Specifications

Production length:20-240mm

Production wall thickness range:0.5-2.5mm

Equipment weight:5.5ton

Production diameter range:50-110mm

production efficiency:30-60/s

Length*Width*Height:3*3.5*2

In the era of smart manufacturing, industries like automotive, aerospace, and HVAC demand tube end processing equipment that delivers uncompromising precision, high throughput, and seamless automation. The Automated double-sided multi punch pipe end forming machine emerges as a transformative solution, redefining industry standards by integrating double-sided simultaneous processing, multi-punch functionality, and full automation. This advanced equipment eliminates the inefficiencies of traditional single-sided or manual processing, addressing core pain points like secondary clamping errors, low production speed, and inconsistent quality.

Designed to handle diverse tube materials and complex forming requirements, this machine has become the backbone of high-volume production lines worldwide. Whether fabricating automotive brake tubes, aerospace hydraulic lines, or HVAC refrigerant pipes, it ensures each tube end meets strict international standards such as DIN EN ISO 8494 and CE certification. 

What is an Automated Double-Sided Multi Punch Pipe end forming machine?

An Automated Double-Sided Multi Punch Pipe End Forming Machine is a high-precision industrial equipment engineered for automated, simultaneous processing of both tube ends using multiple punch tools. Its defining features—automation, double-sided processing, and multi-punch functionality—address the critical limitations of conventional tube end forming equipment.

The "double-sided" design means the machine is equipped with two symmetrically arranged punch mechanisms that operate simultaneously on both ends of the tube. This eliminates the need for manual tube flipping, secondary clamping, and repositioning, which are major sources of dimensional errors and efficiency loss in traditional single-sided machines. The "multi-punch" capability allows integration of multiple punch tools (typically 2–6) on each side, enabling complex forming operations like flanging, beading, ribbing, curling, expanding, and shrinking in a single pass.

Automation is achieved through advanced PLC control systems, pneumatic/hydraulic actuation, and automatic loading/unloading modules. From tube feeding and length inspection to clamping, forming, and the entire process requires minimal human intervention, reducing labor dependency and operational errors. Constructed with robust frames, precision linear guides, and wear-resistant punch tools, the machine maintains stability even during 24/7 continuous operation.

This equipment supports a wide range of tube materials including carbon steel, stainless steel, aluminum, copper, and exotic alloys like Inconel, catering to tube diameters from 4mm to 50mm and wall thicknesses up to 1.5mm with customizable options for larger specifications. It complies with global safety and quality standards, including CE certification and industrial safety norms like GB 17120, making it suitable for international manufacturing facilities.

Core Working Principles

The machine’s exceptional performance stems from the synergy of automated material handling, precision clamping, and synchronized double-sided multi-punch forming. Based on industry-proven technologies and patented mechanisms, the working process follows six key stages:

1. Automated Feeding and Pre-Inspection

The process begins with automatic feeding via a pneumatic or conveyor-based loader system. Tubes are transported to a positioning unit equipped with a V-shaped groove, where positioning and detection cylinders on both sides measure the tube length precisely. Tubes that fail length inspections are automatically rejected to a scrap bin, while qualified tubes are transferred to the clamping station by a robotic gripper or pneumatic claw. This pre-inspection step ensures only suitable workpieces enter the forming process, reducing material waste.

2. Precision Centering and Clamping

Qualified tubes are positioned in a composite clamping mechanism consisting of a fixed main clamp and a movable secondary clamp. The main clamp secures the tube’s midsection, while the secondary clamp—equipped with circumferential annular grooves—provides additional stability. Guide pillars and elastic components between the main and secondary clamps allow controlled movement during forming. A pressure-locking system ensures the tube remains firmly clamped without slippage, even under maximum punching force, eliminating dimensional deviations caused by tube movement.

3. Multi-Punch Tool Positioning

Two punch modules positioned at both tube ends adjust their positions via feed rails and indexing rails. The feed rails control the punch tools’ approach to or retreat from the tube, while the indexing rails switch between different punch tools according to the preset program. Each punch module can accommodate 2–6 tools, enabling seamless switching between forming operations without manual intervention. The tool positioning accuracy is controlled within ±0.05mm via optical rulers and linear encoders.

