FLAWLESS 1 X DIAMETER TUBE BENDING FOR TPCATS

Friday, 10th July 2015 TPCATS, a leading manufacturer and supplier of aftermarket emission control systems, has purchased a highly advanced CSM 1-D tube bending machine plus tooling from Tubefab. The model in question, a CSM 100TDRE-RBE, is a 5-axis, double stack electric hybrid tube bender with electric boost. It has equipped TPCATS with the capability to deliver the very tightest radius bends that are being increasingly sought by motor manufacturers and associated first- and second-tier equipment manufacturers. Leading the way in product development “Today’s drive towards more tightly packed engine bays, wider diameter exhaust systems, and rapid warm-up times achieved by positioning catalytic converters even closer to exhaust manifolds, is clearly signalling a growing demand for 1-D bending,” comments TPCATS’ Managing Director Paul Stubbs. “By purchasing the machine, a 100mm maximum tube diameter 1-D boost bender,” he continues, “we have clearly signalled our intent to lead the way in developing and manufacturing the next generation of aftermarket catalytic converter and DPF solutions.” As well as assisting TPCATS’ research into areas such as multi-branch manifolds and the incorporation of catalytic converters into manifold assemblies, the CSM tube bender has also enabled the emission control specialist to begin producing components that it had not previously been able to source. Flawless 1 x diameter bends “We were already successfully bending at 1.5 x diameter,” adds Paul Stubbs. “The CSM machine, however, has equipped us with the means to produce flawless 1 x diameter bends. We are currently bending 70mm diameter mild steel, stainless steel and titanium at 1-D, as well as producing complex components involving multiple and tight radius bends – with reduced requirements for fabrication and welding. We will soon be extending that capability to 80mm diameter tube for even greater performance opportunities.” Knowledgeable and supportive “Throughout the entire process – from placing the order, to installation and commissioning – Tubefab has been incredibly helpful and supportive,” says Paul Stubbs. “In fact, it has been refreshing to deal with an organisation whose primary concern is using its considerable knowledge to help its customers find the right solution.” Max Capacity / mild steel OD 100 x WT 3.6 Bending CLR 30-300 Bending Speed 58 deg/sec Feeding Speed 450 mm/sec Rotation Speed 120 deg/sec Accuracy / repeatability ±0.01 Mandrel working distance 3500 At-a-glance, the CSM 100TDRE-RBE 5-axis, double stack, electric hybrid tube bender with electric boost: Master 3, PC-based control 15" touch screen for operator interface User-friendly programming 3-D bending simulation, 3-D preview and collision prevention Bend-arm (C-axis) - servo motor + exclusive transmission gears Clamp Die - hydraulic Pressure Die - hydraulic Carriage (Y-axis) - servo motor Rear boost - servo motor Collet (B-axis) - rotation by servo motor, grip by hydraulic. Tooling shift - motion up-down by hydraulic, left-right by servo motor Automatic mandrel lubrication Anticipated mandrel retraction unit Standing pedestal - serves emergency stop and remote control CE mark Laser guard scanner and perimeter safety fence