How to make manual profile bending with your own hands

How to make a manual profile bender with your own hands

A unit for bending metal profiles, pipes, and rolled products of different sections is called a profile bender. Depending on the complexity of the cross-section of the profile, rollers with a simple side surface are used, or it is bored to fit an angle, an I-beam, a channel, or a T-beam. This is done so that it repeats the appearance of the section at the end of the processed shaped steel.

Operating principle of the machine

Using hydraulics, the overall clamping force is ensured, thus deforming metal profiles of large thickness. Pipe benders in the factory produce a force of more than 8 tons, this indicator affects the choice of machine control: manual or electric. Devices with forced and manual clamping bend rolled metal, ensuring cold deformation of the metal. The bending effect in different machines differs in direction:

The pressure shaft moves in a downward direction. The top-shaft arrangement is in demand when operating roll forming equipment with electrical control. In machines with a jack, this direction of movement of the working shaft is rarely used.
The working shaft moves from bottom to top, and the side rollers are fixed statically. This scheme is used in units with hydraulic jacks; the position changes when the central roll moves.

These two working schemes are equally effective, although they differ in the location of the working and auxiliary shafts, as well as the type of pressing device.

Homemade bending unit

In the workshop, they most often design and assemble a profile bending machine with their own hands. The drawings are made for a unit designed for a metal profile, which in cross-section has a diameter of 6 cm or less, since bending powerful rolled products requires a professional electric hydraulic drive.

Selection of designs and materials

Materials are selected taking into account their performance. For the base, take beams that are not curved; rust on them can occupy an area of no more than 10%. So that work does not have to be interrupted to search for missing materials, prepare the elements in advance:

bearing units with pressed rolling rollers;
channel, it should be taken No. 100 or 80;
monolithic steel shafts with a diameter of at least 80 mm;
metal rod with a diameter of 12 mm;
steel strip with a thickness of 5 mm or more;
bicycle chain or timing chain from a Zhiguli gear;
engraving and simple nuts, washers, M20 bolts, the last length is 60 mm.

To make the frame, two pieces of a channel 20 cm long (for transverse guides) and two blanks of 70 cm each (for longitudinal posts) are cut. At the ends of the last two blanks, an angle of 70˚ is formed using a grinder.

Initial stage

To install bearing units, holes are marked at the top of the longitudinal struts for their fastening. To do this, use a core and mark where the bolts will be located. After this, the bearings are removed to the side, and holes are drilled in the marked places using an electric drill using a metal drill.

Source: https://pochini.guru/tehnika/kak-sdelat-ruchnoy-profilegib

Do-it-yourself profile bending: manual homemade how to make it, drawings, dimensions, profile bending machine from auto parts, a vice, easy to manufacture

Any home craftsman is faced with the need to give a curved shape to various parts. If we are talking about sheet metal or rods, the issue is resolved quite simply. But when the question concerns profiled elements, you cannot do without special equipment. Any attempt to bend the profile using conventional methods will lead to deformation and damage to the part. Let's consider specialized equipment used in such cases, and options for self-production.

Description

Profile bender

A profile bender is a device for bending profiled parts without deforming or disturbing the shape of the profile.

Used in the manufacture of structures from different types of profiles:

pipe, including rectangular pipe;
corner;
channel;
I-beam;
beams or rods, etc.

You can deform individual sections or the entire section of the profile. The parts are bent to the required amount, up to 360°. Industrial designs are capable of working with large profiles that require significant effort to change shape without preheating. Hand-held devices are designed for processing relatively small profiles.

Roll bending machines are capable of bending with constant, variable or alternating curvature, with symmetrical or asymmetrical contours. It is possible to produce circles, spirals or other closed shapes. Bending of figures with smooth transitions of outlines is also performed. A special feature of these machines is the ability to perform complex bends of parts in one pass. Such qualities contribute to the spread of profile benders in various fields of industry:

energy;
construction;
petrochemistry;
automobile;
furniture;
sports;
electrical industry, etc.

The manufacturing process of parts occurs quite quickly and allows for high productivity with virtually no waste. There are fully automatic industrial installations that can operate according to a given program.

Simpler devices are also common, in which the adjustment and supply of material are performed manually. They are functional, but the price of such machines is quite high.

It is not practical to purchase such devices for private use, so most users prefer to make profile benders themselves.

Design and principle of operation

The process of bending a part occurs on the principle of applying force to the central part of the beam on two supports. The profile is rolled on two rollers, between which a third, pressure roller, presses on it from above. Its position determines the bend radius.

A profile bending machine is a frame on which two rotating rollers are rigidly fixed to provide feeding. A pressure roller presses on the workpiece from above, the position of which is adjusted using one or another drive mechanism.

This is the most common design with an upper pressure roller, which is most often used when making a machine yourself. There are other types:

machines with a left roller, used for curling spirals;
machines with a bottom roller for bending massive parts with a large profile;
installations with all movable rollers, capable of performing complex operations to form figures with many curves of different shapes.

Important! Often profile benders are combined with more common designs - pipe benders, believing that their functions are the same, and the difference lies only in the narrower specialization of pipe benders. However, these devices have different effects on the part.

