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Mandrel Bending vs. Crush Bending



When it comes to tube bending, there are a few methods available. As with any fabrication, most customers are trying to strike a balance between quality and cost-effectiveness.

For the best quality, mandrel bending can’t be beat, but many turn to the simpler crush bending due to its low price. So which is best for you?

Let’s take a closer look at how these two forms of tube bending work.

Crush Bending

Crush bending is a simple process. The tube is held in place on each end while pressure is placed at the desired spot, bending it accordingly. If additional bends are needed, the tube is repositioned and bent again.

It’s quick and affordable.

But it’s not without flaws. Due to the way the pressure is applied, the tube loses shape, which can affect both performance and structural integrity. Wrinkles are common in crush bending as well.

Mandrel Bending

Mandrel bending is similar to rotary draw bending. The tube is fed through a hydraulic press that bends it using a bending die.  There is a key difference, however. A mandrel is added inside the tube, hence the name.

The mandrel is positioned at the apex of the forming to keep tube shape intact.

There are different types of mandrels such as segmented mandrels and plug mandrels, but the goal is ultimately the same: keeping the strength and the shape of the tube during the bending process.

Which is Better?

In terms of pure quality, mandrel bending is the best. But that doesn’t mean it’s always necessary.

Many applications can benefit from mandrel bending. For example, with burner tubes, mandrel bending prevents wrinkles which cause hot spots. Mufflers, exhaust system systems, and coolant lines can also benefit from mandrel bending.

At Ever-Roll, we can advise you on the best method for your needs, and then perform the tube bending from there. Contact us today!

bent on perfection.

bent on perfection.

3988 Lawrenceville Dr.

Springfield, OH 45504

Phone: (937) 964-1302 (Office)

Email: sales@ever-roll.com