PIPE AND TUBE BENDING - Bends are made by forcing tube against a die to make it change shape. Other methods include pushing a pipe through rollers to force it into a curve. When a pipe is bent the outside wall becomes thinner due to stretching, and compression of the inside wall causes it to become thicker. When a pipe is bent the outside wall becomes thinner due to stretching and the inside wall as it is compressed becomes thicker. This can cause all sorts of problems.

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Pipe and Tube Bending

Principles of Pipe and Tube Bending

Tube bending is a metal forming process used to permanently shape pipe or tubing.

Bending is an important part in the process of manufacturing industrial pipe and tubing.

Pipe can be bent into single or multiple bends and angles depending on what is required by the application.

There are a number of processes used to bend pipes dependent on what the pipe is going to be used for.

Uses for pipes and tubes when bent are both structural; for example, handrails, handlebars, frames for cars, and furniture, or for transporting gases and liquids, such as water lines, hydraulic systems, and exhaust lines.

What Happens when Pipe is Bent?

As a process tube bending starts with loading a tube into a pipe bender and clamping it into place between two dies, the clamping block and the forming die.

The tube is also loosely held by two other dies, the wiper die and the pressure die.

Bends are made by forcing tube against a die to make it change shape. Other methods include pushing a pipe through rollers to force it into a curve.

If you are bending pipes or tubes you need to take note of the following considerations:

1.        Size and wall thickness of the work piece

2.        Materials to be bent

3.        Number of bends in the part

4.        Proximity of the bends to one another (distance between bends, if any)

5.        Plane of bend relationship to one another

6.        Production rates

7.        Finished part tolerances (such as for wall thinning and point-to-point dimensions)

8.        Centreline radius of the bends

9.        Initial cost of equipment (plus training, service, support, repair parts, and tooling)

10.   Return on investment

Basic tools used in pipe bending are:

·                Bend die – tube bent over to create angle

·                Clamp die – holds other side of bend die in place

·                Pressure die – holds tube on top of bend

·                Wiper die – holds tube under bend

When a pipe is bent the outside wall becomes thinner due to stretching, and compression of the inside wall causes it to become thicker.

Four main factors are involved in bending tube:

·                Material – wall thickness

·                Machine

·                Tooling

·                Lubrication needed

Bending Process Types

Basic tools used in pipe bending are:

·                Bend die – tube bent over to create angle

·                Clamp die – holds other side of bend die in place

·                Pressure die – holds tube on top of bend

·                Wiper die – holds tube under bend

Ram type uses a hydraulic ram to force metal against rollers. It is the simplest and cheapest method of tube bending. With ram bending the tube is prone to deform into oval shapes at the inside and outside of the bend. Pipes made using this process are used for bending electrical conduit.

Roll bending passes the pipe through rollers and is used when large bends are required. It causes very little deformation of the pipe. The roll bending process is used to make coils of pipe.

Compression Bending is a simple method that uses a roller to bend the pipe around a bend die. It is used for bending electrical conduit on construction sights. Compression bent pipes cannot be used to make bends with a small radius as the pipe may buckle and brake.

Rotary Draw bending using die sets and is used for more complex work such as when pipe needs to have a constant diameter throughout its length. Rotary Draw products are used to make handrails, ornamental iron work and car chassis.

A Mandrel is used to shape tubing. The mandrel is placed inside the tube to prevent it from being damaged and prevent wrinkles and ovalisation. Pipes made with a mandrel are used to make exhaust pipes, dairy tubing and heat exchanger tubing.

Problems with pipe bending

When a pipe is bent the outside wall becomes thinner due to stretching and the inside wall as it is compressed becomes thicker. This can cause all sorts of problems, including the following:

1. Wrinkling.
2. Hump on outside of pull off end.
3. Scratches in clamp area.
4. Ball segment bumps in bend area.
5. Scratches on inside of bend area.
6. Tooling marks on centreline.
7. Spring back – too much or too little.
8. Collapse.
9. Tearing.

http://www.indanc.academy/principles-of-pipe-and-tube-bending/

CARBON FIBER CLOTH - When the carbon is manufactured into fibers, special additives and elements are introduced to increase strength properties. The primary strength property that carbon fiber is judged upon, is modulus. The carbon is manufactured in bundles of thousands of tiny filaments and wound onto a roll or bobbin. Although we might come in contact with aerospace grade carbon fiber on an aircraft, such as the new 787 Dreamliner, or see it in a Formula 1 car on TV; the majority of us will likely come in contact with commercial grade carbon fiber more frequently.

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Carbon Fiber Cloth

What Is Carbon Fiber Cloth?

Todd Johnson

Carbon fiber is the backbone of lightweight composites.