The difference between the machines is that the pipe bender bends the part that is fixedly fixed in the mandrel. The profile bender acts on it using rolled steel, which makes it possible to bend parts extended along the length with a constant bending radius. A pipe bender makes a point change in shape, and a profile bender processes the part along its entire length, maintaining the shape of the section and protecting the surface from the formation of folds or crumpled areas.

Source: https://2lzz.ru/stanki/profilegib-svoimi-rukami

How to make a profile bending machine with your own hands: drawing and design diagram

Different types of bending machines can be used to bend steel profiles, but the profile bender is considered the most convenient of them due to its special advantages. At the same time, not everyone can buy expensive equipment, but you can design a profile bending machine with your own hands.

Before you start, you need to figure out why you need it. Therefore, we will consider the existing classifications of profile benders, their operating principle and design, drawings, bending process and the main stages of construction.

The main purpose of the profile bender

Now profile bending is widely used in the manufacture of aluminum, copper, steel and PVC pipes, as well as for laying water and gas supply systems, and for laying cables. The profile bender is used for bending various workpieces:

solid blanks of square and rectangular cross-section;
beams;
corners;
pipes;
I-beams;
channels;
metal rods, etc.

When metal needs to be bent at the required angle, then, as a rule, a manual homemade profile bender . This machine makes it possible to bend a metal profile with your own hands using cold rolled products without heating the product. At the same time, profile bending machines make it possible to create products with symmetrical or asymmetrical contours of alternating or single curvature.

The main advantage of profile benders is bending in one roll. In this case, it is possible to process steel profiles in the vertical and horizontal planes, and to make circles or spirals from blanks. The machines make it possible to produce closed and open contours, as well as contours that have a smooth transition.

Now profile benders are very popular in many construction fields: marine, energy, sports, electrical, automotive, furniture, petrochemical industries. The bending process takes place along a radius and has two main stages: the product is rolled between rollers with simultaneous pressing of the side rollers or the top roller.

Structure of the roll forming machine

The design of the bending equipment is an easily transportable machine with a hydraulic, electric or mechanical drive, relatively light weight and compact dimensions, which is intended for bending metal using cold rolling. To achieve optimal curvature, special attachments are often used to help process any product .

There are four types of profile bending systems. The design with an upper movable roller is the simplest type in terms of mechanical operation; in this case, only the upper roller moves. The design of this mechanism may differ:

hydraulic roller – controlled directly by the hydraulic system of the upper roller;
upper manual roller – controlled using a gearbox.

This position of the rollers allows you to calculate the possible radius for bending parts with minimal errors due to metal compression or a small gradient during profile deformation. These do-it-yourself profile bending drawings are the most popular today.

Machines with a left roller are more convenient for curling spirals ; they make it possible to perform similar functions as the profile benders described above, with the only difference being the side roller drive mechanism. The models are equipped with CNC, that is, they control the bending gradient: they bend the product from the original drawing, or they are controlled with preset functions.

Machines with lower rollers are used primarily for bending large profiles, since the bending force is evenly distributed over the two lower shafts, and the drive mechanism is completely hydraulic. Each roller has its own location controller to maintain the possibility of making spirals. This mechanism is considered the most used, since the rollers rotate along a segment of a circle .

Machines where all the rollers are movable have the most complex mechanism and include all the advantages of the machines described above. These profile benders can do the work that previous devices do separately.

Operating principle of roll forming machine

The main difference between a profile bender and other pipe bending machines is that it deforms metal using rolled metal, and not by bending. Any profile bender has the same operating principle. The machine is rigidly installed and fixed through holes in the frame with anchor bolts. Before operation, the device must be grounded and the integrity of mechanical and electrical elements .

Before the first start, the rollers are cleaned of preservative lubricant using a dry cloth, and the network voltage is checked for compliance with that required for the profile bender. Then the device is run in idle mode for half an hour. If deviations from normal operation occur, the profile bender is stopped and the faults are removed.

The workpieces are cleaned of grease and the elasticity of the metal is checked, which must be the same along the entire length of the product. The rollers are then adjusted to process the part in the following sequence:

the nuts securing the pressure and support rollers are unscrewed with a wrench;
install the rollers on the shafts with a key and secure them with nuts;
using the handle, lift the pressure roller up;
the part is clamped between the rollers;
then rolling takes place under high pressure between the shafts.

The level of curvature is set by lowering and raising the upper shaft. In a manual machine, the mechanism operates using a lever that is moved by the operator. The electric profile bender is powered by an electric motor.

Classification of profile benders

In appearance, a classic profile bender has a “T” shape . There are several types of these devices, differing in cost, quality and technical characteristics.

Electric profile benders

Most often, electric profile benders are made in the form of massive and large machines, therefore they are suitable only for stationary work. But these profile benders are also used for bending profiles with a small diameter, therefore, as a rule, they are installed in home workshops and small industries. This equipment is distinguished by a high level of accuracy and retains the strength of products well in the bending area.

The camber angle is marked in different ways. With the mechanical method special marks are installed ; they resemble the hands of a clock. But the most modern method is digital, when the deflection is created using an electronic device and adjusted by the operator through a monitor. But this tool is heavy and expensive.

