Mechanically Assisted / Manual Tube End Flare & Flange Machine

SAE J533 & SAE J1453

I. Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3III. Setup and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4IV. Tube Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5V. Operating Instructions

A. 37° & 45° Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 6-7B. 90° Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 8-9C. Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10

VI. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10VII. Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10VIII. Parts Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11IX. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

Safety and Operating Manual

VERSAtoolTM

I. SAFETY INSTRUCTIONSPREVENT UNAUTHORIZED OPERATION. Do not permit anyone to operate this equipment unless they have read and thoroughly understand this manual.

ALWAYS WEAR SAFETY GLASSES.

AVOID PINCH POINTS. Keep your hands clear of all moving parts. Never allow hands or clothingnear the rotating spindle. Turn ON the spindle motor ONLY when forming a tube end. Turn OFF the spindle motor at ALL OTHER TIMES.

MAINTAIN DIES AND NOSETOOLS WITH CARE. Dies and Nosetools used with the VERSAtool are hardened steel, offering the best combination of strength and wear resistance for long life.Hardened steel is generally brittle and care should be taken to avoid any sharp impact. Never strike a die or Nosetool with a hardened instrument.

USE ONLY SPECIFIED VERSAtool PRODUCTS. Make tube assemblies only with productsdesigned for the VERSAtool machine.

VERIFY CORRECT TUBE DIMENSIONS. Check and verify the correct final Flare or Flange diameters using the VERSAtool Go/No-Go gages prior to tube assembly.

MAKE SURE THAT THE DIES ARE FIRMLY CLAMPED AND THE NOSETOOL IS COMPLETELY IN PLACE PRIOR TO THE FLARE OR FLANGE PROCESS.

SECURE THE EQUIPMENT TO A STABLE WORK SURFACE. Prior to operation, secure theVERSAtool machine to a stable work surface to prevent the equipment from tipping.

UNPLUG THE ELECTRICAL POWER WHEN NOT IN USE.

MAXIMUM INPUT TORQUE AT THE 4-ARM HANDLE WHEEL IS 125 FT-LBS.

CAUTIONFailure to follow proper VERSAtool process and product instructions and limitations could lead to premature tube joint failure, resulting in property damage or serious injury. The use of non-standard components may result in the production of unreliable and unsafeassemblies and is neither recommended nor authorized.

Read and understand the operator’s manual before attempting to operate any equipment.King Forge & Machine hereby disclaims any obligation or liability (including incidental andconsequential damages) arising from breach of contract, warranty, or tort (under negligenceor strict liability theories) should VERSAtool products, tube joints or equipment, or in theevent that product instructions for each specified assembly are not followed.

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II. SPECIFICATIONS Electrical Requirements:

115-Volt AC single phase, 60-Hz circuit with a minimum of 15 amps.

VERSAtool Machine Dimensions:

Width 33 inches

Depth 14 inches (with 4-arm handle)

Height 8 inches (table to top of machine)

Weight 170 pounds

Production Capacity

• Use for Stainless Steel, Carbon Steel and Copper tubing

• 37° and 45° Flare sizes; 1/4" to 1-1/2" [6mm to 38mm]

• 90° Flange sizes; 1/4" to 1" [6mm to 25mm]

• Production cycle time: approx. 15 seconds

• Changeover time: approx. 60 seconds

Note: It is the responsibility of the end user to determine the suitability of VERSAtool’s Flared or Flanged tube ends to his/her application.

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III. SETUP AND INSTALLATION1. Mount the VERSAtool onto a workbench that will support at least 300 pounds. The machine must

be at the corner of the workbench to allow the 4-arm handle and gear reduction system to overhang the edge of the workbench. Secure the unit using the four 27/64" mounting holes provided in the base of the machine.

2. The clamp for the machine will be pre-set. If adjusting is necessary, place a set of dies [any size]in the carrier with a sample piece of tube with the clamp in place, but loose. Adjust either of thetwo set screws so that the clamp arm is approximately 30° to 40° from horizontal. Adjust the second set screw so that it just touches the dies. Clamp the tube and test form the tube to verifythat the tube does not slip during forming. If the tube slips, adjust the set screws so that theclamp arm is at a higher angle from horizontal.

3. Plug the motor’s electrical cord directly into an approved 115-VAC, 60-Hz outlet with a 15 amp minimum rating.

Adjusting the clamp arm.

