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OPERATOR’S MANUAL

ROTARY DRAW BENDER

MODEL: RDB-100

REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL

HOLDINGS LLC IS PROHIBITED. Baileigh Industrial Holdings LLC, Inc. does not assume and hereby disclaims any

liability for any damage or loss caused by an omission or error in this Operator’s Manual, resulting from accident,

negligence, or other occurrence.

Rev. 05/2021

Baileigh Industrial Holdings LLC

P.O. Box 531

Manitowoc, WI 54221-0531

Phone: 920.684.4990

Fax: 920.684.3944

[email protected]

Содержание RDB-100

Страница 1: ...LC IS PROHIBITED Baileigh Industrial Holdings LLC Inc does not assume and hereby disclaims any liability for any damage or loss caused by an omission or error in this Operator s Manual resulting from accident negligence or other occurrence Rev 05 2021 Baileigh Industrial Holdings LLC P O Box 531 Manitowoc WI 54221 0531 Phone 920 684 4990 Fax 920 684 3944 Baileigh Sales jpwindustries com ...

Страница 2: ...16 Material Insertion 19 Material Insertion Limitations 20 Bending More than 180 Degrees 21 UNDERSTANDING SPRINGBACK 21 MATERIAL SELECTION 21 PIPE AND TUBE BENDING DIAGRAMS 23 BENDING GLOSSARY 24 BENDING SUGGESTIONS 25 Aluminum Bending 25 Heavy Wall DOM tubing 25 Bending With Square Dies 26 Square Tooling Setup 26 Large Size Square 27 LUBRICATION AND MAINTENANCE 28 TABLES CHARTS DIAGRAMS 29 Table ...

Страница 3: ...Ratchet Wheel Assembly Parts Diagram 36 Spring Back Lever Assembly Parts Diagram 37 Pull Handle Assembly Parts Diagram 38 Parts List 39 ...

Страница 4: ...en notice to Seller of any suspected defect in the Goods prior to the expiration of the warranty period The original end user must also obtain a RGA from Seller prior to returning any Goods to Seller for warranty service under this paragraph Seller will not accept any responsibility for Goods returned without a RGA The original end user shall be responsible for all costs and expenses associated wi...

Страница 5: ... provided under this Agreement or at law or equity Attorney s Fees In the event legal action is necessary to recover monies due from Buyer or to enforce any provision of this Agreement Buyer shall be liable to Seller for all costs and expenses associated therewith including Seller s actual attorney fees and costs Governing Law Venue This Agreement shall be construed and governed under the laws of ...

Страница 6: ... Description of the functional parts of the machine Capacity charts Setup and start up instructions Machine operation Scheduled maintenance Parts lists GENERAL NOTES After receiving your equipment remove the protective container Do a complete visual inspection and if damage is noted photograph it for insurance claims and contact your carrier at once requesting inspection Also contact Baileigh Indu...

Страница 7: ...azardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which if not avoided could result in property damage IMPORTANT PLEASE READ THIS OPERATORS...

Страница 8: ...NEVER place your hands fingers or any part of your body in the die area of this machine Be aware of the area on either side of the dies for crush points created by material movement BEWARE OF PINCH POINTS Keep hands and fingers away from the drive mechanisms cylinders ratchets and other moving linkage while the machine is in operation KEEP CLEAR OF MOVING OBJECTS Always be aware of the position of...

Страница 9: ...hop If a procedure feels dangerous don t try it REMEMBER Your personal safety is your responsibility Dear Valued Customer All Baileigh machines should be used only for their intended use Baileigh does not recommend or endorse making any modifications or alterations to a Baileigh machine Modifications or alterations to a machine may pose a substantial risk of injury to the operator or others and ma...

Страница 10: ...al filings Eye wear shall be impact resistant protective safety glasses with side shields which comply with ANSI Z87 1 specification Use of eye wear which does not comply with ANSI Z87 1 specification could result in severe injury from breakage of eye protection 12 Do not overreach Maintain proper footing and balance at all times DO NOT reach over or across a running machine 13 Stay alert Watch wh...