Hydraulic profile benders

This equipment is used in industry. They are used in the construction of water supply or sewerage systems, and they are excellent for stationary conditions. Hydraulic profile benders are distinguished by the fact that they can only operate from the network . The main advantage is:

maintaining mobility;
high speed;
no load on the operator;
ease of operation.

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Manual profile benders

This equipment is the most accessible and cheapest; it can be installed in a home workshop for DIY work, since it does not require professional training of the device. But there are also disadvantages:

inconvenience of performing several bends on one product;
high user load;
prolonged arching over time;
work only with small diameter pipes;
almost uncontrolled bend radius.

But even with these shortcomings, this profile bender is the most acceptable option for do-it-yourself work in home workshops. If, when installing plumbing or heating, you only need to bend a few pipes or rods, then there is no point in buying an expensive tool. A manual profile bender will cope with this task perfectly.

Types of manual profile benders

For home use, a manual profile bender is best suited. If you do not plan to use the profile bender for a long time, then it is better to buy an inexpensive model or make a profile bender yourself. There are several ways to make manual profile benders.

The first method is the most popular. Special rollers move along the part that is being bent , exerting their force on it and bending it. This equipment bends the pipe using a fixed frame. Almost all models allow you to bend up to 180 degrees.

The next option is profile benders, which extrude the pipe with a special device. They move the frame towards the bent pipe. This option eliminates the appearance of wrinkles due to the movable frame and does not wrinkle the product. At the same time, it is equipped with ratcheting mechanisms that can significantly increase hand strength.

If you need to bend a very thick pipe , then in this case you cannot do without a hydraulic manual profile bender. It is equipped with special pistons that create pressure on the pipe of several tens of tons. This device can bend up to 180 degrees.

How to make a profile bending machine with your own hands

The design depends on the profile diameter. If the diameter is no more than 20 mm, then the pipe can be bent using a concrete slab with holes where metal pins must be placed. That is, the pipe is passed between the pins and bent to the required angle. If the pipe cross-section is more than 25 mm, then you need to think about the drawing of the profile bender in a more complex way.

To do this, you need to fix two rollers on the base, and the radius of the side edge must have an equal diameter with the pipe . The tube must be installed between the rollers and one end secured. The free end is then secured to the winch and it is activated. When the part reaches the required bend, you can stop the winch.

Then you will need cement mortar, as well as thick pieces of pipes with a diameter of about 60-110 mm. You can use channels, they are great for this. A cement platform is set up on the ground where pipe cuttings are installed. First, they are clearly installed vertically in the crushed stone. The distance between these elements is about half a meter. Then the area is filled with cement, but the pipes must remain vertical. It will take several days for the solution to dry.

To prevent bulging, creasing or cracking, the pipe must be filled with quartz sand before heating. Before filling the pipe with sand, plug the end of the pipe with a wooden plug; its length must be equal to two pipe diameters. In this case, the taper is 1:10 or 1:25 . Then you need to pour some sand into a piece of pipe and heat it until it turns dark red. After cooling, you can fill it completely with sand and carefully look at the walls of the pipe.

Place the pipe in a vertical position and slowly add sand. Here you need to follow one rule: after each portion, you need to lift the pipe and tap it with a hammer. Do this until the voids are filled. This should be signaled by the empty sound of a hammer tapping. Remember, the sand should not reach the top of the pipe by approximately the length of the diameter.

You need to hammer a plug on top, where several holes are first made for the release of gases. Using chalk, a mark is made on the pipe at the place of the largest bend; its radius must be less than 3-4 pipe diameters .

When a pipe is bent at 90 degrees, the heating interval must be equal to 6 times its diameter. If the pipe is bent at 60 degrees, then the interval can be reduced to 4 diameters. Heating must be completed when all the scale has flown off the pipe. This is a sign of complete heating; if sparks form on the surface, this means that the pipe is burned out. It needs to be bent in one warm-up. If there are several of these heatings, they will worsen the structure of the material.

After reading the article, it may seem that it is much more expedient to buy a factory-made profile bender rather than waste time on metal processing, searching for materials and assembling the structure. But in practice, making a profile bending machine yourself is much more profitable, and the savings can be very significant. Agree, this is a very compelling argument in favor of “home” assembly.

Source: https://stanok.guru/oborudovanie/raznoe/kak-sdelat-profilegib-svoimi-rukami.html

Do-it-yourself profile bending

Metal profiles today are widely used in construction. Very often there is a situation when it is necessary to change the shape of the profile used. Profile bending is carried out using a special machine, the industrial version of which is quite expensive.

That is why many are considering the opportunity to make a profile bending machine with their own hands. A home-made device will also have attractive performance characteristics and can be used when establishing mass or serial production.

Let's take a closer look at how to make a profile bending machine with your own hands, what this requires and many other points.

