Resources 6 Tube Forming Die Applications

6 Tube Forming Die Applications

06.04.24 | Blog

In tube forming, material manipulation can be achieved through many different processes. A tried and true method involves pairing some sort of tube forming die with a high-quality hydraulic or servo press machine. Overton specializes in presses ranging from 10 to 100 tons, and with our extensive die design and manufacturing experience, there’s no doubt we can bring your vision to life. From standard forms to special press applications, here are six examples of press tooling that could change your tube forming game for good.

1. Pierce Die

Whether it be a single hole or a series of holes in different planes, Overton has extensive experience with piercing tubular components into other metal products. While most of the pierced holes tend to be round, nearly any shape can be put into the end product. Our design capabilities also allow us to design a tube forming die that can use cams or other actuation to put multiple holes in different radial locations or planes in a single cycle of the machine.

Pierce Die

2. Extrude Die

An extrude die is typically two stations. The first side pierces a hole, typically oval, that not only serves as a pilot for the extrusion but also determines the shape of the extrusion. In the second station a steel or carbide nose is pushed through the hole that had been created through the use of a mechanical cam to create the final “Tee” extrusion. This is often used to create a 90 degree port that gets another tube or fitting welded inside or over the extrusion.

Extrude Die

3. Notch Die

A notch die is actually a specific type of pierce die. The holes that are pierced into the tube are located on the end of the tube and used in collaboration with a clamp to secure two tubes to each other, either through clamping force or welding. There are many different industry types of notches, but the most common we see are “torca” notches and “zeta” notches.

Torca Notch Die

4. Tube Forming Die

This is a broad category of die type. Forming is typically used when you are moving material without any cutting. This could be when putting a “dent” on one side of a component that verifies insertion depth. Another option could be a “flat” die that takes a round tube and puts a flat somewhere along the length, often used for ease of installation when many components are assembled in a small area.

Forming Die

5. Crimping Die

A crimping die is used when you are trying to mechanically lock two parts together. Sometimes this is used when putting a sheet metal shroud over a component. Other times, we have used crimping to lock a tube into a piece of sheet metal at a specific depth (sometimes also known as swaging). Overton’s design capabilities allow for a multitude of different types of design when it comes to crimping one part to another.

Crimping Die

6. Special Press Tooling Applications

The possibilities are endless when it comes to using die technology with Overton. One recent project was a custom 15 ton press with an integrated die set that did a tight tolerance insertion into an existing weldment. The weldment was loaded into the die and the part being inserted was loosely placed inside that weldment. The machine then shuttled under the ram of the press and was servo actuated to a specific depth. This was a custom design that was tailored to the customer’s need. There are dozens of examples just like this over the years where a tailored solution was developed to solve the technical request of the customer.

Custom Crimp Die

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