J D Squared 4, Assembly & Operating Instructions

Page 1: ...ube Bender Assembly Operating Instructions J D Squared Inc 2244 Eddie Williams Rd Johnson City TN 37601 423 979 0309 FAX 423 979 2426 Internet www jd2 com Copyright 2008 by J D Squared Inc Revision 4...

Page 2: ...screws 3 3 4 nuts 3 1 1 2 diameter frame sleeves 3 1 x 8 bolts 6 1 S A E washers 3 1 nuts 1 1 x 8 diameter frame pin 2 7 8 x 8 frame link pins 1 7 8 x 6 1 4 drive link pins 1 Drive link Lower 1 Drive...

Page 3: ...hree 1 diameter x 8 long bolts six 1 washers and three 1 nuts install the upper frame onto the lower frame Lightly tighten the bolts Next install the 1 frame pin as shown in figure 2 Using a small squ...

Page 4: ...nly 1 thread visible This will put the bolt s head roughly even with the spring pin s head Remove the 1 4 bolt Being careful not to turn the 1 4 nut already installed insert the bolt s head through th...

Page 5: ...r surface is facing up the hole is offset to the top From the engraved side of the pusher block insert one of the two 1 2 shoulder bolt and secure tightly with the 3 8 nylock nut When completed it sho...

Page 6: ...om the electric motor side screw the hose into the right side upper port Wrap 2 to 3 layers of teflon tape around the 1 2 pipe plug and screw it into the left side upper port Make sure both are tighte...

Page 7: ...s drilled through them So with those dies you would only use the hole closest to the flat side of the die Rotate the die until the hole in the die lines up with one of the NUMBERED holes 1 4 in the fr...

Page 8: ...to figures 21 and 22 After the forming die has been installed rotate the drive links counter clockwise until they are parallel with the upper frame link Place the tubing or pipe to be bent through th...

Page 9: ...whereyouwantitbent Referring to figure 24 push the workpiece away from you firmly This will seat the workpiece in between the forming die and pressure die removing any play 8 Install the u block and l...

Page 10: ...rees depending on the yield strength of the workpiece and the amount of bend A tube that springs back 3 degrees at 90 degrees of bend may spring back 5 6 degrees at 180 degrees of bend The only way to...

Page 11: ...f desired bend angle 3 1 2 degrees of springback 97 1 2 Degrees total Extend the ram out until the degree reading is over 50 degrees and just before the lever engages stop the ram Quickly tap the ram...

Page 12: ...rs use a method similar to what is de scribed here It is ex tremely easy accu rate and fast However what if you need to bend 500 pieces How would you use this process Don t worry it s a simple techniq...

Page 13: ...ng However for this application I think it s a waste of time Timeusuallycostmorethantubing so here s the fast way Take the total width of the rollbar 62 and add it to twice the height 40 which gives u...

Page 14: ...e of bend indicators this is easily accomplished Once you know the correct over bend required you may want to record it for future reference BEND 2 Place the template above therollbartubewiththetempla...

Page 15: ...UCTION BENDER USING THE TEMPLATE METHOD As I stated earlier this method can be used for production bending The idea of making the bends from the center out doesn t usually work well in production Most...

Page 16: ...it and simply unbend it Obviously this only works for small amounts of over bend If the tubing is under bent it will be necessary to put it back into the bender D With the tube bent correctly to 90 d...

Page 17: ...s the straight sections and we get 20 1 2 tubing in bends 27 the center section 13 1 2 for the left upright 13 1 2 for the right upright 74 1 2 of tubing needed It s usually a good idea to leave a cou...

Page 18: ...far side of the completed bend to the edge of the bending die See figure 46 This measurement should read 40 width of hoop 3 4 radius of tube not in bending die 1 8 springback allowance 39 1 8 Make th...