4. Synchronized Double-Sided Forming

Under PLC control, the hydraulic or servo-driven punch modules initiate simultaneous forming on both tube ends. The hydraulic system delivers stable pressure to drive the punches, which exert uniform force on the tube ends. For example, when forming flanges, the punches expand the tube ends to the preset angle and diameter; for beading, specialized punches create precise annular ribs. The secondary clamp moves slightly under punch pressure, compressing the elastic components to accommodate forming deformation while maintaining clamping stability. This synchronized process ensures consistent dimensions on both tube ends, with processing speeds as fast as 4 seconds per punch operation and 6 seconds for two consecutive punches.

5. Mid-Process Quality Monitoring

During forming, real-time sensors monitor key parameters including punch pressure, stroke length, and clamping force. If deviations exceed the preset tolerance range, the system immediately pauses operation and triggers an alarm, preventing defective products. Some advanced models integrate visual inspection units to check surface quality and dimensional accuracy post-forming, ensuring compliance with ISO 8494 standards for flange formation and deformation resistance.

6. Automated Unloading and Sorting

After forming is complete, the punch modules retract, and the clamping mechanism releases the tube. The finished workpiece is automatically unloaded by the conveyor system and sorted into qualified product bins. The machine then resets to accept the next tube, initiating a new processing cycle. For high-volume production, the system can be integrated with upstream tube cutting equipment and downstream assembly lines, forming a fully automated production cell.

Technical Specifications

The technical parameters of Automated Double-Sided Multi Punch Pipe End Forming Machines vary by model and manufacturer, but core specifications align with industry standards and high-volume production requirements. Below is a detailed breakdown based on leading models :

1. Processing Capacity

Tube diameter range: 4mm – 50mm, customizable up to 100mm for heavy-duty applications.

Wall thickness range: 0.3mm – 1.5mm, extendable to 3mm with reinforced punch tools.

Material compatibility: Carbon steel, stainless steel, aluminum, copper, brass, Inconel, and other ductile metallic materials.

Forming operations: Flanging, beading, ribbing, curling, expanding, shrinking, chamfering, and custom profile forming.

Maximum tube length: 200mm – 2000mm, with adjustable positioning for shorter/longer tubes.

2. Power and Performance

Forming force: 50kN – 200kN, adjustable via hydraulic system to match material properties.

Motor power: 5.5kW – 11kW, with servo motors for precision positioning.

Hydraulic system: Working pressure 10MPa – 16MPa, piston pump delivery rate 36.9cm³/rev.

Processing speed: 4 seconds per single punch operation, 6 seconds for dual-punch operations, up to 15 pieces per minute for simple forming tasks.

Positioning accuracy: ±0.05mm for punch tools, ±0.1mm for tube clamping.

3. Dimensions and Weight

Machine dimensions: 2320(L)×1150(W)×2068(H)mm to 3000(L)×1500(W)×2500(H)mm.

Net weight: 950kg – 2500kg, reflecting robust construction for stable operation.

Worktable area: 600mm×400mm, with adjustable height for integration with production lines.

4. Control and Automation

Control system: PLC + touchscreen HMI, supporting multilingual interfaces.

Program storage: Up to 100 preset programs for different tube specifications and forming requirements.

Automation features: Automatic loading/unloading, tool indexing, length inspection, and fault diagnosis.

Safety controls: Two-handed operation buttons, safety guards, emergency stop, and overload protection.

5. Tooling and Accessories

Punch tool quantity: 2 – 6 tools per side, with quick-change tool holders.

Tool material: High-speed steel or carbide, with wear-resistant coatings.

Quick-change system: Tool replacement time<10 minutes, compared to 1–2 hours for traditional machines.

Optional accessories: Visual inspection unit, automatic sorting system, barcode scanner, and Industry 4.0 data integration module.

