1. Biegen von Profilen mit großen Querschnitten
Graham SKELTON
Angle Ring Co Ltd Tipton, UK

2. Presentation Structure
Introduction
Overview of our bending methods for various types of profiles
The end uses of large curved profiles
The challenges in producing such large profiles
Possible solutions
Summary

3. Started by making rings of Angle Iron
Established in 1951
Started by making rings of Angle Iron
"Angle Ring“ in German is "Winkel Ring“
So, jetzt gehen wir weiter...Die Firma Angle Ring ist in neunzehnhundert ein und fünfzig gegründet. Ganz am Anfang hat die Firma nur kleine Ringen aus Winkelstählen hergestellt. Davon kommt die Name „Angle Ring“ („Angle Ring“ bedeutet“Winkel Ring“).

4. Family company
130 Employees
Situated in Tipton in the West Midlands conurbation

5. Our products are exported worldwide!
21 year working relationship with Alukönig Stahl

6. Bending Methods

7. Cold Bending - used as first choice of bending where possible - for reasons of speed and cost
The section passes several times through the bending rolls until the desired radius is achieved
Not always possible for small radii and larger sections

9. Angle Ring has 3 Induction Bending machines
Possible to bend up to Ø 915 mm tubes and 650 mm SHS
Not only tubes but beams and channels

10. A few examples of induction bent pieces…

11. The Induction Bending Process
More complicated and slower than cold bending
The magnetic field in the coil induces an electric current in the steel
Heated to tempertaures between 700 and 1000º C
Immediated cooled with water
The bend radius is fixed by the Radius “Arm“

12. ‘Pusher’ Allowing bars up to 28 m long to be induction bent
Radius Arm
Used to control the bending radius required

14. Possible to induction bend BOTH small and large radius pieces!
Multi radii pieces such as ellipses are possible
E.g. Kapoor Sculpture in New Zealand
Ø 762 x 35.5 mm

16. Cold Pressing:
Dependent on profile, radius and end use of piece
Largest diameter up to Ø 915 mm tube

17. End uses of the majority of large diameter pieces
Bridge Buidling
E.g. The new Train Station in Vienna
Ø 915 mm Induction Bent
Carried out with AluKönigstahl and RW Montage

18. General Construction
(E.g. Yas Hotel in Abu Dhabi)
Ø 559 mm Induction Bent
Collaboration with AluKönigstahl and Waagner Biro

19. Part bridge, part building
Galerie Inntalcenter
Ø 711 x 30 mm Induction Bent
Carried out with AluKönigstahl and Kamper Stahlbau

20. HEA 800 for a Car Park project in Berlin
Cold Bent in 3 D!

21. Challenges in Bending Large Profiles
Various challenges to overcome for a successful end result!

22. Which bending method? Size of Section dictates...
Ø 508 mm tubes - cold bending limit
Ø 915 mm tubes - induction bending limit
Larger radii and thicker material - cold pressing may be possible

23. Wall thickness of tubes and hollow sections influence bending method
Wall thickness can make smaller diameter tubes too strong for the cold bending process!

24. Deformation
Deformation must be considered at certain radii for certain sizes of section/profile
The end use of the piece often dictates whether deformation is an important consideration

25. When appearance and precision are important - deformation is to be avoided as far as practically possible
Deformation obliges us to use the induction bending method again

26. Take Home Message: consider radius and wall thickness when desiging bent pieces.

27. Material Thicker (wall thickness) material is not always avaialbe
Large (diameter) material not easy to find
Long production times of straight material
Desired lengths of material not always available or even produced at all
6000mm

28. The length of material required is dependent on bending method
In general, more production material is required using the induction bending method

29. Either: produce the piece in several parts...
Or weld on the production ends to save material!

30. At large radii, it may be possible to incorporate the production allowance into the bent length
Whether this is possible is dependent on the radius, bent length and the end use of the piece
Only possible for cold bent/pressed pieces

32. The maximum length of induction bent material lies between 90 and 120º depending on profile/radius/wall thickness.

33. Radius A normal lorry is 2.4 m wide and 13.6 m long
Consider whether that the pieces with the desired radius fit
If the pieces are simply too big...
Either wide/long load (cost!) or offer the pieces in smaller length (if acceptable)

34. If a very large Radius is required
Do we really need to bend?!
(Within tolerance of straight material)

35. Bending with several radii can be complicated (Ellipses, Parabla or 3 D pieces)
We can propose elegant solutions to these problems

36. Material Properties
During Induction bending of higher grade material S355J2(H) mechanical properties can change
If no longer within specification - usually possible to stress relieve to recover the properties

37. A sample of material (approx 300 mm) is tested by an independent Test Laboratory
Heat Treatment is carried out by exetrnal companies
After Heat Treatment mechanical properties are retested
Geometry is re-examined after Heat Treatment and adjusted as required

39. Before despatch every piece we make is checked! (radius and length)
This is usually possible be measuring the chord and the drop .
For multi radius pieces we use a "set out“

40. Delivery Time Dependent on availability of straight material
Any additional production welding
The complexity of bending geometry

41. Factors to Consider Size Wall thickness Availability Length Radius
Material Properties
Delivery Time

42. Thanks for your attention and the opportunity to talk to you today!
Danke für Ihre Aufmerksamkeit und die Gelegenheit!
Ich bedanke mich für die Gelegenheit dieses Präsentation zu geben. Ich hoffe daß dieses Ihnen gefallen hat und Ihre Interesse geweckt hat. Nach dem Präsentation, bei weiteren Fragen werde ich gerne zur Verfügung stehen.

43. Wir exportieren unsere Produkten Weltweit und arbeiten wir schon seit 21 Jahre mit Alu Königstahl in Österreich. Unsere Partnerschaft mit Alu Königstahl ist sehr Stark - wir haben sehr gute Bezeihungen und wir sind sehr stolz auf unsere gute Zusammenarbeit im Laufe der Jahren.