Do-it-yourself profile bending

Profile bending technology

You can make a roll forming machine yourself using available materials. The features of the manufactured design include the following points:

A massive plate can be used as a base. When creating the simplest design, two corners are welded onto the plate, which act as guides. On the Internet you can also find drawings that involve the use of wood. It is worth considering that a profile bender with a wooden base will not be able to withstand serious mechanical stress. That is why, if the machine is used for bending a steel profile, then steel plates and angles of larger cross-section should be used as the main material.
Auxiliary rollers are attached, which are designed to fix the workpiece. It is recommended to fasten the rollers through bolts, for which holes are created in the corners. By using bolts, it will be possible to adjust the distance between the two rollers, changing the bending radius. The machine can be set up within a short period of time.
Corners are welded to the bottom of the plate used. They are designed to significantly increase the rigidity of the base. The corners should be secured at the point where the load is concentrated. Elements that will be used to fix the device to the base are also attached to these corners.
In order to make a profile bending machine with your own hands, a plate with holes is welded to the upper guides. Their diametrical size must be larger than the cross-section of the screw used to transmit force.
The working screw is installed, through which the force is transmitted. A similar element, made by hand, is rigidly connected to the working roller, through which pressure is transmitted.
A mechanism that transmits physical force is used as a drive. An example is a jack or gearbox. When creating a handle, do not forget that as the length of the handle increases, the transmitted force increases significantly. This is due to the fact that the handle is used as a lever. It is quite difficult to make an electric profile bender with your own hands, since it is necessary to install an electric motor and reduce the number of revolutions, increasing the transmitted force. For this purpose, a reduction gear can also be installed.
As a rule, rollers are made from scrap materials. For this, a pipe of a certain diameter is used. In addition, wood can be used in manufacturing. It is worth considering that wooden rollers are designed for a relatively low load. Therefore, such profile benders can be used for bending profiles made of non-ferrous metals.

Drawing of a profile bending machineDiagram of a profile bending machineDrawing of a profile bender

Do-it-yourself profile bending, drawings of which can be found on the Internet, can only be made if certain materials and tools are available. After creating the structure, you can do a test bending, and then adjust the position of all elements. Once all the elements have been adjusted, the structure can be strengthened.

Required tools and materials

To manufacture the device in question, certain materials and tools are required:

Rollers for profile bending can be made independently or purchased. As a rule, when making rollers, heavy-duty steel is used, which must withstand pressure. Shafts can be used as rollers. Videos can be removed from other devices.
When making the base, plates with a thickness of 5-8 mm are used. They are designed to take high loads. To strengthen the structure, you can purchase four corners 30 cm long.
The force can be transmitted using a special mechanism, for example, a gearbox. It is quite difficult to make it yourself, but you can get the device from disassembly. In addition, a jack bending device is very popular.

Homemade profile bender

You can create a machine with your own hands only if you have certain tools:

Welding machine. In order to create a durable structure, the connection of individual elements is carried out using welding. This connection method is characterized by high reliability and durability.
Bulgarian. To change the length and shape of the materials used, a mechanical processing method is used. You can work with metal by using special wheels designed for working with steel.
Various measuring instruments. The structure being created must have exact dimensions, since otherwise it will be impossible to obtain a product with the required characteristics.
Files or grinding equipment. It is worth considering that when cutting, burrs and other defects may form that require processing using a special tool.

It is much more difficult to create a device with an electric or hydraulic drive.

Manual machines

Manually driven machines are the cheapest. This is due to the simplicity of the design. Manual profile bending is characterized as follows:

The device is small in size and easy to operate. Manual roll forming machines are the cheapest and are also easy to make.
Most often, the equipment in question is found in private workshops or garages.
It is worth considering that a manual profile bending machine can be used for bending small diameter pipes. This is due to the fact that a mechanical drive cannot create strong pressure.
When using a manual profile bender, it is impossible to produce a product that matches the drawing.

Homemade manual profile bender

The mechanical drive has become quite widespread because it is easy to manufacture. Most of the drawings that are intended for making structures with your own hands are related specifically to profile benders of the type in question.

Purpose of the profile bender

It is relatively easy to create a homemade profile bender; the device is designed to concentrate and transmit force. When using a bending machine, you can carry out the following types of work:

Bending metal profiles of square and rectangular cross-section. The profile can be made using various metals.
Giving a curved shape to pipes made of steel or non-ferrous metals.
Bending of ponds of various sections.
Bending of various types of rolled products: angles, channels and others.

Most of the manufactured models are used for bending workpieces with various characteristics. In addition, a lot of equipment is used for cold bending of profiles.

In conclusion, we note that for domestic use you can make a profile bending machine with your own hands. This is due to the high cost of industrial versions. The created machine can be relatively small in size and installed in a small workshop. Most models can be used for bending metal workpieces in horizontal and vertical planes.

Source: https://stankiexpert.ru/stanki/gibochnye-stanki/profilegib-svoimi-rukami.html

Do-it-yourself profile bending - manual and electric, drawings and dimensions

The frame of many structures is made of metal profiles, but in some situations the shape of the object requires transformation of a straight line. It is not practical to purchase professional equipment for one-time use. For simple operations, you can make a profile bending machine yourself from scrap materials.

What is profile bending

The scope of application of a profile bender is clear from its name - giving a curved shape to metal products of various sections.

Its functionality allows:

bend square and rectangular workpieces;
bending sections (angles, channels, etc.);
give curved shape to pipes;
bend metal rods.

