Metal Tube Forming

Vulcan Industries provides metal tube end forming for some of America’s most successful and diverse original equipment manufacturers. Metal tube end forming is one method used to add features to the end(s) of tubing to meet the overall design and application of the tube. For example, end forming is necessary for creating a connection to another component or a close fit, such as for fluid-handling systems. Tube end forming can create enhanced tube strength, improvements to connectivity, and increased sealing capabilities.

View case studies for the unique solutions to our customers' problems

• Automating Pushrod Tube Polishing

• Resolving Push Rod Tube Material Defects

Tube End Forming Shapes

With our precise equipment and knowledgeable staff, unique tube forms are not a challenge for Vulcan Industries. We form tubes into a variety of end shapes such as flaring, flange, reductions, expansions, beading, sizing and rounded roll over.

Flare, Angular

Function

The end of tube angular flare feature is used as a sealing surface against an O-ring or gasket.

Process

Using a die or mandrel to support the tube, a punch is inserted to obtain the desired shape.

Flare, Ball, Male or Female

Function

The flare feature is used as a sealing surface against an O-ring or gasket.

Process

Using a die or mandrel to support the tube, a punch is inserted to obtain the desired shape.

Flare, Flat

Function

The flare feature is used as a sealing surface against an O-ring or gasket.

Process

Using a die or mandrels to support the tube, a series of punches are used to displace the material.

Flange with Insert

Function

The larger OD has a special fitting to tighten the flange feature against an O-ring or gasket.

Process

Using a die or mandrels to support the tube, a series of punches are inserted to obtain the desired shapes.

Reduction, End, Taper or Shoulder

Function

The reduced end will fit into the inside diameter (ID) of the same sized tube.

Process

Using a die or mandrel to support the tube, a die is used to reduce the outside diameter (OD) of the tube.

Expansion, End, Taper or Shoulder

Function

The expanded end will fit over the outside diameter (OD) of the same sized tube.

Process

Using a die or mandrel to support the tube, a form punch is used to increase the inside diameter (ID) of the tube.

Expansion, Straight

Function

The larger OD has a special fitting to tighten the flange feature against an O-ring or gasket.

Process

Using a die or mandrels to support the tube, a series of punches are inserted to obtain the desired shapes.

Expansion, Middle (Bulging)

Function

An O-ring groove is formed along with aesthetic features to suit the design requirements.

Process

Using a die to support the tube, an elastomer is inserted into the tube and compressed to obtain the desired shape.

Beading, Hose or Stop

Function

A bead is used in a hose clamp application while a tube stop feature can be used as a feature compressing an O-ring or gasket.

Process

Using a die to support the tube, a punch and die are inserted to compress the tube to the desired shape.

Sizing, OD or ID

Function

Standard tube size tolerances are reduced to create the desired fit with a mating part.

Process

Using a die or mandrel to support the tube, a punch or die is used to qualify the OD or ID of the tube to the desired size.

Tube Forming Process

Tube forming at Vulcan Industries is accomplished using cold forming techniques. In high volume production, using a shearing process, parts are cut to the required length from 20-foot random. Parts are automatically fed into mechanical presses using a vibratory feed system that transfers tube blanks into a die mounted magazine. Using a slide feed system, parts are transferred into a cold forming die to swage the desired shape into the tube. Once formed, the parts are automatically ejected from the die without interruption to a continuous press stroke, resulting in a high-volume of parts, produced with great efficiency. Lower to moderate production parts that do not justify a higher capital investment can use dedicated tooling that requires a press operator to manually load parts. This process offers the ability to produce simple to complex shapes using multiple cold forming stations to achieve a cost-effective piece part. Cold forming offers an effective means to create a variety of shapes to exacting standards. Applications from industrial to cosmetic can be satisfied using cold-formed tubes. Customer-defined features often times replace costly fittings and offer cost reduction benefits.

Capacity

• Tube diameters from Ø.38” to Ø2.50” and larger can be cold formed.

• Tube thickness range from 0.020” wall to 0.12” wall.

Materials

• Commercially available metallic tubing such as carbon steel, stainless steel, copper, brass and aluminum can be formed into a variety of end shapes.

Precision Tube Forming at a Competitive Price

Vulcan Industries utilizes a high-speed scrap-less cutoff machine which allows us to create these precision tube forms at a competitive price. Since we complete all forming operations in-house, lead-time and costs are significantly reduced. With advanced equipment and extensive experience in crafting complex and unique tube forms, we can produce parts at a higher rate than many conventional tube end forming companies.

Schedule a Free Engineering Part Review

In the early stages of product development? Schedule a free consultation with one of our design experts and let’s talk about how we can identify ways to cut costs and prevent mistakes early on in the stages of product development.

Or call (262) 253-5420 to speak directly with one of our engineers.

Metal Tube Forming