Understanding what carbon fiber cloth is required knowing the manufacturing process and composite industry terminology.

Below you will find information on carbon fiber cloth and what the different product codes and styles mean.

Carbon Fiber Strength

It needs to be understood that all carbon fiber is not equal.

When the carbon is manufactured into fibers, special additives and elements are introduced to increase strength properties.

The primary strength property that carbon fiber is judged upon, is modulus.

Carbon is manufactured into tiny fibers through either the PAN or Pitch process.

The carbon is manufactured in bundles of thousands of tiny filaments and wound onto a roll or bobbin. There are three major categories of raw carbon fiber:

·       High Modulus Carbon Fiber (Aerospace Grade)

·       Intermediate Modulus Carbon Fiber

·       Standard Modulus Carbon Fiber (Commercial Grade)

Although we might come in contact with aerospace grade carbon fiber on an aircraft, such as the new 787 Dreamliner, or see it in a Formula 1 car on TV; the majority of us will likely come in contact with commercial grade carbon fiber more frequently.

Common uses of commercial grade carbon fiber include:

·                Sporting goods

·                Car hoods and aftermarket parts

·                Accessories, like iPhone cases

Each manufacturer of raw carbon fibers has their own nomenclature of the grade. For example, Toray Carbon Fiber calls their commercial grade "T300," while Hexcel's commercial grade is called "AS4."

Carbon Fiber Thickness

As previously mentioned, raw carbon fiber is manufactured in tiny filaments (around 7 microns), these filaments are bundled into rovings which are wound onto spools.

The spools of fiber are later used directly in processes like pultrusion or filament winding, or they can be woven into fabrics.

These carbon fiber rovings are comprised of thousands of filaments and are almost always a standard amount. These are:

·                1,000 c (1k carbon fiber)

·                3,000 filaments (3k carbon fiber)

·                6,000 filaments (6k carbon fiber)

·                12,000 filaments (12k carbon fiber)

This is why if you hear an industry professional talking about carbon fiber, they might say, "I am using a 3k T300 plain weave fabric." 

Well, now you will know that they are using a carbon fiber fabric that is woven with Toray standard modulus CF fiber, and it is using fiber that has 3,000 filaments per strand.

It should go without saying then, that the thickness of a 12k carbon fiber roving will be twice that of a 6k, four times as a 3k, etc.

Due to efficiencies in manufacturing, a thicker roving with more filaments, such as a 12k strand, is usually less expensive per pound than a 3k of equal modulus.

Carbon Fiber Cloth

Spools of carbon fiber are taken to a weaving loom, where the fibers are then woven into fabrics.

The two most common types of weaves are "plain weave" and "twill."

Plain weave is a balanced checker board pattern, where each strand goes over then under each strand in the opposite direction.

Whereas a twill weave looks like a wicker basket. Here, each strand goes over one opposing strand, then under two.

Both twill and plain weaves have an equal amount of carbon fiber going each direction, and their strengths will be very similar. The difference is primarily an aesthetic appearance.

Every company that weaves carbon fiber fabrics will have their own terminology.

For example, a 3k plain weave by Hexcel is called "HexForce 282," and is commonly called "282" (two eighty-two) for short. This fabric has 12 strands of 3k carbon fiber per inch, in each direction.

Todd Johnson

·   Regional Sales Manager for Composites One, a distributor of composite materials.

·   B.S. in Business Management from University of Colorado Boulder's Leeds School of Business

·   Business Development Manager for Ebert Composites Corporation

Experience

Todd Johnson is a former writer for ThoughtCo, who wrote about plastics and composite materials for 2-1/2 years between 2010 and 2013. He is a Regional Sales Manager at Composites One, a composite materials distributor in San Diego, CA. Johnson provides support to the Greater San Diego manufacturers of fiber reinforced and polymer products. He regularly attends composite industry trade shows including JEC, ACMA, SME, and SAMPE. In 2008 he presented at the Global Pultrusion Conference in Baltimore, MD. Previously, Todd spent six years as the Business Development Manager for Ebert Composites Corporation. 

Education

B.S., Business, Management, Marketing, and Related Support Services - the University of Colorado-Boulder's Leeds School of Business; attended Griffith University in Queensland, Australia.  

Todd Johnson​

ThoughtCo and Dotdash

ThoughtCo is a premier reference site focusing on expert-created education content. We are one of the top-10 information sites in the world as rated by comScore, a leading Internet measurement company. Every month, more than 13 million readers seek answers to their questions on ThoughtCo.