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IV. TUBE PREPARATIONFully annealed seamless or welded tubing conforming to the specifications listed below is recommended for flaring or flanging with the VERSAtool machine. Seamless tubing is best, if you have a choice.

Stainless Steel Tubing:ASTM: A213, A249, A269. Types 304, 304L, 316 and 316L.Maximum hardness should be HRB 90.

Carbon Steel Tubing:SAE J356, J524, J525, J527

Tube ends should be cut square(within 1 degree), deburred, and lightlychamfered on the ID and OD. Removeall debris. Any abrasive debris orburrs may damage the flange face ofthe tube, allowing leakage after thejoint is made.

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V. OPERATING INSTRUCTIONSEach size tube requires a split die and a flare or flange Nosetool to form the desired end configuration.The first step is to select the proper split die (tube OD, 37° Flare, 45° Flare or 90° Flange), and type of Nosetool (37° Flare, 45° Flare or 90° Flange) for the size tube to be formed. Sizes are engraved on the dies and Nosetools.

1. Place the dies in the carrier with the die angle toward the Nosetoolas shown.

2. Slide the tube to theFeedstop Gage as shown.The 37°& 45° feedstopgage has a single depthfor all OD tube and all wallthicknesses.

A. 37° & 45° Flared Tube Ends

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CAUTIONBe sure the motor is off when not forming a tube end.

Never install or remove a Nosetool while the spindle is turning.Ensure Nosetool size matches the size of the Dies.

3. Close the top clamp and adjust both clamp screwsso that the clamp handle is approximately 30° to 40°from horizontal. The clamp screws should just lightlytouch the dies prior to clamping.A back support for longer tubes may be required to maintain the tube’s horizontal position whileclamping.

4. Insert the Nosetool into the spindle as shown.

5. Brush a small amount of lubricant on the Nosetool.

Split Dies

Nosetool

OPERATING INSTRUCTIONS37° & 45° Flared Tube Ends, continued6. Manually move the carrier toward the spindle until the rack on the bottom of the carrier engages

the pinion gear in the base of the machine.

7. Start the motor with the switch on the side of the electrical connection box. The spindle will beginto rotate and the Nosetool will orbit.

8. Turn the 4-arm hand wheel to slowly move the carrier toward the spindle and drive the tube end over the orbiting Nosetool.

Note: Use both hands on the 4-arm handle during Tube end forming.

Continue to turn the hand wheel. You’ll be able to see the tube end expand as the machine forcesthe tube against the Nosetool.

When the Nosetool has finished forming the flare, hold the wheel position for two to three more spindle rotations to burnish the new tube-end surface. Turn the hand wheel in the opposite direction to back the tube away from the Nosetool. Manually move the carrier away from the spindle to the deadstop.

CAUTIONNever put a "cheater bar" on the 4-arm handle.

Excess force may cause out of spec flares / flanges.Maximum input torque at the 4-arm handle wheel is 125 ft-lbs.

CAUTIONShut the motor off when not forming a tube end.

9. Turn motor off.

10. 37° and 45° Flared tube ends must be removedfrom the split dies to be gaged. Open the topclamp arm, raise the top die half, and remove thefinished tube. It is not uncommon for the tube tostick to the die. Simply tap the tube until itbecomes loose, then remove. Check the formedtube-end with the Go/No-Go gage. If the tubeend is undersized, it can be reflared by reclamping the tube and reforming the end.

Tubes with oversized ends must be discarded.

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V. OPERATING INSTRUCTIONS, continued

B. 90° Flanged Tube Ends

1. Place the dies in the carrier with thecounterbore toward the Nosetool as shown. Slide die tongues into carrier grooves.

2. Hold the Feedstop Gage against the inside face of thedies, and slide the tube end into the appropriate gagepocket. 90° Flange feedstop pocket sizes are markedper OD of tube. A back support for longer tubes may be required to maintain the tube’s horizontal position while clamping.

3. Close the top clamp and adjust both clamp screwsso that the clamp handle is approximately 30° to 40°from horizontal. The clamp screws should lightlytouch the dies prior to clamping.

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CAUTIONBe sure the motor is off when not forming a tube end.

Never install or remove a Nosetool while the spindle is turning.Ensure Nosetool size matches the size of the Dies.

4. If a collar is required, slide it on the Nosetool shaft as shown below with the chamfer toward tip.Refer to the chart for collar requirements.

CAUTION: If collar is used, remove it if not required for next set-up according to chart below.