Depending on the type of profile bender, one or several pipes can be rolled simultaneously

Technologically, it is a device consisting of rollers that provide such wide capabilities:

impact on a separate area or along the entire length;
bending of products without heating;
obtaining contours with different bending angles from 0 to 360°;
compliance with the principles of symmetry or deviation from this rule.

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Bending of the workpiece occurs in one rental. Closed and open workpieces, spiral pipes, circles of different diameters, etc. come out from under the profile bending rollers.

Industrial enterprises use three types of roll forming machines:

Electrical. They differ from the previous category in smaller dimensions and have restrictions on the cross-section of the processed profile. Hydraulic profile bending is designed for intensive industrial use
Hydraulic. They are easy to operate, do not require mechanical effort on the part of the master, but require connection to high-power electrical networks. Some types and models of electric profile benders, due to their dimensions and weight, are suitable for use by individuals in small workshops and even at home, and are also affordable
Manual. Small dimensions, ease of operation and affordable cost more than compensate for the need to use the operator’s physical strength, restrictions on the profile cross-section and the impossibility of manufacturing complex curved structures. When using a manual profile bender, it is almost impossible to control and, much less, obtain a bend corresponding to the drawing

Both electric and manual profile benders are actively used for the production of parts and equipment for the energy, oil refining, chemical, furniture, construction and many other industries.

It is quite possible to create a manual version of a profile bender yourself if you have the necessary components. Such a device will help bend small-section workpieces for the manufacture or repair of curved structures made of pipes or metal profiles.

One of the main characteristics of a manual profile bender is the minimum possible bending radius.

Dimensions and drawings

Before you start assembling a homemade device, you need to decide on its dimensions and drawing. The diagram options below can help with this.

Rollers for profile bending can be made independently or purchased

If you plan to make a structure based on a concrete slab, then before starting work you need to select a site.

The design of profile benders is designed in such a way that their working parts - rollers - can both act on a separate section of the workpiece and exert pressure along its entire length

Step-by-step manufacturing instructions

The process of making a manual profile bender with your own hands consists of the following steps:

Site preparation. We tamp the area chosen for placing the machine and, if necessary, level it with crushed stone or fill it with a concrete solution of sand and cement in a ratio of 4:1.
We make a U-shaped regulator.
We weld the profile bending frame
We cut a hole in a piece of channel, weld a nut, and screw in a screw.
After this stage, we weld all the substrates, clips and shafts
At the ends of the rollers we mark grooves for fastening the sprockets and cut the grooves with a drill, and cut threads in the holes of the stops. We weld the sprockets from the bicycle. On the second side we do the same.
Sprockets and a chain are needed so that by rotating the handle, you can move the pipe
We weld the pedal from the bicycle.
The force will be enough to rotate the profile pipe
We start trial bending to adjust the operation of individual elements; after correction, the manual profile bender is ready for use. This design does not imply high operating speed.
The shafts above the platform are slightly lowered so that the arc enters with a larger diameter
This model of profile bender is suitable for bending pipes with a thickness of 2-2.2 mm and a width of 30 mm.
If you have a lathe, you can turn shafts to more precise sizes

To improve the appearance, the device is cleaned of rust and traces of old paint, treated with an anti-corrosion compound and carefully painted.

Electric profile bender

The electrical modification of a homemade profile bender allows you to roll and bend significant volumes of metal profiles while minimizing the operator’s manual labor. To do this, another element is added to the general layout of the drive chain - an electric drive.

For a homemade electric profile bender you will need:

motor 1500 W 380 V;
worm gearbox with reduction 1/43;
sections of pipes with a cross-section of 70 mm or channel;
2 support rollers and 1 roller;
bearings;
4 limit rings for rollers - the distance between them will be adjusted to the dimensions of the workpiece using bolts;
handle for twisting the roller;
metal plate;
3 sprockets and drive chain;
chain tension limiter;
screw device from an old clamp;
M8 nuts;
springs;
bolts for fixing individual elements.

Other options

Another modification of a homemade profile bender, which allows you to bend beautiful arches for greenhouses and gazebos, will require giving mobility to one of the rollers and an ordinary car jack. In this case, the following changes are made to the design:

one of the rollers is placed on a movable arm, which is attached to the frame with hinges;
The angle of elevation of the shoulder will be adjusted by a jack installed below.

In the presented design, the jack rests against the turntable with its working rod and lifts it

A car jack can also be installed on the top platform of a homemade profile bender - instead of a screw device. In this case, the necessary clamping force will be created by this device.

Instead of a hydraulic jack, you can use a screw car jack to lift the end drum.

Mechanization of the machine can be done without an electric motor, if the home craftsman has at his disposal a drill with a speed controller or a high-power hammer drill. This tool is attached to the working shaft and the machine is put into operation.

If you need to bend a metal profile under an arched structure at home, you will not need to purchase industrial equipment. From scrap metal, spare parts from a car and other available elements, you can assemble a roll forming machine with your own hands. It can be either completely manual or equipped with “assistants” - an electric motor, a jack, a powerful drill, etc.