For more than 20 years, Dotdash brands have been helping people find answers, solve problems, and get inspired. We are one of the top-20 largest content publishers on the Internet according to comScore, and reach more than 30% of the U.S. population monthly. Our brands collectively have won more than 20 industry awards in the last year alone, and recently Dotdash was named Publisher of the Year by Digiday, a leading industry publication.https://www.thoughtco.com/what-is-carbon-fiber-cloth-820396

REFRAMING YOUR FAILURES - Many of life’s failures are people who gave up too soon. If you study history, you will find that the best success stories have also been stories of pressing on through failure. They were not born with some superhuman-like resilience that shielded them from disappointment, self-doubt or misgivings. They each had to wage their own inner battles with fear of failure as they worked hard to overcome the external obstacles that lined their path to success.

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How to Reframe Your Failures

Margie Warrell

Once upon a time, a partially deaf 4-year-old boy arrived home from school with a note from his teacher.

It read, “Your son Tommy is too stupid to learn. We cannot have him at our school.”

His mother decided she would teach him herself.

Young Tommy might have been hard of hearing, but he was a good student and grew up to be Thomas. Thomas Edison.

Yes, the man who forever changed how people lived and communicated, and whose childhood bolstered his resilience to press on through the thousands of failures that preceded the success of the electric light bulb.

He would later say, “Many of life’s failures are people who gave up too soon.”

If you study history, you will find that the best success stories have also been stories of pressing on through failure.

Too often though, we overlook the setbacks and only see the end success.

We think the person got lucky. That they were in the right place at the right time. That they were born with a genius we lack. That they were destined for greatness.

But that’s all garbage. Although it might have included a little bit of each, what ultimately led to their success was a refusal to allow setbacks and failures to define them.

Take Walt Disney. As a budding cartoonist, young Walt faced countless rejections from newspaper editors.

He “lacked natural talent,” they said.

One day a minister from a local church took pity on him and hired him to draw some cartoons in a small rodent-infested shed behind the church.

After seeing a mouse, he became inspired to draw it. Mickey Mouse was born.

Even Oprah Winfrey, my very own hero, had her fair share of setbacks, including being fired from one of her first jobs as a television reporter, being told she was “unfit for TV.”

Had she let the opinion of others define her or taken her setbacks as a sign she could never break out from her humble beginnings, she would not be one of the most influential women in the world today.

Of course, you might feel like you have little in common with people who’ve risen to the heights of Oprah, Disney or Edison.

But that isn’t true. You do.

They were not born with some superhuman-like resilience that shielded them from disappointment, self-doubt or misgivings.

They each had to wage their own inner battles with fear of failure as they worked hard to overcome the external obstacles that lined their path to success.

As Bill Marriott, chairman of Marriott hotels, shared with me in a recent conversation, “You don’t succeed by avoiding failure. You succeed by trying and making mistakes and learning and starting over.”

What distinguishes these people is that they did not become a victim to their failures.

When their efforts fell short, they pressed on.

When they fell down, they got back up. When people told them they didn’t have what it takes, they found new doors to knock on.

They each intuitively knew that failure was an event, not a person.

There are things that you and only you can do. Things that will never be done if you do not do them.

But any worthwhile accomplishment is going to call on you to trust in yourself more fully, to risk mistakes and reframe your failures as par the course of what it takes you to succeed.

Most of all, it will take stepping out of your comfort zone again and again, no matter how loud that little voice of doubt is screaming in your head to play it safe, turn back or give up.

How you choose to interpret your failures will either move you forward in life or hold you back.

Every failure can be turned into a steppingstone to success.

Every mistake is a lesson in what not to do. Every setback is an opportunity to dig deeper into yourself, to access resources you didn’t know you had and to acquire wisdom you could gain no other way.

As Richard Branson shared with me during my visit to Necker Island, we mustn’t be embarrassed by our failures.

Instead, we need to learn from them and use them to “fail forward” and succeed faster than we would had we risked nothing.

As I wrote in Brave, “The things we want most lie on the other side of what scares us most.”

Unless we are willing to risk failure, we will never come to know what we are capable of achieving.

It’s why the most successful people risk failure again and again and again but never allow themselves to be defined by it.

So if your story of past failures hasn’t been moving you forward, then it’s time you rewrite one that will.

Margie Warrell

Find Your Courage, Stop Playing Safe, Train the Brave and Make Your Mark — Margie’s four best-selling books speak to her passion for emboldening people to take braver actions and make their biggest mark in work, leadership and life. A sought after keynote speaker and media commentator, Margie Warrell draws on her diverse international background in business, psychology and coaching. Host of the Live Brave podcast, Margie has worked with global leaders such as Richard Branson and sits on the advisory board of Forbes Business School. An intrepid Aussie with a special passion for empowering women change makers, she’s also the mother of four brave hearted children. More on Margie at www.margiewarrell.com.

https://www.success.com/how-to-reframe-your-failures/

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