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Tube End Former Manufacturer in China
The tube end-forming process is where tube ends are flared, reduced, and shaped using a tube end-forming machine. With years of experience and expertise in the metal tube processing industry, HIPPO’s range of tube end-formers allows you to specify and meet many shapes like swaging, reduction, expansion, flaring, flanging, beading, bulging, chamfering, rounding, tapering, and many other designs.
Our end forming machine is highly utilized by different industries like automotive, construction, motorcycle, air conditioner, lighting, fitness equipment, medical, and other engineering industries. Whatever industry you belong to, the HIPPO tube end forming machine will surely be of use.
HIPPO can shape tubes and pipes with 4mm to 20mm diameter. Our machines can work on different materials, such as stainless steel, carbon steel, mild steel, copper, brass, aluminum, alloys, nickels, and titanium. You name it, just about any metal.
As a professional tube end forming machine manufacturer, we can help you troubleshoot errors and help you achieve high repeatability and accuracy, consistent finished parts, which are with critical tolerances, concentricity, and offsets.
Our clients are satisfied with their HIPPO machines and give us positive feedback. Contact us to be a HIPPO tube end forming machine owner now!
Machines for Choice
You Name It，We Shape It
Hippo tube end former can help you form various end shapes, below are the common ones.
Tube beading is a tube end forming process that creates a bead on the end of a tube. It is the most popular end-forming type.
Tube beads can be used to help hold a hose on the end of a tube or to increase the strength of the tubing, or be used for O-rings. It is often used for products that require a slip-on hose connection.
The principle is to leave a small gap open in-between a clamp that holds one end and a tube forming die that supports the other end. As the two tools hit their end point, the tube collapses at the gap creating the bead.
Slightly adjusting the distance of compression can change the beading width.
Usually, the beading height has to be over the wall thickness. Otherwise, it is very hard to create the shape.
double bead
The tube end outer diameter is increased/stretched. Expanding tube ends is important when connecting tube ends to other parts or assemblies. The expansion is related to the thickness and diameter of the pipe. The wall will get thinner after the end expansion.
Generally, the outside diameter could increase 30-40%, but other results can be achieved if there are special requirements. At the end forming process, different materials will have different reactions.
The tube end outer diameter(OD) is reduced to fit into the inside diameter(ID) of the same tube or similar opening.
Tube flaring is designed to provide an air-tight or fluid-tight seal at the end of a tube, usually applied in hydraulic connecting fittings, it improves accessibility to the interior of the tubing.
The flared joint is close to the fitting and tightly fixed in place with the nut, no gasket or seal is required to prevent leakage.
The end is usually flared to a 37° or 45° angle. 45-degree flares are the most common in automotive direction(brake lines). AN or Army-Navy fittings require 37-degree single flares.
There are three types of flares. Single flare and double flare and bubble flare.
Single flares are easy to crack and leak, only suitable for low-pressure connection demand.
Double flares(also known as SAE and Inverted Style Flare) will fold the material twice, it is more durable and sturdier, it can bear high pressure and make the connecting tighter, can prevent the pipeline connection from crack and leak, usually used in high load connection requirements such as vehicles.
As for bubble flare, it is quite popular in Europe.
Tube flaring and tube flanging are very similar processes. If you flare the tube to 90-degree, then it is a flange. Tube flanging is an end-forming process designed to provide for attachment to other components or hardware.
Round tube ends to make it more smooth when insert it into another tube
Videos
Reducing
Reducing
Reducing
Double beading
Double beading
Double beading
Beading
Beading
Beading
Beading & reducing
Beading & reducing
Beading & reducing
Beading & connecting
Beading & connecting
Beading & connecting
Beading
Beading & chamfering
Beading
Double flare
Flaring & beading
Doming
Notching
Tampering
Expansion
Tailor-made Solutions
HIPPO can customize tube end-forming machines according to your specifications. We can manufacture a double-end forming machine with both ends performing the same function. This machine can help you improve flexibility and is suitable for mass production. A double-head end forming machine where the other end is fixed and one moving is also available.