Key Advantages

Compared to traditional single-sided, manual, or semi-automatic tube end forming equipment, this machine offers transformative advantages that drive efficiency, quality, and cost savings:

1. Unmatched Production Efficiency

The double-sided simultaneous processing eliminates the need for tube flipping and secondary clamping, reducing processing time by 50% compared to single-sided machines. Multi-punch integration allows multiple operations in one pass, replacing 3–4 separate machines with a single unit. For example, a car air conditioning tube requiring flanging and beading can be completed in 6 seconds, compared to 20 seconds with traditional equipment. This translates to a 120%–200% increase in production throughput, meeting the demands of high-volume manufacturing.

2. Superior Processing Precision and Consistency

By eliminating manual intervention and secondary clamping, the machine avoids positioning errors that plague traditional methods. The synchronized punch modules ensure identical forming results on both tube ends, with dimensional deviation <±0.1mm. This consistency reduces the defect rate from 3%–5% to 0.1%–0.5%, significantly lowering rework and material costs. The precision forming also enhances the sealing performance and durability of tube connections, critical for safety-critical applications like automotive braking systems.

3. Reduced Labor and Operational Costs

Full automation minimizes the need for skilled operators—one worker can manage 2–3 machines simultaneously, reducing labor costs by 60% or more. The quick-change tool system cuts setup time from hours to minutes, maximizing machine uptime. Additionally, the machine’s energy-efficient hydraulic system and durable components lower energy consumption and maintenance costs, delivering a typical return on investment within 6–12 months.

4. Exceptional Versatility and Flexibility

The machine adapts to diverse tube materials, diameters, and forming requirements through interchangeable punch tools and programmable parameters. It can handle simple tasks like chamfering and complex operations like multi-step flanging and ribbing, supporting product customization without major equipment modifications. This flexibility is invaluable for manufacturers serving multiple industries or producing a wide range of tube products, enabling quick responses to market demand changes.

5. Enhanced Safety and Ergonomics

Compliant with CE and GB 17120 safety standards, the machine features full-enclosure safety guards, two-handed operation, and emergency stop functions to prevent workplace accidents. Automation reduces manual handling of heavy tubes and repetitive motions, lowering the risk of musculoskeletal injuries. The intuitive touchscreen interface simplifies operation, allowing new workers to master the machine within hours, reducing training costs and operator fatigue.

6. Industry 4.0 Compatibility

Advanced models integrate with smart factory systems via TCP/IP communication, enabling real-time monitoring of production data, machine performance, and maintenance needs. Operators can track throughput, defect rates, and tool wear remotely, facilitating predictive maintenance and process optimization. Data integration with CAD systems and production planning software streamlines workflow management, aligning with modern manufacturing trends.

Industry Applications

The Automated Double-Sided Multi Punch Pipe End Forming Machine’s combination of precision, efficiency, and versatility makes it indispensable across multiple industries, particularly those requiring high-volume, high-precision tube processing:

1. Automotive Manufacturing

Automotive production relies heavily on this machine for processing tubes in braking systems, fuel lines, air conditioning systems, and exhaust systems. It forms precise flanges, beads, and connections that ensure leak-proof performance and structural integrity. For example, automotive brake tubes require consistent flanging to maintain hydraulic pressure, while air conditioning tubes need precise expanding for secure fitting connections. Leading car manufacturers use this equipment to achieve production rates of 1000+ tubes per hour with near-zero defects, supporting just-in-time manufacturing.

2. Aerospace and Aviation

The aerospace industry demands ultra-high precision and reliability for tube components in hydraulic systems, fuel lines, and environmental control systems. This machine processes lightweight, high-strength materials like titanium and Inconel with micron-level accuracy, meeting strict aerospace standards. The consistent forming quality ensures tube connections can withstand extreme pressure, temperature, and vibration during flight, enhancing aircraft safety and performance.

3. HVAC and Refrigeration

HVAC and refrigeration systems use numerous tubes for refrigerant circulation, heat exchange, and air distribution. The machine forms tube ends for secure brazing and fitting connections, ensuring efficient heat transfer and leak-proof operation. It processes copper and aluminum tubes of various diameters, supporting the production of air conditioners, refrigerators, and industrial cooling systems. Manufacturers benefit from increased production speed and consistent quality, reducing warranty claims related to tube leaks.