Страница 11: ... PSI mild steel CLR will vary based upon actual material and wall thickness TECHNICAL SUPPORT Our technical support department can be reached at 920 684 4990 and asking for the support desk for purchased machines Tech Support handles questions on machine setup schematics warranty issues and individual parts needs other than die sets and blades For specific application needs or future machine purch...

Страница 12: ...age painted surfaces Follow manufacturer s label instructions when using any type of cleaning product After cleaning wipe unpainted metal surfaces with a light coating of quality oil or grease for protection Important This waxy coating is NOT a lubricant and will cause the machine to stick and lose performance as the coating continues to dry WARNING SUFFOCATION HAZARD Immediately discard any plast...

Страница 13: ...wer gently to the floor Level the machine so that all the supporting feet are taking the weight of the machine and no rocking is taking place INSTALLATION IMPORTANT Consider the following when looking for a suitable location to place the machine Overall weight of the machine Weight of material being processed Sizes of material to be processed through the machine Space needed for auxiliary stands w...

Страница 14: ...ne work stock and the operator The floor should also be a level surface If the unit wobbles or rocks once in place be sure to eliminate by using shims WORKING CLEARANCES Take into consideration the size of the material to be processed Make sure that you allow enough space for you to operate the machine freely Anchoring the Machine Once positioned anchor the machine to the floor as shown in the dia...

Страница 15: ... 3 and 4 shown 4 Read through the remainder of the manual and become familiar with the die installation and settings as well as normal operation 5 Position the machine as desired following the installation guidelines Two Person Lift Use an assistant or lifting devise to support the weight of this machine WARNING For your own safety DO NOT connect the machine to the power source until the machine i...

Страница 16: ...sembly Supply the bending force to rotate the bending plate D Quick Release shown with a counter die installed For pivoting counter die away from bend die to remove material quickly E Hitch Pin Used to secure counterdie to quick release F Main Spindle and Drive Pins shown with a pipe forming die installed For supporting and driving the forming die G Bend Angle Scale A graduated scale used to indic...

Страница 17: ...ormation to the operators while operating and maintaining Failure to follow these instructions may result in great damage to the machine or injury to the operator OPERATION Bending 1 Before actually bending a dry run may be performed This will help to become familiar with the machine functions 2 Keep hands away from the bending zone 3 All bending must begin at the 0 latch point Rotate the anti spr...

Страница 18: ...allows the operator to gradually reach a bend angle on the first set up piece Once the proper degree of bend is achieved document the degree ex 98deg 90deg bend 8degrees of spring back so multiple bends to that same degree can be accomplished Material Removal 1 After reaching the desired angle the material needs to be removed 2 Pull the anti springback lever clockwise to release tension 3 Rotate t...

Страница 19: ... color coded to avoid confusion between pipe and tube see table 2 IMPORTANT Damaged or worn tooling should be replaced before attempting to bend material This will ensure that bends are correct and provide a longer life to machine components When handling large heavy dies and or material make sure it is properly lifted and supported 1 To install the die slip the die over the centering pin until th...

Страница 20: ...ine up 5 Now insert the hitch pin through all the holes 6 The counter die should be positioned approximately 1 8 3mm away from the die This is accomplished by a combination of the slide plate position and changing between the two provided quick releases See the Counterdie Placement Chart near the end of the manual 7 In combination install the recommended quick release silver or gold and then posit...

Страница 21: ...Counterdie Position Too far away from die Touching die Correct Counter Die Position Approximately 1 8 3mm away IMPORTANT Be sure the long end of the counter die points away from the hook arm or to the right of machine ...

Страница 22: ...erting material to start Lubricating counter die bending Important Liberally apply lubricant along the counterdie and the 1 2 of the material that contacts the counter die A with a WD 40 style lubricant or equivalent Do not lubricate the bending die Lubricating the bending die will encourage slipping of material in the bending die 3 Rotate the quick release counter die assembly until it firmly sto...