Beginning with the layout design, HIPPO can integrate pipe cutting, chamfering, pipe bending, automatic feeding, auto lubrication, welding seam recognition, ultrasonic cleaning, lathe processing, laser coding, and automatic unloading into your tube end forming processing system. It maximizes productivity, efficiency, and product stability and consistency.
Whatever the customer requires, we at HIPPO assure you that our customized machines will exceed your expectations.
Durable Tooling
The design of the tools is one of the most fundamental aspects of the tube end-forming machine. Tooling specifications include material type, surface coating, and hardness.
HIPPO’s in-house technician is an expert in designing and developing tools for your specific requirements. Our team can manufacture a complete set of end forming tools that include punching die, mandrel (in some cases), and clamping dies, equipped with different materials, depending on the customer’s request. HIPPO uses alloy tungsten steel in the tube end reduction process. Alloy tungsten lasts longer and is more cost-efficient than other steel. On the other hand, we use Cr12 for the tube end expansion and beading process. Tool replacement is simple and takes only a few minutes.
At HIPPO, we go beyond producing quality, consistent, and reliable products for our customers.
Simple Operation
The operation of the HIPPO tube end former can either be manual or automatic according to your preference. The operating system is simple to grasp and comprehend. Complicated skills are not necessary, which saves you time while setting up.
Strict Production Process
HIPPO designs and manufactures high-quality tube end former machines using modern and innovative tools and technology. We make sure that all of our designs are continually improving and conforms to the standards.
HIPPO uses advanced and fully automatic CNC machining equipment, ensuring a fast and efficient manufacturing process. We also use a high-quality Q235 welded steel plate to make the machine’s body. After that, it passes through overall tempering and a thorough quality examination to eliminate internal stress, induce sufficient strength, stiffness, and life. We use nodular cast iron QT500 for clamping devices and other machine parts. Hippo specially selected well-known brands for the machine components like the electrical system, hydraulic system, solenoid valve, guide rail. Our entire HIPPO tube end-forming machine undergoes strict quality assurance before being delivered to your hands.
24/7 Service
Once the HIPPO tube end-forming machine is shipped, we will be providing you photos and video tutorials for guidance and instruction. It will come with a 14-month warranty period. Our customer support team is friendly and immediately available to assist you, answer your questions, and provide technical support 24 hours a day, seven days a week.
Tube End Forming Machine Ultimate FAQ Guide
Contents
End-forming techniques modify the geometry of tubes. Tubes are reduced, machined, and shaped into different configurations. They are reshaped so that features like seals, rings, and nut fittings are fixed to connect the tubing to critical components i.e. braking system.
In this quick guide, you’ll learn the basics of operations and recommendations regarding the working/applications of end-forming machines.
Chapter 1. What is end forming？
End-forming is a process used to alter and improve the geometry of a tube. Usually, the transformation occurs near or at the end of the material. This traditional process was once performed using special castings.
But manufacturers now prefer custom, machine-forming for better quality and cost-efficiency.
End forming can be done by beading, expanding, flaring, grooving, reducing, knurling, and flanging the tube. This operation also entails a diversity of part arrangements and components i.e. steel, copper, aluminum, brass, and stainless steel.
Chapter 2. What is an end forming machine？
End-forming is a proper and efficient technique for tube fabrication. But if done by an old process i.e. using castings, it can be time and asset-consuming.
Premium end formers or end forming machines can be used for prompt yet more accurate results. The tubes transformed by using tube end forming machines can be round, rectangular, or square in shape.
By using end-forming machines you can also generate contact points between two different media normally used in automobiles and offers leak-proof services.
Chapter 3. How many types of tube end forming machines are there?
The tube-end formation process for changing the shape of the end of a tube is carried out by some basic methods:
- Segmented tool sizing
- Ram forming
- Rotary forming
- Roll forming
- Spinning
The most common ones are segmented tool sizing and ram forming.
Rotary forming, roll forming, and spinning have their particular benefits, as they are capable of functioning around the circumference of the metal tube. Particularly, they are used for progressive tube-forming processes i.e. sharp angles and essential diameter alterations.
Segmented tool sizing, ram forming is used to work the entire circumference at one time.
Chapter 4. What is the working principle of a tube end former?
