Tube End Forming Services

Metal Tube Forming Services

Since 1947, Vulcan Industries has provided metal tube end forming services for some of America’s most successful and diverse original equipment manufacturers (OEMs). Metal tube end forming is 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
  • metal tube end forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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.
    Tube forming services

    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 services

    Tube Forming Process

    Tube forming at Vulcan Industries is accomplished using cold forming techniques. In high volume production, tube blanks are cut to length using a shearing process from 20-foot long lengths of tubing. Parts are 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.
    metal tube end forming services

    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 crafting complex and unique tube forms, we can produce parts at a higher rate than many conventional tube end forming companies.

    Variety of OEMS and Applications

    We’ve worked within specifications from a variety of OEMS to develop and manufacturer tube end forms for a wide variety of project applications and industries. Projects we frequently engage in include tube forming for:

    • Covers and seals
    • Medical equipment
    • Power tools
    • Electrical distribution
    • Engine components
    • Fluid transmission
    • Air compressor pump components
    metal tube end forming services

    Vulcan Industries Corporation

    We are ISO 2001:2015 certified. We are also compliant with international material standards and NAFTA. All finished projects are rigorously tested using any requirements necessary for each project. We use conventional metrology methods, vision systems, continuity checks, hipottesting, function testing for electrical, and continuity in a circuit. Additional testing procedures may be employed as the customer dictates.

    In addition to being experts in unique and challenging tube end forming services, we also offer a range of assembly and metal stamping services to meet all your manufacturing needs. We are a single source solution for OEMs who need a turn-key, hassle-free manufacturer.

    If you would like to further discuss how Vulcan Industries Corporation can work with you on your application please give us a call at 262-253-5420.

    SCHEDULE A FREE ENGINEERING PART REVIEW

    Schedule a free consultation with one of our design experts and let’s talk about how we can identify ways to improve processes, reduce waste and reduce your overall costs.

    Ready to get started? Call Vulcan Industries today at 262-255-1090 or send an email!