Tube forming system produces roll-over bars

Specialising in the manufacture of tubular steel type components for the motor industry - a South African company wanted a tube bendier capable of producing rollover bars with a central arc.

World leaders in the manufacture of tube forming machinery for the automotive and truck component industries, Lancashire-based AddisonMcKee has recently completed a contract for the supply of an innovative tube forming solution to South African company.

Specialising in the manufacture of tubular steel type components for the motor industry - as well as high quality rollover bars for pick-up trucks - The company concerned required a tube bending solution that was capable of creating rollover bars that incorporated a central arc in their design.

At the same time, the company was keen to invest in newer 'clean' electrically powered technology - with all the advantages of increased plant output, reduced wastage and enhanced product quality.

* A complete tube forming solution - highly experienced in providing complete work-cell solutions for its clients, Addison-McKee created a precision-built, all-electric DB 89 'Databend' CNC tube bending machine for Giflo.

With a key requirement being the ability to bend highly polished stainless material with minimum marking and a central arc in the top horizontal of the rollover bar design, without affecting its structural integrity.

To do this the machine also incorporated the company's push-bend 'Boost' technology.

Capable of bending tubing of a maximum diameter of 90mm, the electrically powered DB 89 machine offers significant advantages over its conventional hydraulic counterparts, where issues such as temperature, setting and positioning inaccuracies can result in a variation in end product quality.

With a fully programmable 9-axis and CNC control of all movements, traditional tube manipulation problems were also removed, whilst multi-stack tooling enabled complex bend on bend solutions with rapid tool changes.

* Push-bend 'Boost' technology - with considerable experience in 'Boost' technology during the bending process (by pushing more of the tubular material into the tooling, any potential for weakness or thinning at the point of the bend is greatly reduced.), Addison-McKee also engineered a large boost stroke system capable of push-bending material lengths of up to 1.5m for the forming of the arc in the required design.

The boost feature was also highly influential in reducing the clamp pressure required for bending the tight radii also demanded.

Surface finish quality is paramount on this type of application.

* Enhanced control and versatility - at the heart of the Addison-McKee tube bender, 'Databend' is an intelligent, flexible computer controlled system that has the capacity to provide complete control, immediate reaction to commands and display total machine operating status.

Through a touch screen interface, all machine and axis moves are selected by the operator.

Fundamental to the Databend system, a novel 'teach mode' also eliminates the need for bespoke machine software sequences, allowing the machine to be 'taught' specific configurations for the creation of specific shapes and improved repeatability.

* Advanced, yet proven features - easy-to-operate and featuring Addison-McKee Windows NT4 software with enhanced 3D graphics and touch-screen programming, the Databend controller harnesses Siemens 840D control technology, incorporating Profibus fieldbus wiring.

World-class design.

Addison-McKee's skilled workforce is capable of manufacturing CNC tube bending and tooling to suit virtually any application large or small.

The company's UK site is equipped with a large variety of modern CNC machine tools, supported by CAM and up to 30 design engineers working within integrated management TQM procedures.

Addison-McKee systems are also used for tube bending and forming applications in the shipbuilding, aerospace, furniture, sports and hospital equipment industries.

Addison-McKee machines are supported by a fast response round-the-clock spare parts and on-site assistance service manned by a team of skilled service engineers.

With over 3,000 of its machines installed worldwide, Addison-McKee enjoys a global reputation for meeting and servicing its customers' needs.

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