Страница 23: ...aken when bending material with an existing bend There must be enough straight material to complete the bend If there is not enough material the bent part of the material will crash into the counter die and damage the machine and tooling In the left figure there is not enough material to complete a 90deg bend This bend will damage the dies IMPORTANT Orienting your material in this fashion will cau...

Страница 24: ... type and wall thickness so it will never be consistent from size to size The best way to determine a materials springback is to do sample bends to 90 degrees until a perfect 90 is obtained At that point document the actual machine degrees Full manual mode is the best place to do these tests Use the overbend amount and enter that value into the springback field MATERIAL SELECTION When selecting ma...

Страница 25: ...is easiest For non symmetrical bends continuous one direction bending is best Another way to layout material is to draw them in a 2D computer software program like Auto Cad There are many free programs on the internet In a 2D program you will draw the parts centerline only with corresponding clr s Then you will be able to list individual segments of the bent part This data can be directly entered ...

Страница 26: ...de D Tube outside diameter t Tube wall thickness a First bend arc angle H Height of offset b Second bend arc angle L Length of offset A First tangent R1 First radius B Straight between bends R2 Second radius C Second tangent t Tube Wall Thickness D Tube outside diameter ...

Страница 27: ...s required by the bending machine to form the bend Neutral Axis That portion of the pipe or tube that is neither in compression or tension O D Outside diameter in inches of the tube or pipe Out of Plane The deviation of the horizontal plane of a single pipe bend between its tangent points based on the theoretical centerline of the pipe bend Ovality The distortion or flattening of pipe or tube from...

Страница 28: ...d primarily for polished aluminum Steel rollers would be used for non polished materials Some aluminum will crack as it is being bent 6061 T6 is very hard and may need to be annealed or ordered in the T 0 condition Aluminum will age harden so if possible try to get freshly run material Heavy Wall DOM tubing If heavy wall materials are bent to a tight radius they can tend to slip in the hook arm ca...

Страница 29: ...e Note tighten clamps without material in the die The clamps are lift and turn so you can position them anywhere This allows the handles to clear the counter die mount during bending 4 Insert the material into the hook arm 4 and pull in to the die It may be a tight fit Continue to pull until the material is fully seated in the die s groove 5 Lube the counter die and the material that will slide al...

Страница 30: ... bent and repeat these steps Large Size Square When bending larger than 1 5 38 1mm thinner wall square tubing the counter die position seems to work better between 1 2 and 1 12 7 25 4mm farther away from the die This seems do reduce side wall distortion and inner wrinkling Although this suggestion is to help on large size the same steps can be used for any square if trying to achieve better result...

Страница 31: ...nted surfaces Note Proper maintenance can increase the life expectancy of your machine There are two grease zerks on the machine at the main spindle pivots Grease these zerks every month with only two pumps from a standard grease gun Check for any loose or worn parts WARNING Make sure the electrical disconnect is OFF before working on the machine Maintenance should be performed on a regular basis ...

Страница 32: ...0 091 0 126 1 2 0 840 0 700 0 080 0 109 0 147 0 188 0 294 3 4 1 050 0 700 0 080 0 113 0 154 0 219 0 308 1 1 315 0 700 0 110 0 133 0 179 0 250 0 358 1 1 4 1 660 0 700 0 110 0 140 0 191 0 250 0 382 1 1 2 1 900 0 700 0 110 0 145 0 200 0 281 0 400 2 2 375 0 700 0 110 0 154 0 218 0 344 0 436 2 1 2 2 875 0 800 0 120 0 203 0 276 0 375 0 552 Table 2 Die Color Code Chart Material Color Pipe Green Tube Blue...