Tube end forming processes depend mainly upon the deformation of ends of the tube. The deformation is followed by desired shape production rather than adding caps or welding. A tube end fabrication by using a tube end forming machine is quite clear-cut and simple:
- You can insert a hollow tube into any tube end forming machine, using a manual or automatic loading method.
- Fix the tube in position and secure it with clamp dies.
- Then the end forming starts working; it uses some sort of pressure i.e. hydraulic pressure.
- The hydraulic cylinder hit and pushes punches towards the tube.
- It presses the ends of the tube against a forming tool to form the desired shape on the tube end
- The method and machine type used depends upon the material thickness, shape required, and tolerances.
Chapter 5. What metal can tube end forming machine work with?
Tube-end forming machines are highly functional. They are designed to be compatible with a variety of part specifications and materials. The incredible durability and strength of the machine allow it to work with the hardest metal tubes as well.
Any type of metal that is capable of being molded in a cylindrical shape can be processed using end formers, comprising but not restricted to the following metals:
- Carbon steel
- Aluminum
- Stainless steel
- Copper
- Nickel and steel alloys
- Brass
Chapter 6. What are the benefits of a double-head end former machine?
Double head pipe end forming machine is a highly efficient and automatic machine. It allows you to perform a different type of end forming i.e. reduction, flanging, flare, beads, and expansion. Here are some benefits of having a double-head end machine:
- Each of these categories is operational in a broad range of applications, that’s why they have typical requirements.
- The machine can be controlled by hydraulic and electrical power at the same time.
- It is capable of mass production for volume applications, i.e. with double heads.
- You get a perfect blend of easy-to-use operations and high-end forming accuracy with cost-effectiveness.
Chapter 7. What is the tube end forming machine applications？
Tube end forming has virtually limitless applications. The tubing process is being used in a variety of applications.
Tube formers remodel tubes so that features like seals, rings, and nut fittings and coils are fixed. It will connect the tubing to critical component applications i.e. braking system, air conditions, oil filters, and hydraulics lines.
Automotive and motorcycle industries use tube end forming for power transmission applications i.e. fuel lines and exhaust pipes, water transfer pipes.
Many other industries use tube end formation for A/C lines, gas lines, fuel filters, oil filters.
Chapter 8. What are the benefits of tube-end formers?
Tube end formers are quite functional. They are mostly used for mass production with reliable and long-lasting performance:
- You can decrease the expenses of fittings and brazing materials with an end former.
- The machine is convenient to assemble. You won’t need any expensive fitting pieces.
- It decreases the overall working time.
- Recovers product integrity by eradicating leak points.
Chapter 9. What shapes can tube end-forming machines make?
Tube-end forming machines are designed to transform tubes into different configurations. The tubes are altered by a premium tube end former, and they can be round, rectangular, or square in shape. Usually, some of the most common shapes can be molded by:
- Reduction(swaging): reduction is used to lessen the outside diameter (OD) of any tube so that different parts can fit into each other.
- Expand: You can enhance the overall exterior diameter (OD) of a tube by expanding technique.
- Bead (or bulge): It is used to form a bead on the tube end and so that the hose can easily move over a tube.
- Flare: It enables the connection of tubes or other assemblies together.
- Nose: The technique is used exclusively to restrain the movement of a gas or fluid out of the tube’s end.
- Groove: Seal a part of O-rings into an assembly by grooving.
- Notch: Notching allows you to weld a part onto another tube.
- Flat: By flattening a tube’s end, you can combine it with other parts by piercing a hole in the flattened surface.
Chapter 10. How to perform beading for efficient tube fabrication?
Beaded tubes can be created by using a combination of hand beading tools or, end-forming machine beading rolls. The diameter and thickness of the tube walls determine the method used for its production.
A beaded mount is added to the tube forming machines to generate bead-shaped tubes. For gaining efficient results the bead frame should also include proper rollers.
Lubricate the exterior as well as the interior of the tubes. You can use a light oil to reduce friction between rollers. By doing so you can also prevent different tube damage i.e. scratches.
The marks present on the sixteenth inch on the rollers designate the exterior diameter of the tubing. This is the diameter that can be beaded by using the rollers.
Chapter 11.What are the applications of beaded tube ends?
