www.swagelok.

com

Hand Tube Bender Manual

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . Bender Components

.................. 4 5

Tube Preparation . . . . . . . . . . . . . . . . . . . . . . Bender Setup

......................... 6 8

Making Bends . . . . . . . . . . . . . . . . . . . . . . . . .

Springback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Determining Changes in Plane and Direction . . . . . . . . . . . . . . . . . 11 Vise Clamp Block

. . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . 13

Adjustment (Gain) Calculations

Offset Bend Formula . . . . . . . . . . . . . . . . . . 16 Preparation for Accurate Bends . . . . . . . . . . . . . . . . . . . . . . . 17 Tubing Installation Conversions
. . . . . . . . . . . . . . . . . . . . 18

. . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . 20

Decimal Equivalents

Introduction
Swagelok hand tube benders provide consistent, highquality bends in tubing made of stainless steel, copper, steel, aluminum, and a variety of other materials. This handbook will assist you in tube preparation and proper use of the bender. We recommend reading this handbook in its entirety BEFORE using the bender.

Bender Components
Vise Clamp Block Bender Dies Roll Die Link Roll Support Short handle Clevis

Long handle Nameplate Tube Latch

Nameplate Straight Tube Length Mark

Tube Preparation
It is important to use high-quality, annealed tubing and quality cutting tools. Proper deburring of both the inside diameter (ID) and outside diameter (OD) is required to remove all metal chips and burrs.

Tube Cutter

Tube Sawing Guide

Tube Deburring Tool Prior to making bends, it is necessary to mark the tubing. First make a reference mark on the end of the tubing to indicate where layout measurements begin. Next, make a measurement mark to indicate where the tube should be aligned in the bender. Always make this mark a full 360 around the tubing. 5

Bender Setup
0 45 R L

Short handle

Tube latch

MS-HTB-4

1/4

0
45

90
13 5

9/16 RADIUS 180

Bender die

Swing the short handle up so it is above the bender die. Lower the tube latch. Place the tubing in the bender groove, and press the tube latch forward just enough to hold the tubing. This will prevent movement of the tubing during its initial positioning, yet still allow for additional tubing alignment.

0 45 R L

Short handle

MS-HTB-4

1/4

0
45

90
13 5

9/16 RADIUS 180

Carefully lower the short handle until the roll dies rest gently on the tubing. Keep the link straight and parallel to the long handle to prevent premature bending. 6

Straight tube length mark

0 45 R L

Roll support

MS-HTB-4

1/4

0
45

90

Reference mark

9/16 RADIUS 180

Bender die Next, align the zero on the roll support with the zero on the bender die. Then, align the measurement mark under one of the markings on the roll support (see table below).
Angle 45 90 to right of roll support R Reference Mark either side of roll support to left of roll support Mark 45 L

0 45 R L

MS-HTB-4

1/4

0
45

90
13 5

9/16 RADIUS 180

Push the tube latch firmly over the tubing to secure the tubing in the bender die.

13 5

Measurement mark

Making Bends
Bends 90 or Less

MS-HTB-4

1/4

0
45

0 45 R L

90
13 5

9/16 RADIUS 180

After properly positioning the tubing in the bender, slowly push the short handle down until the 0 on the roll support reaches the desired degree mark on the bender die.

MS-HTB-4

1/4

0
45

9/16 RADIUS 180

After completing the bend, swing the short handle up and away from the bender die. Unlatch the tubing and carefully remove it from the bender groove. Avoid scratching or marring the tubing during removal, since this could adversely affect sealing surfaces. 8

13 5

0 45 R L
90

Bends Greater than 90

The right angle design of the Swagelok tube bender offers maximum leverage when making bends. The bender's unique design lets you continue using right angle leverage for bends greater than 90.

MS-HTB-4

1/4

0
45

0 45 R L

90
13 5

9/16 RADIUS 180

Clevis

Begin by following the directions for bends of 90 or less. When the 0 on the roll support reaches the 90 mark on the bender die, loosen the short handle from the clevis (approximately four turns).