4. Furniture and Decoration

In the furniture industry, this machine shapes metal tubes for chair frames, table legs, handrails, and decorative components. It creates aesthetically pleasing flanges, curls, and beaded profiles that enhance product appearance and structural strength. The ability to process different tube diameters and materials allows furniture designers to explore diverse styles, from modern minimalist to ornate decorative pieces, while maintaining production efficiency.

5. Hydraulic and Pneumatic Systems

Hydraulic and pneumatic equipment manufacturers use the machine to produce precision tubes for cylinders, hoses, and fittings. The machine’s multi-punch capability forms specialized profiles that ensure tight seals and efficient fluid flow, critical for hydraulic system performance. It processes high-pressure tubes with consistent wall thickness and dimensional accuracy, reducing pressure loss and improving system reliability.

6. Medical Equipment

The medical industry uses this machine for processing tubes in diagnostic equipment, surgical instruments, and fluid delivery systems. It forms small-diameter tubes with smooth, burr-free ends that meet biocompatibility and sterility requirements. The precise forming ensures tubes can be easily sterilized and connected to medical devices, supporting patient safety and treatment effectiveness.

Maintenance Best Practices

To maximize the machine’s lifespan, performance, and reliability, follow these maintenance guidelines:

1. Regular Cleaning and Lubrication

Clean the machine daily to remove metal chips, dust, and hydraulic oil residues, particularly from clamping mechanisms and punch tools. Lubricate linear guides, tool holders, and moving parts weekly with high-quality lubricants to reduce friction and wear. Replace hydraulic oil every 6–12 months and maintain proper oil levels to ensure system stability.

2. Tool Inspection and Replacement

Inspect punch tools regularly for wear, damage, or deformation. Replace worn tools immediately to prevent defective products and machine damage. Store spare tools in a dry, clean environment to maintain their precision. Use the quick-change system correctly to avoid damaging tool holders or positioning components.

3. System Calibration

Calibrate the machine’s positioning accuracy and forming pressure monthly using precision measuring tools. Verify PLC program parameters and sensor functionality to ensure consistent performance. Recalibrate after tool replacement or major maintenance to maintain processing precision.

4. Safety System Checks

Test safety features  weekly to ensure they function correctly. Inspect electrical wiring, hydraulic hoses, and pneumatic lines for damage or leaks, repairing or replacing components as needed. Keep safety labels and instructions visible and legible.

5. Preventive Maintenance

Follow the manufacturer’s preventive maintenance schedule for major components like motors, hydraulic pumps, and servo systems. Replace filters, seals, and wear parts at recommended intervals to avoid unexpected breakdowns. Document maintenance activities and machine performance to identify trends and optimize maintenance cycles.

Would you like me to help you create a customized technical specification sheet for this machine, tailored to a specific industry  or tube size range? It will include detailed parameters, tooling options, and performance metrics to support equipment selection or sales documentation.

Details description

Jiangsu Yanruilin Precision Machinery Co., Ltd. is a research and manufacturing enterprise specializing in metal straight pipe forming and processing equipment.

Main business: professional equipment for Vertical pipe end forming machines, horizontal forming machines, and dual station Pipe end forming machines.

The company has independently developed over a thousand casing section forming molds, including cutting, CNC machining, precision machining of machining centers, wire cutting, and dozens of sets of equipment. We specialize in mold research and development to meet user production needs, with a market share of 85%. All cooperative users meet various customized requirements. The products are exported to the domestic market. Up to now, thousands of casing section forming equipment have been delivered to the Chinese market. The product is widely used in industries such as aviation, shipbuilding, automotive construction water supply and drainage, municipal pipelines, household appliances, and pipeline smoke exhaust. The company, with its unique technology and advanced research and development concept, produces and sells six generations of models, develops and designs seven sets of models, which have far exceeded the current usage scenarios of market users. Company business philosophy: Never be satisfied with current technology, always maintain advanced research and development, make our users' products competitive in the market, warn employees not to meet current technological levels, and always maintain innovative thinking. We warmly welcome customers to visit our factory for inspection, exchange and cooperation.