End formers have come a long way in the past decade or so.The days of manually loading single tubes and hitting them in one click are coming to an end.
Modern end formers are CNC-equipped; offer automatic feeding, forming, unloading; are designed with tool carousels so they can provide multiple clicks; and often process two tubes at a time, doubling productivity.Sensors check for the presence of features or take measurements that help determine if all processes are performed and completed correctly.These features help manufacturers that lack experienced staff, making the process more automated and reliable than ever before.
This type of machine can meet the needs of most industries, but it is not the only way to perform the end forming process.Airmo Inc., which specializes in pressure technology, has developed a series of end-forming devices based on compact designs, some of which are hand-held.Hydraulic power units are controlled by programmable logic controllers, but these units eliminate tool dials, sensors and other features that facilitate mobility.This type of machine is very handy for applications where it is more beneficial to bring the machine to work rather than the other way around.For some applications, such as working in confined areas, it may be the only way to get the job done.
The company’s largest line is not as portable, but still offers end-forming mobility for manufacturers who need to move the machine from time to time as the process changes.
“The heat exchanger assembly is an ideal application for hand-held end formers,” said CEO Harry Morán.”It allows you to form all the tubes for the heat exchanger on the line.
“You can form both ends of the tube and you don’t need a separate station. You can form the ends, make the U-bend and start welding in one smooth process. If you had to set up the final forming process on a separate station, you would Additional material handling and time are required, adding to the cost of building the unit.”
The company’s 400-series devices are small enough to be handheld, but even at this size, they perform as expected.
“The tube sheet is sandwiched between two beads to create an airtight seal,” he said.“The assembly does not require gaskets, which can deteriorate over time. The tool has been proven to create an airtight seal that lasts for over 20 years.”
These machines are suitable for many applications where space is limited and traditional end-forming machines are difficult to use, especially when other methods have been tried and abandoned – for example, assembly by welding or brazing.If the work area does not provide 360-degree unrestricted access for welding, brazing or brazing around a pipe or pipe, it may be a candidate for a portable endformer.
The company’s Model 400 uses a hydraulic plunger to push the die through the OD or into the ID to compress or expand the tube end.Models M and M6 are available in this and finger style.Also known as a segmented tool, the finger craft uses a series of tools segmented around a center point.When the tube is inserted into the end forming head, the segments either expand the tube from the inner diameter or compress it from the outer diameter.
Although the company’s designs are more compact than traditional end formers, their functionality is unlimited, offering the same expanded, reduced, flared, beaded, and other end forms as full-size machines.
Model 400 Series machines handle diameters from 0.19 to 1.38 inches.outer diameter.Model M is a bit larger than the 400 and can handle diameters from 0.13 to 3.00 inches.outer diameter.The largest is the M6, which forms 3.00 to 6.00 inch tubes.outer diameter.Manufacturers often use this tool by hand, but for a long time it requires a balanced tool holder that can support its weight.Another option is to make a mobile workstation by mounting the hydraulic pump inside the mobile cabinet and mounting the end formers on top of the cabinet.
As with conventional end formers, cycle times are not long.Cycle times can be as short as a second for simple shapes with small diameters of flexible material; Morán says that when machining thicker-walled materials or machining alloys with a lot of springback, the molding cycle time increases accordingly, possibly taking 5 or even 6 seconds.All use a common hydraulic power source, a double-acting type – providing power to extend and retract – capable of delivering 3,000 PSI.
The company provides a complete set of cutaway views for every tool it ships, along with disassembly and assembly instructions.The purpose is for the end user to change the tool and maintain the tool when necessary, with regular disassembly, inspection and repair.
That doesn’t mean Airmo ships the devices out and never sees them again.In many cases, customers require equipment that is certified to meet specific industry standards.The company certifies equipment upon request prior to shipment and re-certifies it when requested by the customer.
Airmo isn’t a big company — it has just a dozen employees — and it’s free of bureaucracy, always trying to stay in touch with customers.
