Taper the edge of a metal tube to eliminate burrs or sharp edges. Most metal tubes are used in plumbing, architecture and furniture construction. They are relatively simple to taper with the proper tools and techniques. Choose your method based on your budget, skill level and personal preference. Here are ways you can taper a metal tube.
Tubing Benders
Several types of tubing benders are available for creating tapered bends. These include manual hand tools that leverage the strength of your arms and body weight to bend tubing. Hydraulic-powered benders use hydraulic pressure to bend tubing with minimal effort on your part. Pneumatic-powered benders use compressed air to perform similar functions.
Band Saw
A band saw is a tool that uses a long blade to cut through metal. It has a cutting table that you place the end of the metal tube on and a blade guard that protects the blade from contact with skin. Band saws can be expensive if you don't own one, but if you have access to one, use it to taper your metal tube by simply sliding it through the cutting table while the blade is rotating.
Using End Mill
Taping a metal tube is necessary in some cases if the tube has to fit into another piece of metal, such as when you are making a replacement part. If one end of the tube is smaller than the other end, you will have to taper it. You can taper a metal tube using an end mill or a file.
· Set the workpiece on the machine. Set up your desired workpiece on the machine, such as an end mill that is perpendicular to the floor and has clamps set to a 90-degree angle.
· Measure the length of the cut. Please measure the length of cut you want to make with a ruler or measuring tape, and then adjust your cutting tool to match it.
· Begin cutting. Place your cutting tool at one end of the metal tube and use slow, even pressure to begin cutting as you move down the metal tube.
· Add oil or coolant while cutting if needed. Most metal tubes will require some lubricant to not get too hot from friction during the cutting process, which can damage them and cause them to bend or warp out of place.
· Stop once you reach your desired cut length and remove your workpiece from the machine when finished.
Bench Grinder
A bench grinder is a standard tool used in many machine shops. It consists of two grinding wheels that spin at very high speeds when activated. A bench grinder is easy to use as long as you hold the tube steady and hold it against both wheels at an angle so that they shave off small amounts of material each time, taping the end of the tube gradually. However, this can be dangerous if you do not have much experience using power tools.
Compound Bend Formers
A compound bend former is an excellent option for manufacturers who need to create hundreds or thousands of identical tapered bends. Compound bend former machines allow operators to program in exact angles and radii for each bend. The machine then uses hydraulic or pneumatic pressure to create consistent bends.
Tapered Pipe End Preparation
Tapered pipe ends are preferred when you need to butt-weld two pipes with different diameters. For example, if you have a pipe with an inner diameter of 2 inches and another pipe with an inner diameter of 2 1/4 inches, you can weld these pipes together by cutting each with a tapered end. The 2-inch pipe will have a smaller taper than the other one. Both pipes must tapered ends for them to be correctly aligned during welding.
Using A File
The first method is done by mounting the workpiece onto the lathe and then using a cutting tool to remove material from one side until the taper is achieved. The second method involves marking lines with a protractor and then using a file to remove material from one side of the tube until the desired taper is achieved.
Wrapping Up
Using a bench grinder, you can get a professional finish on a brass or copper tube. Before you start, use masking tape to mark the tube's length and where you want to make the taper. This will help you get consistent results. You can also use a hobby knife to mark the end of the taper for more precision. Next, place the tube on the workbench and secure it using a clamp so it won't move as you're working. Move the grinder from side to side across the tube, stopping only when your reach your marked endpoint. Finally, roll up some fine sandpaper around a dowel rod and smooth down any rough edges. Once you've finished grinding and polishing, remove all of the sanding dust before painting or sealing your piece.
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