In the pipe bending business, the most expensive line item isn't the machine—it's the material. Every time an operator has to scrap a piece of stainless steel tubing because of a wrinkle or a crack, profit margins shrink. At Wonsten Group, we see many shops accepting a 5-10% scrap rate as "normal." It shouldn't be.
The "Test Bend" Problem
The old way of setting up a job involved cutting a few pieces of pipe, running them through the machine, measuring the error, adjusting, and trying again. This trial-and-error method wastes valuable raw material.
Simulation is Key
Modern CNC benders from Wonsten Group utilize advanced simulation software. Before you cut a single piece of metal, the software predicts springback and potential collisions. By entering the material properties (tensile strength and elongation) into the control system, the machine can adjust the bend angle automatically to compensate for springback. This means the first part off the machine is correct, not the third or fourth.
Optimizing the Cut Length
Another source of waste is cutting the raw tube too long "just in case." If you are bending a part that requires a 100mm straight section at the end, but you cut the raw tube with 150mm of extra length, that is 50mm of waste per part. Over a run of 10,000 parts, that is half a kilometer of wasted pipe. Wonsten Group’s software calculates the exact arc length needed, allowing you to cut raw material with minimal allowance, tightening your material usage.
Check Your Mandrel Condition
Finally, waste often comes from tooling failure. A worn mandrel or a wiper die that isn't seated correctly will cause internal collapsing. Regular inspection of your Wonsten Group tooling ensures that the consumables aren't the cause of your scrap pile.
