Technologies
26.02.2021
Ken Cleal
Estimated read time: 4 minute/s
Technologies
26.02.2021
Ken Cleal
Estimated read time: 4 minute/s

Automatic Correction During Production

Why the dimensional accuracy and stress-free assembly of manipulated tubes essentially depends on the detection and correction of springback during the production process

Springback is the term used to describe the geometric change in a component after it has been formed, as soon as the forces of the forming tool cease. After completion of sheet metal forming, for example, deep and stretch-formed parts spring back in the direction of their original state. This influences the dimensional accuracy of the finished part. 

The detection and correction of springback is also one of the special challenges in the mechanical cold bending of hydraulic tube – for example made of steel, stainless steel or copper, but especially when more 'exotic' materials are being used. The extent of springback is influenced by various factors such as the tube material, the tube diameter, the tube wall thickness as well as the bending angle, the bending radius and the bending speed. If the springback is not checked and, if necessary, compensated for after the actual bending process, the tube will not be dimensionally accurcate and may not be able to be installed stress-free later during assembly. The result: potential leakage risks at the connection points! 

The latest generation of tube bending machines with a laser-assisted springback monitoring and correction system are used in the worldwide STAUFF production facilities for manipulated tubes.

Laser-Assisted Springback Correction System

The bending values recorded by a laser measuring system during the production process are transferred directly to the machine's control system, where they are compared with the defined target values and converted into an automatic correction bend. The laser measuring system measures this achieved bend while the tube remains clamped on the machine. The innovative system works by recording the reflection distance of two laser beams using a reference measurement on a straight section of the tube. After bending, the system automatically orders the opening of the clamping mechanism until the material has sprung back, and then takes a second measurement from which the current bending angle is calculated. A determined difference to the programmed bending angle results in the tube being automatically clamped again and corrected to the required bending angle in an additional bend via a simple button operation. 

The laser-assisted springback monitoring and correction system enables STAUFF to produce good parts immediately without the usually required test bending to determine springback and to keep the quality of the production process consistently high right from the beginning.

Ken Cleal | Head of Production STAUFF UK and Global Product Manager Tube & Tube Manipulation

"From simple to complex geometries, the STAUFF Group has all of your requirements covered. With a vast tooling inventory, state of the art all-electric bending machines at all STAUFF Line locations and highly skilled staff, the STAUFF Group is the only supplier required to fulfill your needs for manipulated tubes."

Tube Manipulation from STAUFF Worldwide

The companies of the STAUFF Group and their authorised system partners offer original equipment manufacturers in the fields of mobile and industrial hydraulics the following services with regards to the production and further processing of ready-to-install hydraulic pipes and tubes:

  • Automatically controlled and monitored bending of seamless precision tubes made of carbon steel (Zistaplex®, Zista® Seal, zinc plated, phosphated, untreated), stainless steel, copper and various special materials in a large variety a common metric tube diameters and wall thicknesses and lengths up to 6 metre
  • Automatically controlled and monitored assembly of cutting rings and union nuts 
  • Tube end forming with STAUFF Form and other common systems
  • Inductive soldering, brazing as well as WIG, MIG and MAG welding for non-positive connections
  • Testing according to standard or customer’s specification
  • Cleaning to achieve specific cleanliness levels and specifications
  • Sealing and protecting the tube ends and other connections

STAUFF Center of Excellence for Tube Manipulation

With its headquarters located in Sheffield (United Kingdom), STAUFF UK Ltd. forms the Global Center of Excellence for tube manipulation within the STAUFF Group. For almost 30 years, the design of complex pipework systems and the  manufacturing and processing of tubes in accordance with customer requirements has been part of the daily business of the specialists on site.

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Head of Production at STAUFF UK and Global Product Manager Tube & Tube Manipulation
Ken Cleal
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