Страница 33: ... 0 6631 68 1 1866 9 0 1571 39 0 6806 69 1 2041 10 0 1745 40 0 6980 70 1 2215 11 0 1920 41 0 7155 71 1 2390 12 0 2094 42 0 7329 72 1 2564 13 0 2269 43 0 7504 73 1 2739 14 0 2443 44 0 7678 74 1 2913 15 0 2618 45 0 7853 75 1 3088 16 0 2792 46 0 8027 76 1 3262 17 0 2967 47 0 8202 77 1 3437 18 0 3141 48 0 8376 78 1 3611 19 0 3316 49 0 8551 79 1 3786 20 0 3490 50 0 8725 80 1 3960 21 0 3665 51 0 8900 81 ...

Страница 34: ...LD HOLE 2 SILVER HOLE 3 3 5 GOLD HOLE 2 SILVER HOLE 3 GOLD HOLE 3 3 75 SILVER HOLE 3 GOLD HOLE 3 SILVER HOLE 4 4 SILVER HOLE 3 GOLD HOLE 3 SILVER HOLE 4 4 5 GOLD HOLE 3 SILVER HOLE 4 GOLD HOLE 4 5 SILVER HOLE 4 GOLD HOLE 4 SILVER HOLE 5 5 5 GOLD HOLE 4 SILVER HOLE 5 GOLD HOLE 5 6 SILVER HOLE 5 GOLD HOLE 5 SILVER HOLE 6 6 5 GOLD HOLE 5 SILVER HOLE 6 GOLD HOLE 6 7 SILVER HOLE 6 GOLD HOLE 6 SILVER HO...

Страница 35: ...32 32 Diagram 1 ...

Страница 36: ...33 33 Diagram2 ...

Страница 37: ...34 34 PARTS DIAGRAM Stand Assembly Parts Diagram ...

Страница 38: ...35 35 Main Frame Assembly Parts Diagram ...

Страница 39: ...36 36 Ratchet Wheel Assembly Parts Diagram ...

Страница 40: ...37 37 Spring Back Lever Assembly Parts Diagram ...

Страница 41: ...38 38 Pull Handle Assembly Parts Diagram ...

Страница 42: ... Pin 3 14 ME M300 7A003 Center Pin 1 15 ME M150 5A002 Quick Release Assembly Thin 1 16 ME M100 7A016 Long Stop Pin 1 17 M100 7A007 Latch Shaft 1 18 ME M100 6A011 Slide Block 1 19 PP 0289 3 4 Set Screw Collar 1 20 PP 0090 3 4 Split Collar 1 21 ME M100 6A013 Link 1 22 M100 6A020 Ratchet Pivot Lever 1 23 M100 7A012 Long Lever Sleeve 1 24 M100 6A022 Drive Link 1 Longer 1 25 M100 6A021 Drive Link 1 Lon...

Страница 43: ...SM 0162 M8 X 1 25 X 10 Shoulder Bolt 1 50 BSM 0039 M20 X 2 5 X 40 SHCS 1 51 BS 0165 M8 X 1 25 X 55 HHCS 1 52 BSM 0088 M8 Flat Washer 1 53 BSM 0118 M8 X 1 25 Hex Nut 1 54 BSM 0113 M8 X 1 25 X 10 Set Screw 2 55 BSM 0145 M5 X 0 8 X 6 Set Screw 1 56 BSM 0003 M6 X 1 0 X 25 SHCS 1 57 ME M175 7A005 Spindle 1 58 BSM 0147 M16 X 2 0 X 50 Hex FLG 5 59 BSM 0164 M20 X 2 5 X 150 SHCS 1 60 BSM 0175 M20 X 2 5 X 1...

Страница 44: ...0 BSM 0067 M12 X 1 75 X 30 Hex FLG 2 71 BS 0070 25 28 Grease Zerk 2 72 ME M100 5A009 Release Lever Assembly 1 NOTES BAILEIGH INDUSTRIAL HOLDINGS LLC 1625 DUFEK DRIVE MANITOWOC WI 54220 PHONE 920 684 4990 FAX 920 684 3944 www baileigh com ...

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