leadforensics Unison Tube Bending Blog: Mandrels - the key to challenging tube bending - Unison Ltd

Unison Tube Bending Blog: Mandrels – the key to challenging tube bending

Last time it was mandrel links & cables. Now let’s talk mandrels

Blog by Luke Gibson

Last time, I talked about mandrel links and cables – the bits that sit inside mandrel assemblies.

This time, I thought I’d take a closer look at the mandrels themselves.

They don’t always get the attention they deserve, but they play a crucial role in achieving a clean, accurate bend; especially when you’re working with tight radii or tricky materials.

At Unison, we see first-hand just how much difference the right mandrel can make.

It keeps the tube stable during bending, helps prevent wrinkles, and ensures consistent, high-quality results.

The thing is, there’s no one-size-fits-all. Depending on the job, we might use:

  • Plug mandrels – simple and reliable for bigger-radius bends.
  • Ball mandrelsthe most common type we use for various bending jobs. Normally, these range from one to six balls, but we’ve made mandrels with 10 balls for some tricky projects. The number of balls is determined by the D factor (Outer Diameter to Centre-Line Radius ratio, or OD/CLR) and the wall factor (Outer Diameter to Wall Thickness ratio, or OD/WT). This helps us verify how much support is needed based on the material and bend complexity.
  • Custom mandrels – for those projects where you need something a little more unique.

Mandrel

And, of course, it’s not just about the mandrel. Things like material choice, lubrication, and alignment all matter.

Even a top-quality mandrel won’t work right if it’s not the right size or properly positioned.

If you’re not sure which mandrel is the best fit for your project, we’ve got a free web app to help. Check it out here: https://app.unisonltd.com/

Got questions? Or facing a tricky bend you need help with?

Reach out to us at sales@unisonltd.com – we’re always happy to chat!