Common failures and solutions of the bending molds in hydraulic pipe benders

1. Mold Wear

Problem: Inaccurate bend angles, scratches, or uneven surface on the bent tube.

Solution: Inspect the mold for wear and replace any severely worn molds in a timely manner.

2. Wrinkling on the Inside of the Bend

Problem: Wrinkles appearing on the inside of the bend, affecting the quality of the tube.

Solution: Check if the proper mandrel is being used. If not, add one. Adjust the wrinkle-prevention plate’s position and angle to bring it closer to the forming mold’s pinch point. Increase the bending radius or use tubing with better elongation properties.

3. Cracked Mold Installation Holes

Problem: Cracks in the mold installation holes.

Solution: Ensure the mold is installed correctly to avoid lateral loads. Make sure the support wheel is positioned symmetrically, and apply wax to the contact points of the support wheel and conical surfaces if needed.

4. Tube Jam During Bending

Problem: The bending process suddenly jams.

Solution: Check for foreign objects inside the tube. Clean the bending machine thoroughly. Ensure the mold and tube are properly aligned to prevent jamming caused by mold issues.

5. Hydraulic System Issues

Problem: Oil leaks or insufficient pressure in the hydraulic system.

Solution: Inspect the hydraulic seals and repair or replace any leaking parts. Regularly change the hydraulic oil and ensure the oil paths are clear.

6. Inaccurate Bending Angle

Problem: The bent tube’s angle doesn’t match the set value.

Solution: Check if the mold is worn or incorrectly installed. Adjust the mold position or replace it with a new one.

7. Excessive Noise

Problem: High noise levels during operation.

Solution: Check for loose components and tighten any loose screws. Ensure the equipment is balanced and adjust if necessary.

8. Loose Mold Installation

Problem: The mold loosens during use.

Solution: Inspect the mold’s mounting bolts to ensure they are tight, and replace any damaged bolts if needed.

9. Debris on the Mold Surface

Problem: Scratches or uneven surfaces on the bent tube.

Solution: Clean any debris or metal shavings from the mold surface to ensure it’s free of contaminants.

10. Mold and Tube Mismatch

Problem: The tube deforms or fails to bend properly during the process.

Solution: Check that the mold and tube specifications match. If needed, replace the mold with one that’s more suitable.