Tube OD Requiring a Nosetool CollarWall 1/4" 3/8" 1/2" 3/4" 1"

Thickness Collar Thickness Required0.028 None — — — —0.035 None None None — —0.049 None None None None —0.065 — None None None None0.083 — 0.058 None None None0.095 — — — None None0.109 — — — — 0.058

Split Dies

Nosetool

Nosetool

Continue to turn the hand wheel. You’ll be able to see the tube end expand as the machineforces the tube against the Nosetool.

When the Nosetool has finished forming the flange, hold the wheel position for two to three morespindle rotations to burnish the new tube-end surface. Turn the hand wheel in the opposite direction to back the tube away from the Nosetool. Manually move the carrier away from thespindle to the deadstop.

10. Turn motor off.

11. For 90° Flange ends, the formed tube end can be gaged while it is still clamped in the die. If the tube end is undersized, it can be reflanged without unclamping.

12. When the tube passes the Go/No-Go gage, open the top clamp arm,raise the top die half, and remove the finished tube. It is not uncommon for the tube to stick to the die. Simply tap the tube until itbecomes loose, then remove.

13. Double check the formed tube end with the Go/No-Go gage.

V. OPERATING INSTRUCTIONS90° Flanged Tube Ends, continued5. Insert the 90° Flange Nosetool into the spindle as shown.

6. Brush a small amount of lubricant on the Nosetool.

CAUTIONNever put a "cheater bar" on the 4-arm handle.

Excess force may cause out of spec flares / flanges.Maximum input torque at the 4-arm handle wheel is 125 ft-lbs.

CAUTIONShut the motor off when not forming a tube end.

7. Manually move the carrier toward the spindle until the rack on the bottom of the carrier engagesthe pinion gear in the base of the machine.

8. Start the motor with the switch on the side of the electrical connection box. The spindle willbegin to rotate and the Nosetool will orbit.

9. Turn the 4-arm hand wheel to slowly move the carrier toward the spindle and drive the tube end over the orbiting Nosetool.

Note: Use both hands on the 4-arm handle during Tube end forming.

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OPERATING INSTRUCTIONS, continued

C. Tube AssemblyEach end of the formed tube requires a sleeve and nut. These must be installed on the tube prior to forming the ends.

The face seal fitting holds a captured o-ring that is compressed against the face of the tube when the union is assembled, providing a leak-free coupling.

VERSAtool expands the tube immediately behind the flange to prepare the tube for an interference fit with the sleeve. The nut will draw the sleeve over the expanded area of the tube during assembly.When the face of the fitting comes in contact with the face of the tube, a sharp rise in the torque will be evident. A solid pull of the wrench will now complete the assembly. (Follow tube fitting manu-facturer’s assembly instructions.)

VI. MAINTENANCEThe bearings for the VERSAtool are pre-greased with a 100,000 run hours time interval between re-greasing.

Sliding and gear surfaces must be kept free of dirt and other abrasive materials.

All exposed black metal surfaces should be coated occasionally with a light film of oil to prevent corrosion.

Clean up any lubricant that accumulates under the nosetool.

VII. TROUBLESHOOTING TIPSSymptom Possible Cause Corrective Action

Machine won’t start. No power or � Make sure unit is plugged in.wrong voltage. � Check Voltage.

� Check fuse.

Tube End Face is rough. Debris or dirt. � Clean all tubes well.Tooling not smooth. � Contact supplier.Burr on tube end. � Deburr tube end & chamfer.

Improper Flange. Tube slips in die. � Reset clamp to be tighter.Feed stop length wrong. � Use gage correctly.

4-arm handle does Dirt, debris in gears. � Clean gear teeth.not move freely. Dirt in shaft or bushings. � Disassemble & clean.

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VIII. PARTS SCHEMATIC

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TOP VIEW

FRONT VIEW

IX. ACCESSORIES

© 2003 King Forge & Machine, all rights reservedSLVOMA/002-03A

Flange, 90° Collar

Flange, 90° Go/No-Go Gage

Flange, 90° Feedstop GageFlare, 37° & 45° Feedstop Gage

Flare, 37° & 45° Go/No-Go Gage

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A. Split Dies

B. Nosetools

Flange, 90° NosetoolFlare, 37° and 45° Nosetool

C. Collar

D. Feedstop Gages

E. Go/No-Go Gages

Flange, 90° DiesFlare, 37° and 45° Dies