“When you’re on the phone, you’re talking to someone at Airmo,” Moran said.The company does not sell its products through any sales representatives and uses only a few suppliers for resale, which keeps the company close to the market.
PLC, foot switch and tool holder sum up the convenience of using a compact mobile end forming system.
“We don’t use an R&D team,” Moran said.”We rely entirely on customer input for ideas for new products and mods.” While it does make products for common or standard applications, it doesn’t make products that go into stock.Each machine is ordered and run at Airmo prior to shipping.Building each unit to order enables the company to manufacture complete kits tailored to customers.The company does not have a single general catalog of parts, dies and couplers.Each market (e.g. US, Europe and Japan) has its own industry standard or specification, so if Airmo gets an order from a European customer, it provides a 220 V hydraulic power source and includes metric threaded connectors.
“We don’t want customers to develop or modify their processes to match the functionality of our product,” he said.This is the opposite way.”We make everything to order.”
This requires close collaboration with its customer base, which helps the company build expertise.
The company is not limited to using 3,000 PSI units.This is just a starting point.For thick wall applications, it is known to manufacture units that use 15,000 PSI hydraulic pressure, which greatly expands the company’s ability to solve challenging forming problems.
Morán admits that Airmo hasn’t fixed all the problems it encountered, although he estimates the company is able to fulfill about 85 percent of the requests it receives.For the other 15%, it seeks to provide advice based on its many years of experience handling pipes in many applications.As a manufacturer and technical advisor, the company sees its role as a problem solver.
“In some cases, customers may be able to use another machine, such as an off-the-shelf orbital welder,” Morán said.In this case, Airmo makes a recommendation and skips the sale.
The adage “time is money” has many applications, but time often competes with money when a manufacturer decides how to proceed with an end forming project.For tubes that require two or three operations, they have options.
For manufacturers on a tight budget but with extra time, a single-end former can do the job.They can change from one process to the next simply by changing the mold.Those who are pressed for time but have a little extra money on the budget should invest in more than one end former and have a second (or even third) die set installed and ready to maximize their output.
Having multiple forming heads also gives the manufacturer some breathing room so it can periodically remove, inspect and clean the end formers between jobs.
These guidelines also apply to order size.For long-running manufacturers, using a single unit and changing tools may be the way to go.For short runs, having a dedicated unit on hand may be the most effective way to avoid frequent changeovers.
An end former that is too large to be handheld can still be the heart of a versatile mobile system when mounted to a wheeled cabinet.
The world is moving fast, and the speed seems to be accelerating all the time.The product life cycle is certainly not as long as it used to be, is it?Believe it or not, some manufactured products can still be used for decades.Because Airmo is small and flexible, it can supply parts for machines made by large manufacturers that may become obsolete.
“In May 2020, we received a call from a customer who needed a new collet for one of our end formers,” Morán said.“They were a tool we sold in 1955.” Airmo still had prints on hand and was able to ship new collets on short notice.
Products with extremely long lifespans can be problematic for other reasons.For example, if a tubular part is made of an unusual alloy that is hard to find, and the supplier discontinues it, the manufacturer could find itself in a bind.Different suppliers may have similar materials with slightly different molding characteristics, or the company may need to substitute a completely different material.In this case, Airmo’s expertise in metallurgy can help.The solution might be a new toolset or simply a new molding procedure.
“Each alloy has its own forming characteristics and springback characteristics,” Moran said.”Even though a set of tools can form two alloys, the forming process is not necessarily the same. One metal may require a slower forming process or longer dwell time than the other to compensate for the difference in how they are formed.”
In this case, the company draws on its formed knowledge base, some of which is book wisdom and others based on practical experience accumulated over its 75 years of existence.
“We have 6,000 customers,” Moran said.”Each one is unique. Everyone takes a different approach to the molding challenge. But it’s all over, so everyone does the same thing in a different way.”
Tube & Pipe Journal became the first magazine dedicated to serving the metal pipe industry in 1990.Today, it remains the only publication in North America dedicated to the industry and has become the most trusted source of information for pipe professionals.
Post time: Mar-15-2022