Hulk Tube Roller

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Hulk Tube Roller
Hulk Tube Roller.jpg
Owner/Loaner PS:One
Serial Number N/A
Make/Model Hulk Tube Roller
Arrival Date 4/17
Usability yes
Contact Cold Metals Area Host
Where Cold Metals
Authorization Needed yes
Hackable no
Estimated Value $1800
Host Area Cold Metals


Hulk Tube Roller Area: Cold Metals https://wiki.pumpingstationone.org/Hulk_Tube_Roller



Overview

The SWAG Tubing Roller “Hulk” is used for adding a bend radius to materials such as round and square tube, flat bar stock, and handrails. Depending on the size and thickness of the material to be bent, the effort to crank the tube roller can be significant. The “Hulk” name makes reference to the effort involved in producing the finished product. For an overview of the machine including a demonstration of its use, watch Youtube video from SWAG.

Safety

The tube roller applies significant force to the material being rolled. This force is applied with a two-ton bottle jack. Always be cognizant of where your fingers are when using the tube roller. There are pinch points throughout the tube roller that will crush your fingers, or anything else that gets inside of them. While the dies and axles are constructed of solid material, significant force can cause parts of the machine or your material to crack or shatter. You should always wear safety glasses when using the tube roller.

Available Dies

PS1 stocks the dies listed below for use in the tube roller. In addition to the dies at PS1, the manufacturer has dozens of other dies available for purchase. All of the dies available from the manufacturer are listed here. The manufacturer also sells Delrin dies. Delrin dies are useful for bending soft and polished materials that are easily scratched (e.g. aluminum or copper).

Round Tube

  • 1”
  • 1 ¼”
  • 1 ½”
  • 1 ¾”
  • 2”

It is very important to note that the round tube dies are for use with tubing, not pipe. Tube and pipe are not the same thing. The actual dimensions of 1” round tube and 1” pipe are not the same. The nominal trade size of tubing is equivalent to its outside diameter. Pipe, at least for the sizes supported by the tube roller, is specified in a nominal trade size that is not equivalent to its outside diameter.

Square Tube

  • 1”

Machine Use

To use the tube roller, you should follow the four steps in this section:

  1. Place the dies in the desired position
  2. Adjust the handle leverage setting (if necessary)
  3. Zero the depth gauge
  4. Roll your material

You must use the correct die set for the material you are rolling. If you need to change the die set that is installed in the tube roller, follow the steps in Change the Die first.

Die Placement

The outer dies can be placed in three positions on either side of the tube roller as shown below. The position on the outside (position 1) requires the least amount of force to bend material while the innermost position (position 3) requires the most force to bend material. The placement of the dies also affects the bend radius. When you change the die position, be careful to make sure both dies are fully seated. The axles fit snugly into the notches and they may need to be pushed into position.

HulkPosition1.jpg HulkPosition2.jpg HulkPosition3.jpg

Handle Leverage Adjustment

The handle has three positioning holes shown in the image below. The outermost hole provides the most leverage while the innermost hole provides the least leverage. You can move the handle between these holes by loosening the nut.

HulkHandle.jpg

Depth Gauge Zero Setting

A depth gauge, shown in the picture below, is attached to the machine. You can use the depth gauge to create repeatable bends.

HulkDepthGaugeNoZero.png

To use the depth gauge, you must first set a zero point. To set a zero point, follow these steps:

  1. Place your material in the tube roller.
  2. Raise the jack piston until the center die is flush and snug with your material, but also not applying pressure to the material.
  3. Turn the depth gauge on by pressing the green power button.
  4. Press the gray unit button until the unit on the lower right corner of the LCD reads mm.
  5. Press the black zero button and wait for the reading on the LCD to show 0.00, as shown below.

HulkDepthGaugeZero.jpg

As you raise the jack, the depth gauge will measure the depth of the center die. You can save this reading to replicate your bend in the future.

Roll Your Material

Now that you have configured the machine for use, you can begin rolling your material. This process is a matter of trial and error. You can always add additional radius to your material by rerolling it at a higher depth setting. You cannot straighten rolled stock that you have rolled to too large of a radius, so it is always a good idea to start small. Plan to have extra material on hand to get the settings right.

  1. Close the release valve on the jack.
  2. Place your material in the tube roller. Be sure your material is in contact with all three dies.
  3. Set the jack piston to the depth you wish to roll the material at.
  4. Turn the handle clockwise to begin rolling the material.
  5. You may need to roll the material in both directions (by turning the handle in both directions) to achieve the desired bend.
  6. Remove the material and check if the bend radius is as desired.
  7. Repeat steps 1 - 5 as necessary to achieve your finished product.

Changing the Die Set

Each die set consists of three pieces: a pair of identical roller dies for the left and right sides and a center die with a square keyed slot. Before you begin, you will need the following tools:

  1. 5/32” Allen wrench
  2. 3/16” Allen wrench

Follow the steps below to change the die set in the machine.

Remove Existing Die Set

  1. Open the jack release valve
  2. Depress the jack piston so it is no longer in contact with the machine
  3. Remove the left and right side dies and set them aside
  4. Use the 5/32” Allen wrench to loosen the set screws on the center die axle
  5. Remove the handle to release the center die. Be very careful when you remove the handle. The jack is being held up by the center die and will fall down when the handle is removed.
  6. Set the center die set screws and the brass key stock aside.
  7. Use the 3/16” Allen wrench to remove the end cap from the left and right dies. Use the 5/32” Allen wrench to prevent the axle from turning, as shown below. Set the screws (2x) and washers (2x) aside.
  8. HulkChangeDieCollar.jpg

  9. Use the 5/32” Allen wrench to loosen the set screw on the collars closest to the end caps that you removed. DO NOT loosen the other collar or you will break the alignment of the dies.
  10. Remove the left and right dies from the axles and the bearings. Place dies on the marked post on the bottom of the tube roller stand.
  11. Place the center die on the marked post on the bottom of the tube roller stand.

Install New Die Set

  1. Insert the bearings into the centers of the left and right dies.
  2. Place the left and right dies on the axles.
  3. Place the collars over the axles and tighten them with the 5/32” Allen wrench. The set screws should be snug but not overtightened.
  4. Reinstall the washer and cap screw using the 3/16” Allen wrench at the end of each axle. Use the 5/32” Allen wrench to prevent the axle from turning. The cap screw should be snug but not overtightened.
  5. Insert the handle through the frame just far enough to hold the die rack at the right height, as shown below.
  6. HulkHandleShim.jpg

  7. Insert the handle through the center die using the key stock to center the handle and center die.
  8. Use the 5/32” Allen wrench to tighten the center die set screws. The set screws should be snug but not overtightened.

Maintenance

The tube roller requires the following consumable parts:

  1. 2xCR2032 batteries – depth gauge

There are spare set screws and key stock in a white box marked “Tube Roller Parts” on the bottom of the tube roller cart.


Authorized Users

  • Bryan Gleason
  • Aaron Carlock
  • Ray Doeksen