MS-HTB-4

1/4

0
45

0 45 R L

90
13 5

9/16 RADIUS 180

Short Handle Then swing the short handle up counterclockwise until it is slightly above the perpendicular position in relation to the long handle. Retighten the short handle. Now you will have continual right angle leverage for the rest of the bend. 9

MS-HTB-4

1/4

0
45

90
13 5

9/16 RADIUS 180

Springback

9/16 RADIUS 180

All tubing will exhibit springback after a bend is completed. Softer tubing, such as copper, will have less springback than harder tubing, such as stainless steel. Experience will help you predict the amount of springback. Expect to allow 1 to 3 compensation, depending on tubing material and hardness. 10

13 5

0 45 R L
MS-HTB-4

Continue the bend until the 0 on the roll support reaches the desired degree mark on the bender die.

1/4

1 to 3
90

45

0 45 R L

Determining Changes in Plane and Direction

When making multiple bends on a single piece of tubing, it is important to keep track of the correct bend directions. You can do this by simply marking the tubing longitudinally on the outside of the intended tube bend direction or the side opposite the bend.

Directional Mark

To ensure that bends will lie in the same intended plane, make sure the tubing is positioned and aligned correctly in the bender.

For bends in the opposite direction of the previous bend, align the end of the tubing with the raised short handle. For bends in the same direction as the previous bend, align the end of the tubing parallel with the long handle. 11

Vise Clamp Block

45 R
9

L
0 18

45

The Swagelok tube bender features a vise clamp block which allows you to clamp the bender in a vise. This feature is especially helpful when bending tubing of a hard material or heavy wall thickness.

12

-H

1 -4

/4

/4

A R

S IU D

135

Adjustment (Gain) Calculations

When determining tube bend locations, adjustment factors must be considered to achieve proper layout.

Radiused Bend
25 .4

P1
1. 00 0 R ad iu s =

Length = 1.57 in. (39.90 mm)

in .(

Sharp Bend
P1

1.000 in.
(25.4 mm)

Length = 2.000 in. (50.8 mm)

m m )

P2

P2 1.000 in.
(25.4 mm)

Adjustment (gain) is the difference in the length of tubing used in a radiused bend compared to the length of tubing required in a sharp bend, when measured from P1 to P2. See Figure above. The distance around a radiused bend is always less than a sharp bend. 13

MS-HTB-4

1/4

0
45

90
13 5

9/16 RADIUS 180

The adjustment factor is determined by the radius of the tube bender and the number of degrees of the bend.

Bend Adjustment
50

% of Bender Radius

40 30 20 10 0

= 43 %

(For other adjustments, use formula) BEND ANGLE = 28 % = 18 % = 11 % =6% =4%

40

90

80

70

60

50

Adjustment Formula = (2 TAN 1/2 - 0.01745 ) R TAN = Tangent = Bend Angle R = Radius

14

Fractional Adjustment Calculations

Tube OD, in. 1/2 Bend Angle 90 85 80 75 70 65 60 55 50 45 3/8 5/16 Bend Radius 1 1/2 5/8 1/2 7/16 11/32 9/32 7/32 5/32 1/8 3/32 1/16 15/16 13/32 11/32 9/32 7/32 11/64 1/8 3/32 5/64 1/16 1/32 15/16 13/32 11/32 9/32 7/32 11/64 1/8 3/32 5/64 1/16 1/32 9/16 1/4 3/16 5/32 1/8 3/32 5/64 1/16 3/64 1/32 1/32 3/4 5/16 1/4 7/32 3/16 1/8 3/32 5/64 1/16 3/64 1/32 1/4 1/4

Metric Adjustment Calculations

Tube OD, mm 12 Bend Angle 90 85 80 75 70 65 60 55 50 45 10 8 6

Bend Radius 38 16.5 13.5 11.0 8.5 7.0 5.5 4.0 3.0 2.5 1.5 24 10.5 8.5 7.0 5.5 4.5 3.5 2.5 2.0 1.5 1.0 24 10.5 8.5 7.0 5.5 4.5 3.5 2.5 2.0 1.5 1.0 15 6.5 5.0 4.0 3.5 2.5 2.0 1.5 1.0 1.0 0.50

Adjustments on angles of less than 45 are minimal.

