Induction bending is a pipe bending technique that involves the application of heat from an electric power source using an induction bending machine. Compared to cold bending, induction bending minimizes distortion of the material's cross section, wall thinning, and surface defects that can compromise the structural integrity of the final product. To achieve quality and precision during the induction bending process, there are various parameters that should be monitored and controlled. Failure to do so can compromise the outcome of the pipe bending process. Here are some of the key parameters.
Process speed
It is essential that the speed does not vary during the bending process. The amount of temperature exposed to each part of the pipe during the bending process should be restricted to a narrow range. If the temperature fluctuates, some bend regions will cool at lower rates than others, and the pipe will have variable properties along the arch length. The most common cause of speed variation is slipping of the pipe clamp that's located on the radius arm of the pipe. It is essential to secure the pipe clamp properly so as to avoid slipping.
Temperature requirements
Temperature plays a critical role in the final outcome of the bends. The level of the temperature applied will depend on the type of metal tubing and the nature of the desired bends. Some bending processes are temperature sensitive; therefore, it is essential to identify the suitable level of temperature for your specific application. The process of determining the ideal temperature should be carried out at the preliminary stages of testing the metal pipes.
Pipe cooling
After the heat treatment process, pipe bends should be allowed to cool as they emerge from the induction coil. This process is known as quenching and it gives the pipe bends structural strength. Improper cooling can result in spotty hardness or low hardness rates which can cause the pipe to crack and lose its structural integrity. Proper cooling is especially critical in bending pipeline pipes as cracks can lead to petroleum spillage.
Power interruptions
Induction bending machines make use of electric power. Any form of power interruptions during the induction bending process can significantly affect the outcome of the bends. It can lead to wall thinning, cracks, low hardness rates, and subsequent rejection of the bends. An alternative, automatic source of power should always be available during induction bending.
Induction bending is a highly effective technique of pipe bending that's suitable for applications where high strength and precision are critical to the manufacturing process. Ensuring that these parameters are controlled will ensure the success of the entire process.