Beaded tube ends are quite useful. They have various benefits and applications in different industries:
- Beaded joints between tubes are most commonly used for O-rings
- They are capable of forming optimum diameters to connect a hose to the end of a tube.
- It is also used to link exhaust tubes or fuel lines with lower pressure together.
- These tubes are also compatible with lower-pressure air, exhaust system, and liquid systems in the locomotive and boating industries.
- You can also use these tubes to diminish trembling in solid lines.
Chapter 12. What are different types of Tube flaring?
The flaring tube fabrication is categorized into two different types:
1. Single Flaring
This tube end formation method is typically used to create a liquid-tight, airtight connection at the end of a tube. You can perform rotary or spinning techniques for a flared end, or just ram forming
2. Double-Lap Flaring
It offers extra strength to the tube ends. Mostly used for the tubes are exposed to more stress and fatigue. The joint is created to have a larger diameter for the inner surface of the flare. An increased tube end diameter prevents it from restricting the flow characteristics of the system.
Chapter 13. What is the working principle of Tube End Spinning machines?
Spinning end formers are fully automatic machines. They are ideal for closing, reducing, and expanding copper and brass tubes. Adjust the tube in the machine and fix it using special clamps. A rotating die will spontaneously be fed against the tube end.
The friction is created because the rotating die heats the tube end. This movement allows the tube end to rapidly take the shape of the die.
Chapter 14. What is a CNC tube end-forming machine?
CNC tube end forming machines can take your tube end forming project to the next level. Computer-numerical control (CNC) machining is capable of automatic and rapid mass production for volume applications.
Every machine requires a skilled technician, for proper functioning. But with CNC machining only one skilled person can operate several machines.
Whether your project requires custom or standard tube end formation, these machines can deliver reliable and long-lasting performance. So it can easily handle the most complicated manufacturing operations by consistent production and repeatable results.
Chapter 15. What are the advantages of CNC tube end forming machines?
CNC tube end formers are a must-have item for both large and small industries.
It offers efficient, convenient, and precise production capacity. The machine is ideal for mass generation i.e. large quantities of items.
Chapter 16. What is a ram tube end-forming machine??
Ram ending is one of the most general types of tube end processing. Ram end formers are ideal machines platforms for the production of multiple types of end formations at the same time in one operation.
Some ram machines are considered as impeccably advanced tube end formers. They are constructed with the ability in being prepared with several tools. They can create different end forms on a single tool.
Aside from exceptional power, a ram tube end machine is capable of progressive expansion or reduction of the tube for minimizing the tube OD (outer diameter). Thus, the technique is also termed progressive ram end forming.
Chapter 17. What is the principle of ram tube end former?
The ram tube end fabrication is carried out by loading the tube into some clamp dies. The clamps die contain cavities cut within them for the tube to fit in. As the end forming cycle starts in an end former, immediately the dies are closed.
It will allow you to hold the tube in place during the process.
A shuttle with a single or a set of tools moves the tube forward. These tools are responsible for the formation of the tube’s end. They induce the metal to move rather slowly in the machine also referred to as cold flow. The metal follows the path created by the tools at minimum resistance.
The tube keeps moving until a sketch is prepared and separated inside the tool and forms the dies.
Chapter 18. Are ram tube end forming machines worth it?
Having a Ram end formers can be quite advantageous. The machine can generate powerful wall thicknesses of approximately 0.500 by using its hydraulic power. Some of the most premium end former models can provide almost 250 tons of force for end-forming.
The hydraulic power can considerably amplify their expansion and reduction range capabilities. You can get exceptional services as compared to other machines i.e. rotary or segmented method following end formers.
Apart from its many benefits, the ram tube end forming machines possess some drawbacks as well. Depending on the material used for the tube, beads with tight or radical radii formation may be quite challenging.
This all happens because the movement of materials into the radii profiles cut within the dies is difficult.
Chapter 19. What is the difference between ram tube end former and segmented tool sizing？
Most ram end forming applications are compatible with segmented tool sizing as well. However, these processes still have some important features with distinctive differences.
Ram tube end forming machines
Ram forming also known as bulldozing utilizes a powerful process. It is capable of driving a tapered plug on the interior or tapered cup around the exterior of any firmly held tube end.