Source: https://fasad.guru/material/profilegib-svoimi-rukami.html

Making a profile bender with your own hands - drawings of a homemade machine

Not everyone is able to purchase a factory machine for bending various metal profiles, and the need for it may rarely arise. In such situations, a profile bender will come to the rescue - a simple manual device that you can make yourself.

One of the profile bending options

Why is a profile bender needed?

Making a profile bending machine with your own hands is not at all difficult, and applying it is even easier. As its name suggests, it is necessary to give a curved shape to metal profiles of various sections. Using a profile bender you can perform the following technological operations:

bending of workpieces with a solid profile of square or rectangular cross-section;
bending of various types of long products (channels, I-beams, angles);
giving a curved shape to pipes made of various metals;
performing bending of metal rods of various sections.

Homemade profile bender with a hydraulic jack

The design of profile benders is designed in such a way that their working parts - rollers - can both act on a separate section of the workpiece and exert pressure along its entire length. Thanks to the peculiarities of their design, profile bending machines effectively bend metal profiles without preheating them and allow you to obtain contours with different bending angles - up to 360°.

Profile bending makes it possible to obtain metal contours with different or identical bending angles, symmetrical or asymmetrical configurations. You can bend a metal workpiece in a horizontal or vertical plane using such a device in one roll through its rollers.

The profile bending machine allows you to produce bent metal products of the following configurations:

closed and open;
spiral, made of metal profiles or pipes;
circles of different diameters.

Both electric and manual profile benders are actively used for the production of parts and equipment for the energy, oil refining, chemical, furniture, construction and many other industries. Such devices are also widely used in small private workshops.

Types of roll forming machines

Roll benders are divided into three main categories.

Hydraulic

These are the most powerful of the profile benders, used primarily to equip industrial enterprises.

A hydraulic type roll bending machine belongs to the category of stationary equipment; with its help, at production enterprises, you can efficiently and quickly bend profiles of any section in any quantity.

The hydraulic profile bender has such significant advantages as ease of operation and the absence of the need to use physical force during the bending process. The only drawback of such profile benders is that they require a connection to an electrical network to operate.

Hydraulic roll forming machine - HPK 65

Electrical

Although this equipment is smaller in size than hydraulic equipment, it also falls into the stationary category.

The use of electric profile benders makes it possible to produce bent contours that exactly match the drawing, as well as to ensure the strength of the finished products at the bend points.

Electric profile benders are used to equip small enterprises and workshops (that is, where there is no need to bend large cross-section profiles). There is also electromechanical equipment that operates semi-automatically under operator control.

Homemade profile bending machine with electric drive

Manual

Such equipment for bending metal profiles is characterized by its small size, ease of operation and affordable price. It is the manual profile bender that can most often be found in private workshops or garages, where it is used to, if necessary, make a bent profile from a metal profile or a pipe of small cross-section.

It should be borne in mind that when using such a profile bender, it is almost impossible to control, much less obtain, a bend that corresponds to the drawing. In addition, to bend a profile or pipe using a manual profile bender, you will have to exert significant physical effort.

However, all these disadvantages are more than compensated by the affordable cost of a manual profile bender, especially when compared with the price of hydraulic or electric machines.

Universal manual profile bending machine PG-4

Two options for the simplest homemade profile benders

A manual device for bending metal profiles of various sections, as mentioned above, is easy to make with your own hands. A profile bender can be useful in many everyday situations. A homemade device that can be used to bend profiles of small cross-sections will help you independently make or repair structures that use pipes or profiles bent at different angles.

Before you start manufacturing, you need to accurately determine the design of your homemade profile bender and make at least the simplest drawing. At this stage, numerous photos and videos of similar devices that can be found on the Internet can help.

Let's start with the simplest designs, the simplicity of which automatically means that the functionality of such devices will be very limited. But in a number of cases, the capabilities of such devices are quite sufficient, and the simplicity and low cost of their production will allow you to start working in a short time.

In order to make a device for bending pipes with a diameter of up to 20 mm, you don’t even have to watch a training video. This type of profile bender has a very simple design, consisting of a concrete base and steel pins fixed in it, between which bending is carried out.

First of all, it is necessary to compact a small area of soil, cover it with crushed stone and level it. Then this area must be filled with concrete mortar, which is prepared from a mixture of sand and cement (in a ratio of 4:1).

Before you start pouring the concrete solution, you need to strengthen several sections of channels or pipes with a diameter of at least 70 mm on the prepared base.

In this case, they must be fixed so that they make an angle of 90° with the surface of the base, and a distance of about 4–5 cm is maintained between the exposed metal sections.

Unpretentious in appearance, but quite functional homemade product

After the concrete solution is poured, it is necessary to wait a certain time. After 2-3 days, you can already use such a homemade pipe bender. The bent pipe or profile is placed between the pins protruding above the concrete base and bent to the required angle. Conveniently, such a DIY pipe bender can be successfully used for bending stainless steel products.

If you need to bend pipes with a diameter of more than 20 mm, then a homemade device for this will look a little more complicated. To make such a pipe bender, you also need to pour a concrete base and fix two round metal rods in it.

