Tube End Forming Machine — DuralBend Vulcan

Reducing, expanding, flaring, beading, flanging — if you need to reshape the end of a tube or pipe, that is what the DuralBend Vulcan tube end forming machine is built for. The Vulcan is not a one-size-fits-all product. It is a hydraulic platform that we configure around your part, your material and your production volume. As tube end forming machine manufacturers based in Istanbul, we engineer the stations, dies and cycle around what you actually need to make.

A Platform, Not a Catalogue Item

The Vulcan covers tube diameters from Ø6 mm all the way up to Ø150 mm. That is from small precision tubing for automotive fuel and brake lines at the small end, right up to heavy structural pipe end forming at the big end. Same machine concept, scaled to your application.

What changes between configurations is what the job actually needs: number of stations, die geometry, stroke length, clamp force, cycle automation. If your part needs one operation we build a single station machine. If it needs three or four operations on the same end — say reduce, then bead, then flange — we add stations so you do it all in one cycle without changing tooling. Station count goes up with operation count, and dies are designed for your specific part geometry. It is an engineered solution, not a stock machine.

How the Vulcan Naming Works

The model code tells you the configuration at a glance. The number after B is the number of stations on the machine, and the number after the dash is the maximum tube diameter in millimetres. So a Vulcan-B1-38 is a single station pipe end forming machine for tubes up to Ø38 mm. A Vulcan-B2-76 is a two station machine for tubes up to Ø76 mm. Need a three station setup for Ø150 mm? That is a Vulcan-B3-150. The naming scales with the build — see the Model Codes and Range tab below.

Why Multi Station Matters

A lot of finished tube ends need more than one forming operation. Maybe a reduction followed by a flare. Maybe an expansion, then a bead, then a flange. On a single station machine you would have to change tooling between each step, which kills cycle time and introduces handling errors. On a multi station Vulcan the tube moves through the stations in sequence and the operator just loads and unloads. Cycle times drop to 3–4 seconds per stroke depending on model size, and consistency improves because the tube is not re-clamped between operations.

This is also where square tube end forming gets handled — square and rectangular sections need specific clamp design and die geometry, and we build that into the relevant Vulcan configuration when the application calls for it.

Materials and Tooling

The Vulcan works with mild steel, stainless steel, aluminium, brass and copper tube end forming applications. Copper specifically needs careful die design because it is soft and tears easily if the forming geometry is not right — we have done a lot of copper work for HVAC and refrigeration customers, so the tooling know-how is there. The same goes for stainless, where the work hardening behaviour changes the forming approach.

Dies are high grade tool steel, designed for your part — not generic off-the-shelf tooling. This is the difference between a tube end former that lasts six months and one that runs for years. We design, machine and harden the dies in-house and supply them with the machine.

Production Integration

The Vulcan is compact enough to drop into existing production lines. Standard configurations run with operator load/unload and foot pedal initiation. If your volumes justify it we can add automatic feeding, automatic part discharge and PLC integration with upstream cutting or chamfering equipment. Tell us what the line looks like and we will specify the integration.

Getting a Quote

End forming is always application specific, so we cannot quote a Vulcan from a model number alone — we need to see the part. Send us your tube drawing, a sample part, or just describe the operations and material. We will come back with a recommended station count, die design and machine size. Email info@duralbend.com or call +90 212 482 41 07.