How to Prevent Wrinkling in Tube Bending

Understanding the Causes and Solutions

Wrinkling is one of the most common problems in tube bending. When a tube is bent, the inside of the bend is compressed while the outside is stretched. If the process parameters or tooling are not properly configured, the inner wall of the tube may form wrinkles.

For manufacturers, this issue not only affects product appearance but can also reduce structural strength and product quality.

Understanding the causes of wrinkling is the first step toward achieving perfect bends.

Why Tubes Wrinkle During Bending

Several factors can cause wrinkling during the bending process.

1. Bending Radius Too Small

When the bending radius is too tight relative to the tube diameter, the material on the inside of the bend has nowhere to go and begins to fold.

2. Lack of Proper Mandrel Support

Without a correctly positioned mandrel, the inner wall of the tube cannot maintain its shape during compression.

3. Incorrect Pressure Die Setting

If the pressure die force is too low, the tube will not be properly supported during bending.

4. Material and Wall Thickness

Thin-wall tubes are more prone to wrinkling because they are less resistant to compression forces.

5. Tooling Design Issues

Improper tooling configuration, including clamp dies and wiper dies, can also lead to wrinkles.

Effective Solutions to Prevent Wrinkling

Use a Proper Mandrel

A mandrel supports the inside of the tube and helps maintain the internal shape during bending. Multi-ball mandrels are often used for tight radii.

Install a Wiper Die

A wiper die helps smooth the inner surface of the tube and prevents material buildup that causes wrinkles.

Adjust Machine Parameters

Correct pressure die force, boost settings, and bending speed can significantly improve results.

Optimize Tooling Setup

Proper alignment of clamp die, pressure die, and bend die is essential for stable bending.

Select the Right Bending Radius

When possible, increasing the bending radius can reduce compression and prevent wrinkles.

The Importance of Professional Tube Bending Equipment

Advanced CNC tube bending machines allow operators to precisely control the bending process. With proper tooling and machine settings, manufacturers can achieve consistent and high-quality results.

Modern machines also support complex bending applications in industries such as:

• Automotive manufacturing

• Furniture production

• Fitness equipment

• Construction and energy equipment

Achieving High-Quality Tube Bending

Wrinkling can be avoided with the right combination of machine technology, tooling design, and process control.

By using professional tube bending equipment and experienced setup methods, manufacturers can ensure smooth bends, accurate shapes, and reliable production.

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