual tube bender for prototype or lowproduction. Produces tight radius bends inthin wall tubes with minimal collapse.

Look at what TFB can do for you!

1

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-of-

difficulty 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" (323.85 mm) round, square, rec-

tangular, 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.

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 1-1. TFB President Eric Stange inspects large rec-tangular mandrel.

Figure 1-2. Five-piece, reverse interlocking tool set (2.00” O.D.x 0.022” wall on 2.00” C.L.R.) for aerospace tube fabrication.

2

Tube bending has come a long way since wet-packed sand cerrobend or cable man-

drels. TFB has more than four dozen chrome and Ampro bronze mandrels ready-

to-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 man-

drels, used for hydroforming, wave guide, tube-within-a-tube, bend-on-a-bend, siz-

ing, bullet-nosed, expanding, plastic, sheathed, brute, and ultra-close pitch.

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 produc-

tion 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.

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.

TFB Mandrels

Mandrel Selection

Clamp End

Outer WallThin Out

Inner WallBuild Up

Neutral Axis

Tangent Lines

Springback

Clamp End

Outer WallThin Out

Inner WallBuild Up

Outer Wall

Inner Wall Neutral Axis

Tangent Lines1

8

7

6 4

3

2

5

(Clamp Die End)Neutral Axis

Clamp End

Outer WallThin Out

Inner WallBuild Up

Neutral Axis

Tangent Lines

Radial Growth

Wall Factor

O.D. ÷ Wall = W.F.

"D" of Bend

O.D.

C.L.R.

BendC.L.R. = "D" ofTube Tube T O.D.

Figure 2-1. Types of Mandrels

Figure 2-2. Bending Design Factors

Figure 2-3. Reaction of the tube to bending

REGULAR (RP): Universal Flexing for standard tube & pipe

CLOSE PITCH (CP): Universal Flexing for thinwall tubes

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

3

“D” of bend 1 x D 1.50 x D 2 x D 2.50 x D 3 x D 3.5 x DDegree of bend 90° 180° 90° 180° 90° 180° 90° 180° 90° 180° 90° 180°

10 Ferrous P P P PNon-Ferrous P P P P P P

20 Ferrous RP-1 RP-1 RP-1 RP-1 RP-1 RP-1 P PNon-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 PNon-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 PNon-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 PNon-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-1Non-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-1Non-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-1Non-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-3Non-Ferrous UCP-8 UCP-10 UCP-8 UCP-10 UCP-6 UCP-6 UCP-6 UCP-6 CP-4 CP-4 RP-3 RP-3

100 Ferrous UCP-6 UCP-8 UCP-6 UCP-6 UCP-5 UCP-5 UCP-5 UCP-5 UCP-5 UCP-5 CP-4 CP-4Non-Ferrous UCP-8 UCP-8 UCP-8 UCP-8 UCP-8 UCP-8 UCP-6 UCP-6 UCP-5 UCP-5 CP-5 CP-5

125 Ferrous UCP-6 UCP-6 UCP-6 UCP-6 UCP-5 UCP-5 UCP-5 UCP-5 CP-4 CP-4Non-Ferrous UCP-6 UCP-6 UCP-6 UCP-6 UCP-6 UCP-6 CP-4 CP-4

150 Ferrous CAUTION: UCP-8 UCP-8 UCP-6 UCP-6 UCP-6 UCP-6 CP-5 CP-5Non-Ferrous UCP-8 UCP-8 UCP-6 UCP-6 UCP-6 UCP-6

175 Ferrous BETTER CALL: UCP-6 UCP-6 UCP-6 UCP-6 CP-6 CP-6Non-Ferrous UCP-8 UCP-8 UCP-8 UCP-8

200 Ferrous TOOLS FOR BENDING, INC. UCP-6 UCP-6 CP-6 CP-6Non-Ferrous

“D” of Bend = centerline radius tube outside diameter

(2.0 C.L.R. ÷ 1.0" O.D. = 2 x D)

Wall F

act

or

= t

ub

e o

uts

ide d

iam

ete

r (2

.0" O

.D.