If you require powerful and high-precision, long-lasting performance, ram tube end formers would be an ideal option. Ram-type tube end formers are proficient in constructing tubes having serious tolerances, concentricity, and offsets.
Segmented tube end forming machines
Segmented tool sizing affects the tube circumference outwardly. For tube OD reduction the process consumes a set of segmented dies. These dies are designed bigger in size.
You can use segmented tube end-forming machines for low-volume products. It doesn’t offer high-end forming precision. But it still works perfectly with lower capacity items. These machines contain eight finger tools power-driven by the mechanical drawbar.
Chapter 20. What is the difference between the rotary tube end former and the ram tube end former?
Both methods are used for effective tube fabrication, but differ in some aspects;
Ram tube end former
It is exceptionally powerful and functional end former. The machine provides working in both interior and exterior tube circumference. Heavy-duty ram machines are mostly used for mass production applications. They can efficiently create tubs having severe tolerance and offset.
Rotary tube end former
Rotary end formers can fabricate tube and pipe ends anywhere ranging from 0.50” – 18.0” in diameter. These tube end forming machines are used for progressive tube-forming procedures i.e. sharp angles and critical diameter alterations.
Chapter 21. Are any tools required for tube-end forming?
End fabrication process requires some particular tools. Tools used in each process are designed in contrast to the divisions needed for the application, the nature of the material, and the type of machine being used.
Hardness, tube end planning, tooling coatings, and materials required are in control of defining the tooling conditions.
Centered on the materials and preferred expansion, lubricants of various categories are also used in the process
Chapter 22. What is the most popular tube end-forming machine?
CNC tube end formers are without any doubt most popular among industries today. Because of their large-scale production and automatic features many large and small companies prefer this machine over any other manual one.
The computer-numerical control (CNC) offers many commercial and production advantages over the conventional method. Plus, they don’t require a team of skilled technicians to work, only a single person can use it to control multiple machines at the same time.
Its convenience and exceptional performance make it the most preferred tube-end machine among many industries.
Chapter 23. How much does the tube end-forming machine cost?
Tube end forming machines are available at a wide range of prices. The cost of an end former model depends upon its applications, quality, performance, and management.
Most machines are available in exceptional quality, high-performance machines at affordable prices. You can look for products that could be worth your investment.
Chapter 24. How to choose a suitable tube end former？
A high-end tube end former can help you boost your business. But it is important to invest in a highly functional product. There are should some features you should take into account before buying a tube end forming machine.
1. Material
The machine should be compatible with many tube materials. An ideal tube end-forming machine can work with several materials.
2. Performance
An end former should offer constant, high-quality performance for decades. It is best to opt for a machine that is capable of providing durable and long-lasting performance.
3. Installation
A machine with easy installation settings and assembling should be preferred to save time and money. Some machines require special tools and installation methods, which can be time-consuming.
Consider a machine with more convenient installation settings to start working right away.
4. Sizes and shapes
The machine should work with different tube sizes and offer a wide range of shape configurations. Tube-end forming machines with higher compatibility with various tube shapes and sizes make it more preferable.
You will be able to work with different tubing sizes and form distinct shapes by using a single machine.
Chapter 25.Do tube end formers require maintenance?
For constant and efficient performance it is obligatory to clean and maintain your tube-end forming machine. The cleaning process isn’t much complicated. By following a maintenance schedule, you can help avoid major problems before they occur.
Most companies provide a complete guide for machine cleaning and maintenance with the product. It will allow you to learn proper methods and tricks for effective cleaning.
Chapter 26.Where to find tube end forming machine manufacturers?
Tube end forming machines are quite eminent nowadays. Because of their increased demand, many companies have started supplying these end formers. You can find many manufacturers but for your business’ sake, it is necessary to opt for an ideal option.
Most metal tube processing machinery manufacturers concentrate on the research and development, manufacturing, and sales of premium quality tube end forming machines. You can easily find them on the internet providing their best services.
Conclusion
Tube end forming machines are highly convenient and offer long-lasting, reliable performance. For a better selection, it is important to be well-informed before buying.
We hope this guide helps you learn and make better choices.
From design, manufacture, and installation to ongoing service and support, be sure that your machine is perfect in each aspect.