Flanges Formed by Bending

Abstract
A flange is a key component used to connect pipelines and equipment; its main function is to ensure the sealing and strength of the pipeline system. As an important connector in the pipeline system, the forming of flanges directly affects their quality and service life. There are many types of flange forming processes, among which bending is widely used in flange manufacturing due to its high efficiency, precision, and good adaptability. Bending, as a common manufacturing process, is important in flange production. This paper describes the bending process of flanges, including its principles, main methods, technical points, and application prospects.
 
Principles of bending
Bending is a process that shapes a sheet or pipe into a desired form using mechanical force. This process mainly uses external force to bend the material within the range of plastic deformation to achieve the desired shape and size. The principle of flange bending is to deform the material on a bending die with a specific radius by applying a bending moment to achieve the desired shape.
 
Main methods of flange bending
There are many methods for flange bending, including free bending, die bending, and CNC bending. Free bending is a simple bending that bends the material freely by applying bending moment. This method is suitable for flanges with simple shapes; it has a low process cost but requires high technical skill from operators. Die bending is a forming method that uses special molds to bend materials. The advantage of die bending is that it ensure the dimensional accuracy and shape consistency of the finished flange, making it suitable for mass production. Common die bending methods include rolling bending, press bending and stretch bending. CNC bending uses CNC equipment to accurately control and bend materials. This method controls the bending angle and radius through a computer program, offering high precision and high efficiency, and is suitable for manufacturing complex-shaped flanges.
 
Technical points of flange bending
In the process of flange bending, the following technical points need attention:
Material selection
The selection of flange materials is crucial to the success of bending. Common flange materials include carbon steel, stainless steel, and alloy steel. The mechanical properties and plastic deformation capacity of the material directly affect bending quality.
 
Bending radius
The bending radius is an important parameter in bending and is directly related to the shape and dimensional accuracy of the flange. Generally, the larger the bending radius is, the easier the bending becomes. However, the appropriate bending radius must be selected according to specific requirements.
 
Bending speed
The bending speed significantly influences the deformation and forming quality of the material. Too fast a bending speed may cause material breakage or surface defects, while too slow a speed will reduce production efficiency. Reasonable control of bending speed is key to ensuring forming quality.
 
Lubrication and cooling
During the bending process, lubrication and cooling effectively reduce friction and heat accumulation, preventing damage and deformation on the material surface. Appropriate lubrication and cooling measures improve forming quality and the mold’s service life.
 
Application prospects of flange bending
With the development of industrial technology and increasing demand for high-quality flanges, the application prospects of bending in flange manufacturing are broad. Several possible development directions are as follows:
Automation and intelligence: Automation and intelligent technology improve the efficiency and accuracy of bending, enabling large-scale production and personalized customization.
New material application: Develop and apply new high-performance materials to improve  corrosion resistance, strength and service life of flanges, meeting the needs of special working conditions.
Green manufacturing: Promote green manufacturing technology, reducing energy consumption and environmental pollution in the bending process, and achieving sustainable development.
 
Conclusion
The bending process for flanges plays an important role in flange manufacturing. Through the study of bending principles, methods, and technical points, the quality of flange forming and production efficiency can be continuously improved. In the future, with advancements in technology and changes in demand, the bending process will play a greater role in flange manufacturing and promote the sustainable development of the industry.