÷.0

32 =

62.5

W.

F.)

wall o

f tu

be

Tooling Selection Guide

*

KEY P-Plug or Empty-BendingRP-Regular PitchCP-Close PitchUCP-Ultra Close PitchNo. 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.

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

bend die, will produce good

bends, have a longer tool life,

and will be the most cost effi-

cient. Conversely, the most expensive wiper die is the one that takes

longer to position, produces marginal bends, requires frequent oper-

ator repairs, and has more down time than running time. And it

may even cost more.

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® sur-

face.

TFB Wiper Dies

4

Figure 4-5. Conventional, square back, wiper die and wiper die tips, with standardand offset holders to clear collet and reduce drop length.

Figure 4-2. To prevent tube scratches and prolong tool life,the new TFB wiper die finishing process provides extraor-dinary polished tube grooves and C.L.R. machined surface.

Figure 4-1. With moderate thumb nail pressure, thewiper’s leading edge must deflect evenly all around,often 0.005” to 0.010” (0.13 mm to 0.26 mm).

Figure 4-3. Replaceable,round back, wiper die tips, avail-able in aluminum bronze oralloy steel. Inventoried sizes

range from 1” (25.4mm) to 3” (76.2 mm).

Figure 4-4. The ultimate wiper die, withKro-Lon® on special steel and lube holes onboth tube groove and C.L.R. surfaces.

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, fac-

tors 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 52-55

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 com-

pound clamp die and matching bend die clamp

inserts. For multiple bend die machines, TFB can

furnish stacked tooling from your bent tube print.

5

Figure 5-1. Types of Bend Dies

Figure 5-2. Pressure Dies and Clamp Dies

1

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

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.

TFB Empty-Bending®

(Patent No. 4765168)

6

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.

Figure 6-1.Empty-Bending® Dies

Figure 6-2. Cross-section illustration ofbent tube, showing compression of innerwall and stretching of outer wall.

Figure 6-3. Empty-Bending® tool sets for one-piece fittings on conventionalbender.

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 leftshows true radius groove tube. Gauge on right shows multiple radius tube groove.

TFB Kro-Lon® Surfacing

Kro-Lon® is TFB’s patented process for surface treat-

ment of TFB bending tools that dramatically extends the

tool life and prevents tube scratches. Results from test-

ing and customer reports show a typical Kro-Lon man-

drel, 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 sur-

face of approximately 60% hard chrome and 40%

Teflon®. First the tool is heat treated, ground, and pol-

ished. Then controlled captivation of the plating, to a

thickness of 0.002", produces thousands of microscopic

openings and fissures (micropores) that penetrate the entire thickness of the plat-

ing. Using a capillary ther-

mal-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.

7

Figure 7-3. Kro-Lon test sample showing Teflon impregnationthroughout the sample.

Figure 7-2. Cross-section of Kro-Lon testsample, showing micropores.

Figure 7-1. Kro-Lon plated mandrel and wiperdie. Note: when the Kro-Lon surface

wears out, it can be re-surfaced.

1

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, alu-

minum, 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.

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.

TFB Squaring and Deburring Blades andEnd Forming Tools

8

Figure 8-2. End Forming Tools

Figure 8-1. Squaring andDeburring Blades

CB-12 1/8" Thick Carbide Squaring and Deburring Blades

TL17-2 Tri-Life™

Coated Deburring Blades

Before

After

Flaring Dies

Deburring Head

Tools For Bending

Our Only Business IsTooling Your BusinessAll the players on your TFB

team - engineering, estimat-

ing, 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.

Tools For Bending, Inc.194 West Dakota Ave.

Denver, CO 80223-2195Phone: 800-873-3305

303-777-7170Fax: 303-777-4749

www.toolsforbending.comEmail: tfb@toolsforbending.com

Form number: HT-08/02