In this case, the pins will serve as axes for placing rollers on them, the dimensions of the grooves of which must correspond to the diameter of the pipe being bent. This profile bending machine is used in the following way: the pipe is inserted between the rollers and one end is securely fixed.

The second end is attached to a manual or electric winch using a metal cable, which creates the necessary force to perform the bend.

A simple manual profile bender for bending corrugated pipes at an angle of 90°

There is another option for a simple device that will allow you to manually bend profile pipes at an angle of 90°. Its design is quite clear from the photo; it is only worth noting that a low groove on the bend will significantly simplify the work and reduce the necessary force that will need to be applied when bending profile pipes.

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Drawings for making a homemade bending device

In order to make a high-quality and efficient pipe bender, it is best to use a drawing (you can either draw it or find it on the Internet). As an example, consider the diagram of one of these devices, which you can make with your own hands for bending pipes of square or rectangular cross-section.

Drawing of a manual profile bender with three rollers

A simplified homemade version of the above drawing

The main elements of such a device are three rollers, two of which are used as supports, and the third is the working shaft. To facilitate pipe bending, the working roller of the profile bender deforms it gradually until a bend with the required parameters is obtained. The gradual effect on the bent pipe is ensured by the fact that the working shaft has some free play, which is limited by special guides.

Diagram of a factory-made profile bender, which can be used as a basis for a homemade device

Appearance of a finished factory profile bender

The design of such a homemade pipe bender includes the following elements:

plates 5–8 mm thick;
massive supporting plate;
four corners 30 cm long, with shelves measuring 5 cm;
auxiliary rollers.

Two corners are welded onto the massive plate, which will act as guides, and the auxiliary rollers are fixed with bolts. To give it greater rigidity, two corners are welded to the bottom of the base. A plate with a hole is welded to the upper ends of the guide angles, the diameter of which must be larger than the cross-section of the screw used to exert the required pressure on the pipe being bent.

Drawing of another version of the profile bender (click to enlarge)

Option with channel base

Finally, all that remains is to install the working screw, the lower part of which is rigidly connected to the working roller, which forms the required bend of the pipe. In order for the processed pipe to move along the auxiliary rollers, you can use a manual (using a special handle) or electric drive.

When the profile bender is assembled according to the drawing, you can do a trial bending to adjust the operation of all its elements, and only after that use it for its intended purpose.

Source: http://met-all.org/oborudovanie/prochee/izgotovlenie-profilegiba-svoimi-rukami.html

Instructions on how to make a manual profile bender with your own hands, what this device looks like

During construction work, it is often necessary to use metal products, and in most cases there are no problems with their installation, since this occurs in straight sections.

But sometimes metal pipes need to be bent at a certain angle. In industrial construction, special bending devices are used.

But if we are talking about private minor work, there is no need to buy expensive equipment, you just need to know how to make a manual profile bender with your own hands.

Making profile benders yourself is not that difficult, and they are also easy to use. They are needed to give metal profiles with different sections a curved shape. The design of the equipment is provided in such a way that their key components, rollers, are capable of influencing both individual sections of the products and their entirety.

Using profile benders, you can process profiles without the need for preheating and obtain contours with bending angles of up to 360 degrees. Using such devices you can perform the following operations:

deform workpieces with a solid profile with a rectangular or square cross-section;
bend corners, channels and other long products;
bend pipes based on different metals;
perform bending of metal rods with different sections.

Metal contours can have the same or different bending angles , as well as an asymmetric or symmetric configuration. A metal blank is bent vertically or horizontally through rollers in one roll. As a result, you can purchase closed or open structures, spiral-shaped, and also with different diameters.

Manual and electric profile benders are widely used in the production of equipment and parts for the following industries:

oil refining;
chemical industry;
energy;
furniture manufacturing;
construction and more.

Homemade profile benders are mainly used in small private workshops or for home work.

Pipe bender design

The device for bending profiles can be of different types, in any case it is light in weight and size. The work takes place using cold rolling technology; special attachments are used for processing and bending products.

As already mentioned, the key part of profile benders are rollers . According to the type of their operation and placement, equipment is divided into the following categories:

with a movable roller on top - this type is the most common and simplest. If the design is manual, then the roller moves through a gearbox; if it is hydraulic, then thanks to the hydraulic system. The device provides minimal error;
with a movable roller on the left - in addition to the ability to bend parts, the device can make spirals. The machines are equipped with CNC, with which you can set operating parameters;
with movable rollers at the bottom - used for processing large products. They are only hydraulic and operate with full automation;
with all moving rollers - this device is the most complex and combines the properties of the previously listed types. Performs a full cycle of bending work.

The drawing for a homemade pipe bender is made depending on its type. However, each one must contain:

pipe stops;
frame;
shafts.

The frame is needed in order to attach other parts to it. Factory products are characterized by a closed, complex design that is safe to use. And for homemade profile benders, an open frame is used , which is easy to make yourself, however, compared to a closed one, it will be less safe.

How the product works

Roll benders are designed for rolling and deforming workpieces. Regardless of the design of the product, the principle of its operation is always the same:

Before work, remove the grease from the device with a dry cloth and run it idle for about half an hour. During this time, it will be possible to find possible errors or breakdowns;
unscrew the roller nuts;
install and fix the rollers;
lift the pressure roller;
Clean the workpiece and secure it with bolts.

