Rotary bender with hybrid saddle

Abstract

A bending apparatus consisting of a rocker rotating in a hybrid constructed saddle. The saddle is preferably made of a steel casing with a low friction liner disposed therein.

1 . A rotary bending tool comprising:
 a saddle having an elongated member formed with an at least partially cylindrical open recess extending lengthwise along the saddle; and   a rocker having an elongated member with at least a partially cylindrical outer surface fit to the at least partially cylindrical portion of the saddle recess, such that the saddle recess allows relative rotation of the rocker therein;   wherein the saddle comprises a high strength housing with a liner disposed therein, the liner formed of a low friction material.   
   
   
       2 . The rotary bending tool of  claim 1  wherein the liner is selected from the group consisting of bearing bronze, aluminum bronze and phosphor bronze, manganese bronze, and silicon bronze. 
   
   
       3 . The rotary bending tool of  claim 1  wherein the liner is phosphor bronze. 
   
   
       4 . The rotary bending tool of  claim 1  wherein the liner is aluminum bronze. 
   
   
       5 . The rotary bending tool of  claim 1  wherein the liner comprises s a polymer. 
   
   
       6 . The rotary bending tool of  claim 1  wherein the liner is a filament wound composite. 
   
   
       7 . The rotary bending tool of  claim 1  wherein the liner is a graphite composite. 
   
   
       8 . The rotary bending tool of  claim 1  wherein the rocker is a graphite composite. 
   
   
       9 . The rotary bending tool of  claim 1  wherein the liner comprises a plurality of individual lengths. 
   
   
       10 . The rotary bending tool of  claim 1  further comprising:
 one or more openings within the saddle, the openings open to the recess therein; and friction reducing plug(s) mounted in the one or more openings, the plugs each having an end engaging the rocker cylindrical surface thereby lubricating the rocker cylindrical surface.   
   
   
       11 . The rotary bending tool of  claim 10  wherein the plugs are an oil-impregnated metal. 
   
   
       12 . The rotary bending tool of  claim 10  wherein the plugs are an oil-impregnated graphite. 
   
   
       13 . The rotary bending tool of  claim 10  wherein the plugs are an oil-impregnated polymer. 
   
   
       14 . A method of fabricating a rotary bending tool of the type having:
 a saddle having an elongated member formed with an at least partially cylindrical open recess extending lengthwise along the saddle; and   a rocker having an elongated member with at least a partially cylindrical outer surface fit to the at least partially cylindrical portion of the saddle recess, such that the saddle recess allows relative rotation of the rocker therein;   the method comprising:   forming a saddle housing;   former a saddle liner; and   inserting the saddle liner within the saddle housing.   
   
   
       15 . The method of  claim 14  comprising forming the liner of a material selected from the group consisting of bearing bronze, aluminum bronze and phosphor bronze, manganese bronze, and silicon bronze. 
   
   
       16 . The method of  claim 14  comprising forming the liner of bearing bronze. 
   
   
       17 . The method of  claim 14  comprising forming the liner of aluminum bronze. 
   
   
       18 . The method of  claim 14  comprising forming the liner of a polymer containing material. 
   
   
       19 . The method of  claim 14  comprising forming the liner of a filament wound composite. 
   
   
       20 . The method of  claim 14  comprising forming the liner of a graphite composite. 
   
   
       21 . The method of  claim 14  comprising forming the rocker of a graphite composite. 
   
   
       22 . The method of  claim 14  comprising forming the liner of a plurality of individual lengths. 
   
   
       23 . The method of  claim 14  comprising forming the liner by extruding a polymer-containing material. 
   
   
       24 . The method of  claim 14  comprising:
 forming one or more openings within the saddle, the openings open to the recess therein; and   inserting friction reducing plug(s) in the one or more openings, the plugs each having an end engaging the rocker cylindrical surface thereby lubricating the rocker cylindrical surface.   
   
   
       25 . The method of  claim 24  comprising:
 wherein the plugs are an oil-impregnated metal.   
   
   
       26 . The method of  claim 25  wherein the plugs are an oil-impregnated graphite. 
   
   
       27 . A method of bending a workpiece comprising:
 placing a workpiece in a rotary bending tool according to  claim 1 .   
   
   
       28 . A die press having a rotary bending tool according to  claim 1 . 
   
   
       29 . A rotary bending tool comprising:
 a saddle having an elongated member formed with an at least partially cylindrical open recess extending lengthwise along the saddle; and   a rocker having an elongated member with at least a partially cylindrical outer surface fit to the at least partially cylindrical portion of the saddle recess, such that the saddle recess allows relative rotation of the rocker therein;   wherein the saddle comprises a composite having a polymer binder, and wherein   
   
   
       30 . A method of fabricating a rotary bending tool of the type having:
 a saddle having an elongated member formed with an at least partially cylindrical open recess extending lengthwise along the saddle; and   a rocker having an elongated member with at least a partially cylindrical outer surface fit to the at least partially cylindrical portion of the saddle recess, such that the saddle recess allows relative rotation of the rocker therein;   the method comprising:   forming the saddle by extruding a high strength composite.