Ultrathin-wall or ultra close-pitch mandrels are for the thinnest walls (wall factor of 200 or more) and the tightest radii commonly found in aircraft applications. Thin-wall or close-pitch mandrels are used for thinner walls (wall factor of 70 or more) and tight radii. The smaller the wall thickness of the pipe, the greater the number of balls and the shorter the distance between them so that they can support more points of the pipe wall. Ball mandrels with low steps (balls are closer to each other): There are several types of ball mandrels that can be used for different thicknesses.Ball mandrels: This type of mandrel is used to create critical bends with high accuracy.These types of mandrels are intended for similar applications to rigid mandrels, but the shaped part of the mandrel bends better to support the outer radius. A formed-tip mandrel generally is used with heavier-wall tubing and an average radius. The formed end gives more support to the inside of the tube. Formed mandrels: Formed mandrels: A formed-tip mandrel is a variation of a plug mandrel, but it has a radius cut into the tip to match the radius of the bend.It is used quite often in international pipe size (IPS) applications without a wiper. Plug mandrel: Plug mandrel: These mandrels are like rigid rods and are used mainly for heavy-wall tubes and larger radii, but they are not used to create critical high-angle bends.The picture right shows the components needed to produce a mandrel bend (except the metal tube or pipe itself.) After clamping the tube or pipe with the clamp die, the bend dies body rotates up to 180 degrees supported internally by the mandrel and externally by a pressure die and a wiper die. Mandrel bending is a method of rotary draw bending, a solid mandrel(up to five segmented, donut-shaped, balls that are just slightly smaller than the ID of the pipe/tube that is being bent) shaft is inserted into the pipe/tube to provide internal support during bending, its held in a fixed position and holds it firmly in the groove of the bend die.
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