Then the part is rolled between the shafts , thereby ensuring its bending. To adjust the movement, you need to move the upper shaft up or down. If the device is manual, this occurs by raising the lever, and if it is electric, then using a drive.

Designs for deforming profiles have several classifications. They may differ from each other in the degree of mobility, type of drive and transmission mechanism. According to the type of drive, the product can be: hydraulic; manual; electric.

The hydraulic type device is most common in industrial applications; it is capable of quickly and efficiently processing structures of various sizes. It is also relevant when working with sewerage or pipelines. Hydraulic pipe benders can be both factory-made and home-made. However, if you are going to do them yourself, you need to have sufficient experience working with industrial equipment.

Electric pipe bender

This design is not very large and heavy, but must be installed permanently. Thanks to them, you can do high-quality and precise work. Roll benders of this type can be either entirely electric or partially mechanical. The second option will cost less, but its control will be partially manual. And devices with automation for long battery life will cost much more.

They are used for industrial purposes and are often purchased ready-made. But some people make electrical structures on their own based on sheet metals and scraps of ship hull steel. The body is made using a milling machine, and an old ship's shaft is used for the pulleys.

The drive uses motor with a power of 1500 W. Optimal speed and torque are achieved through the selection of gears. Profile rolling is simplified due to the fact that the engine has two directions of movement.

However, this design is very complex . The simplest method of mechanizing a manual profile bender is to connect it to the working shaft of a hammer drill or drill with a speed controller.

Manual design

A manual pipe bender is most common among those who bend pipes for private purposes. This product has the following advantages:

low price. The finished product is very simple and inexpensive to produce;
mobility or light weight;
breakdowns occur very rarely - the device does not contain electronics, so the risk of breakdowns is reduced;
the ability to assemble a product with your own hands from available materials.

Manual pipe benders for profiles are the most common. However, they also have their disadvantages:

the accuracy of the work will not be high, since there is no hardware control;
physical effort will be required;
the inability to process large parts, since the maximum allowable size of parts for bending is 4 by 4 cm;
To make the result more accurate, you need to spend more time.

Usually, such a device is quite sufficient for home needs . However, if the volume is large and the workpieces themselves are very large, then it is better to give preference to hydraulic and electronic devices.

Do-it-yourself manual profile bending

You can make such a design with your own hands in different ways. In one of the options, the power base is the bed. To make it, you will need to take steel channels of different sizes and angles.

The moving particles are made from old support bearings and classic scrap. The screw stop can be taken from old clamps. The screw must have a power rectangular or trapezoidal thread, but a metric thread will not withstand pressure. To assemble the structure, prepare:

grinder;
powerful drill;
welding machine.

The frame must have a U-shaped bracket for a screw stop. Welding is performed with a conventional semi-automatic machine. The seams must be of high quality , since it is to them that tensile forces are applied.

Make a hole in the upper channel and weld a nut, then screw in the support screw, which will act as a height adjuster for the pressure roller.

The support rollers are made from simple scrap and processed using a grinder.

Two support rollers will move simultaneously; for this purpose, identical bicycle sprockets should be welded onto each axle; the bearings are welded so that symmetry is maintained with the central part of the frame, while maintaining the tension of the chain.

One axle needs to be slightly longer to accommodate the manual drive, and the rollers are mounted on podiums. In the case of the maximum lowering of the central roller, the bending radius of the part will not be large.

For the drive handle, you can take a connecting rod from the pedals; it needs to be welded to the long axis of one of the rollers.

If you need to increase the force on the pressure roller collar, put a pipe of the required diameter on it.

Another option for manufacturing the structure will solve similar problems, but will have a different operating principle.

This design will be equipped with a support roller. Pins of the required diameter are used as rollers; the use of old piston bearings is allowed.

In this design there will be no special fastening for bearings; they will be welded directly to the frame using angles. The handle is made from a connecting rod, and a flat is ground off on the axis of the support roller. The fixation is a simple screw.

The profile is pulled through the upper pressure roller. A special feature of this product is the support lifting roller . The arm is connected to the frame; a hydraulic car jack is suitable as a drive. The bending radius of the profile pipe decreases due to the gradual raising of the rod.

Both the first and second design options can be an excellent homemade solution for use on the farm and even in a small workshop.

As you can see, expensive factory profile benders are not at all necessary for home use, especially if you will not use them often. In this case, you can make them from scrap materials with your own hands, especially since it is not very difficult.

Source: https://tokar.guru/samodelkin/osobennosti-samostoyatelnogo-izgotovleniya-ruchnogo-profilegiba.html

Instructions on how to make a manual profile bender with your own hands, what this device looks like - Machine

deform workpieces with a solid profile with a rectangular or square cross-section;
bend corners, channels and other long products;
bend pipes based on different metals;
perform bending of metal rods with different sections.

Manual and electric profile benders are widely used in the production of equipment and parts for the following industries:

oil refining;
chemical industry;
energy;
furniture manufacturing;
construction and more.

Homemade profile benders are mainly used in small private workshops or for home work.