15

Offset Bend Formula

C
(O) (L) E

When offset exists, determine the length of offset (L) before calculating for the adjustment from the tube bend. To determine the length of offset, select the offset angle (E). Then, multiply the offset dimension (O) by the offset bend allowance. Angle Offset Bend E Allowance 22 1/2 30 45 60 2.613 2.00 1.414 1.154 Offset (O) = ________ = ________ = ________ = Length of Offset (L) _______________ _______________ _______________

An offset bend calculation chart has been provided in 30, 45, and 60 offset angles. For offset dimensions (O) greater than 4 in., use the Offset Bend Formula to determine the length of the offset (L).
Dimensions 30 Offset (O) 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4 4 (L) 2 2 1/2 3 3 1/2 4 4 1/2 5 5 1/2 6 6 1/2 7 7 1/2 8 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4 4 45 Offset (O) (L) 1 7/16 1 3/4 2 1/8 2 1/2 2 3/4 3 3/16 3 9/16 3 7/8 4 1/4 4 5/8 5 5 5/16 5 9/16 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4 4 60 Offset (O) (L) 1 3/16 1 7/16 1 3/4 2 2 5/16 2 9/16 2 7/8 3 3/16 3 1/2 3 3/4 4 4 5/16 4 5/8

16

Preparation for Accurate Bends

C
Reference mark

3 in.
(76.2 mm)

3 in.
(76.2 mm)

9/16 in. R

P1

2.5 in.
(63.5 mm)

P2

To achieve configurations, mark the tubing as follows: P1 = 3 in. P2 = P1 + 2.5 in. 1/4 in. adjustment = 5.25 in. P3 = P2 + 3 in. 1/4 in. adjustment = 8 in. 90 adjustment = 1/4 in. 45 adjustment = 1/32 in.

17

Tubing Installation
Properly selected tubing, combined with quality Swagelok tube fittings, can provide leak-tight systems. When installing fittings near tube bends, there must be a sufficient length of straight tubing to allow the tube to be bottomed in the Swagelok tube fitting:
T R

R Radius of tubing bend as

required or minimum allowed for specified wall thickness and tube size as recommended by tubing manufacturer

SWAG

L T

Straight tube length required from end of tube to beginning of bend Tube outside diameter

Metric, mm T Tube OD Fractional, in. T Tube OD 1/16 1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 2 L 1/2 23/32 3/4 13/16 7/8 15/16 1 3/16 1 1/4 1 1/4 1 5/16 1 1/2 2 2 13/32 3 1/4 3 6 8 10 12 14 15 16 18 20 22 25 28 30 32 38 50 34 40 53 52 54 63 80 32 L 19 21 23 25 31

18

Reliability
For maximum assurance of reliable performance, use Swagelok tube fittings assembled in accordance with catalog instructions, and use properly selected and handled high-quality tubing.

Conversions
Dimensions in. 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1 1/4 1 1/2 2 = mm 1.59 3.18 4.76 6.35 7.94 9.53 11.11 12.70 14.29 15.88 17.46 19.05 20.64 22.23 23.81 25.40 31.75 38.10 50.80 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25.4 Dimensions mm = in. 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.590 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.905 0.944 0.984 1

19

Decimal Equivalents
Dimensions in. 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 = decimal 0.01563 0.03125 0.04688 0.0625 0.07813 0.09375 0.10938 0.125 0.14063 0.15625 0.17188 0.1875 0.20313 0.21875 0.23438 0.250 0.26563 0.28125 0.29688 0.3125 0.32813 0.34375 0.35938 0.375 0.39063 0.40625 0.42188 0.4375 0.45313 0.46875 0.48438 0.500 in. 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 54/64 29/32 59/64 15/16 61/64 31/32 63/64 1 = decimal 0.51563 0.53125 0.54688 0.5625 0.57813 0.59375 0.60938 0.625 0.64063 0.65625 0.67188 0.6875 0.70313 0.71875 0.73438 0.750 0.76563 0.78125 0.79688 0.8125 0.82813 0.84375 0.85938 0.875 0.89063 0.90625 0.92188 0.9375 0.95313 0.96875 0.98438 1.00000

SwagelokTM Swagelok Company 1999, 2003 Swagelok Company Printed in U.S.A., GLL March 2003, R2 MS-13-43