Abstract: A method is provided for setting up a tube bender having a bend die, a clamp die, a pressure die and a wiper die. The method includes providing a test-piece having an outer surface defined by a length and a substantially round cross-section. The method also includes arranging the pressure die, the clamp die, and the wiper die relative to each other in the tube bender, and arranging the test-piece relative to the pressure die, the clamp die, and the wiper die. The method further includes applying a force by the tube bender to clamp the test-piece, and determining whether the applied force is within a predetermined range of forces. Additionally, the method includes adjusting the arrangement of at least one of the pressure die, the clamp die, and the wiper die to apply a force to the test-piece that is within the predetermined range of forces.

Abstract: A high pressure pump includes a pump housing. A piston rod located within the pump housing defines a plurality of pump cavities and a plurality of piston cavities. Movement of the piston within the piston cylinder pumps the fluid from the piston cavities out of the high pressure pump. The continuous pumping of HWBF from the pump housing provides fluid at a relatively constant flow and pressure. The HWBF pressure is also at a higher pressure than traditional single stage high pressure pumps can provide.

Abstract: A method is provided for setting up a tube bender having a bend die, a clamp die, a pressure die and a wiper die. The method includes providing a test-piece having an outer surface defined by a length and a substantially round cross-section. The method also includes arranging the pressure die, the clamp die, and the wiper die relative to each other in the tube bender, and arranging the test-piece relative to the pressure die, the clamp die, and the wiper die. The method further includes applying a force by the tube bender to clamp the test-piece, and determining whether the applied force is within a predetermined range of forces. Additionally, the method includes adjusting the arrangement of at least one of the pressure die, the clamp die, and the wiper die to apply a force to the test-piece that is within the predetermined range of forces.

Abstract: A hydroform die includes a plurality of seal units to provide fluid to die cavities. The plurality of seal units each define a piston cylinder. A piston is located within the cylinder and is selectively moveable between an open and a closed position. Additionally, the piston at least partially defines a valve chamber located on a first side of the piston and a piston chamber located on a second side of the piston. A piston fluid passage is defined by the piston to fluidly connect the valve chamber and the piston chamber.

Abstract: A high pressure pump includes a pump housing. A piston rod located within the pump housing defines a plurality of pump cavities and a plurality of piston cavities. Movement of the piston within the piston cylinder pumps the fluid from the piston cavities out of the high pressure pump. The continuous pumping of HWBF from the pump housing provides fluid at a relatively constant flow and pressure. The HWBF pressure is also at a higher pressure than traditional single stage high pressure pumps can provide.

Abstract: A hydroform die includes a plurality of seal units to provide fluid to die cavities. The plurality of seal units each define a piston cylinder. A piston is located within the cylinder and is selectively moveable between an open and a closed position. Additionally, the piston at least partially defines a valve chamber located on a first side of the piston and a piston chamber located on a second side of the piston. A piston fluid passage is defined by the piston to fluidly connect the valve chamber and the piston chamber.

Abstract: In a rotary tube bender, a first set of pressure sensors is located between the normally disposed mating surfaces of a wiper die insert and its wiper die holder; and a second set of pressure sensors is located between the axially disposed surfaces of the wiper die insert and the wiper die holder. Signal outputs of the first and second sets of pressure sensors over the course of bending cycles are compared to previously determined nominal signal outputs for drift indicative of whether a realignment or replacement of the wiper die should be performed.

Abstract: A method of bending a metal object, such as a tube, is provided that uses real time, closed-loop feedback of the actual springback of the object in order to modify the applied bending force or preprogrammed bending coordinates so that the final desired bend geometry is achieved. The variability of springback from object to object is thus accounted for and the number of objects that must be scrapped due to incorrect bends (over bend or under bend) is reduced. The method is carried out using an apparatus such as a rotary draw bender with a measuring device operable to measure actual bend coordinates of metal objects bent by the bender. A controller is operatively connected to the bender and the measuring device and is configured to control the bender to bend the metal objects at least partly based on measured bend coordinates provided by the measuring device.

Abstract: A method of bending a metal object, such as a tube, is provided that uses real time, closed-loop feedback of the actual springback of the object in order to modify the applied bending force or preprogrammed bending coordinates so that the final desired bend geometry is achieved. The variability of springback from object to object is thus accounted for and the number of objects that must be scrapped due to incorrect bends (over bend or under bend) is reduced. The method is carried out using an apparatus such as a rotary draw bender with a measuring device operable to measure actual bend coordinates of metal objects bent by the bender. A controller is operatively connected to the bender and the measuring device and is configured to control the bender to bend the metal objects at least partly based on measured bend coordinates provided by the measuring device.