A tube end forming machine should do more than change the diameter of a tube. It should produce a controlled connection geometry that fits the next operation, meets the drawing and can be repeated economically. The right purchase combines the machine, workholding, tooling, material and inspection method into a proven process.

The Ercolina Era Press range and Pedrazzoli Stern Brown series address different end-forming and metalworking needs. Era Press offers programmable hydraulic pressing and tube expansion or reduction with application-specific tooling. Stern Brown provides multi-station CNC forming and machining sequences. Neither should be selected from tonnage, diameter or a drive-system label alone.

This guide explains their published features, when to evaluate hydraulic or electric equipment, and how correctly planned end forming can improve fit, consistency and production cost.

What is tube end forming?

End forming changes the shape of a tube end to create a required connection or functional feature. Depending on the machine, material and tooling, operations may include:

• Expansion: increasing end diameter to make a socket or mating section.
• Reduction: decreasing end diameter to create an insertion section or transition.
• Flaring: forming an angled or bell-shaped mouth.
• Flanging: forming an outward lip or face; this is distinct from flaring.
• Beading: producing a controlled circumferential feature for a specified retention or joining application.
• Closing: reshaping the end toward a specified closed geometry.
• Associated machining: facing, chamfering, threading or tapping where the machine and tooling support it.

“Swaging” is used broadly in shops for reducing or reshaping tube ends. Rotary swaging is a particular process involving repeated radial tool action. A machine advertised for swaging or reduction should not automatically be described as a rotary swager. Specify the finished geometry and required process.

Likewise, no operation list means that every model performs every operation on every material. A supplier must evaluate the drawing, forming depth, wall thickness, material and tool sequence.

What improves when end forming is done properly?

More consistent fit and assembly

A controlled expansion or reduction can create repeatable overlap, insertion depth and alignment. A properly specified bead, flare or flange can provide the geometry needed for the intended connection. Consistent fit can reduce adjustment during assembly and make downstream welding, brazing or mechanical joining more predictable.

For sealed connections, geometry is only one factor. Surface condition, wall integrity, mating components and the applicable assembly and test requirements also matter. End forming alone does not guarantee a leak-free or pressure-rated joint.

Fewer separate components and operations

Where the product design permits, a formed tube end may replace a separate sleeve or transition component. That can reduce purchased parts, inventory and some joining operations. The design must be reviewed and validated; not every fitting or certified connection can be replaced by a formed feature.

Combining forming and machining in one controlled sequence can also reduce handling between machines. The benefit should be measured on the complete part, including setup, loading, inspection and any subsequent cleaning.

Less scrap and more predictable quality

Appropriate tooling and staged forming can help control cracking, buckling, wrinkling, excessive thinning and unwanted marking. Better control can reduce rework and scrap, but only when the material and process have been qualified. More press force does not correct an unsuitable reduction ratio, insufficient support or incorrect tooling.

Better repeat production

Stored settings and defined tooling sequences help operators return to a proven job. Combine those settings with material specifications, tooling identification and an inspection plan. A saved program is valuable, but it is not a substitute for checking the first part after a changeover or material change.

Start with the finished connection—not the machine size

Give the supplier a drawing showing the starting tube and final end. Include material grade and condition, outside diameter, wall, seam information, finished diameters, transition shapes, depth, tolerances and surface requirements.

For an assembled connection, include the mating component, required insertion depth, sealing geometry and joining method. Identify applicable pressure, pull-off, fatigue, leak or customer-specific tests. Specify whether the end is formed before or after bending and whether both ends need work.

A bent tube can have limited clamping space or interfere with the machine. Long, heavy or irregular parts need suitable support. Very short parts need enough approved grip length. These details can determine machine suitability even when the tube diameter appears to fit.

Ercolina Era Press: hydraulic flexibility for forming and metalworking

Ercolina publishes the EP25H2-V2 and EP60 as horizontal hydraulic presses for tube and pipe swaging and other metalworking operations. Their forming functions depend on the selected tools; a machine-only quotation is not a complete application package.

Published Era Press features and their practical benefits

• Expansion and reduction tooling: supports application-specific changes to tube and pipe ends.
• Flaring and flanging tooling availability: allows additional end geometries to be evaluated without treating the two operations as interchangeable.
• Metalworking press operations: provides versatility for suitable folding and pressing jobs as well as tube work.
• Quick-change modular tooling: helps organize changes between approved applications.
• Adjustable working speed and hydraulic force: allows the process to be set for the material and tooling rather than always applying maximum force.
• Programmable cylinder positioning: supports repeatable stroke settings and control of the formed length or press operation.
• Heavy-duty structure and rigid components: provide the mechanical foundation for controlled pressing.
• Remote pendant with low-voltage controls: supports the intended operator workflow within the prescribed safety arrangement.
• Published hydraulic material clamping: helps hold the work for appropriate forming applications; confirm the supplied workholding for the model and tooling.

EP25H2-V2: 25-ton hydraulic press

The published EP25H2-V2 catalog lists 25 tons of hydraulic force, a touchpad with backlit LCD, eight-program storage, programmable cylinder stroke and punch-style swage tooling. It is a candidate for a shop seeking programmable hydraulic forming and general metalworking versatility within its confirmed capacity.

The catalog lists a 3½-inch × 0.120-inch tube reference, based on mild-grade material. Higher-strength or heavier-wall work reduces applicable capacity. Its listed maximum swage depth is 6 inches, with special tooling required beyond 4½ inches. These are application-screening values, not a promise that every form can be made at those limits.

EP60: 60-ton hydraulic press with additional options

The EP60 adds higher published force and features aimed at broader forming and setup requirements:

• 60 tons of hydraulic force.
• LCD touchscreen control and programmable working speed.
• USB program storage: the manufacturer describes storage expansion through USB; confirm the supplied controller and workflow.
• Punch- or finger-style swage tooling for application-dependent forming methods.
• Square and rectangular tube tooling capability for suitable applications.
• Motor shutdown when not in use to reduce unnecessary idle running.
• Optional side shift intended to reduce tooling changeover.
• Handheld remote control with the published safety classification; the complete machine’s approved safety procedure still applies.

Do not extend EP60-only features to the EP25H2-V2. In particular, the EP25 catalog marks square-tube capacity as not applicable, while the EP60 specifically supports square and rectangular applications with appropriate tooling. Published EP60 swage depth is tooling-dependent and must be specified at order.

Electrical planning: the U.S. material lists 220V or 480V three-phase for the EP25H2-V2 and 480V three-phase for the EP60. Confirm the exact ordered configuration, installation requirements and site service before purchase.

See the Era Press range or request an Ercolina application quotation.

Pedrazzoli Stern Brown: multi-station CNC forming and machining

The Stern Brown series is designed to perform multiple forming and machining operations in a programmed work cycle. Its published range includes the 25, 50, 80 and 160. It is particularly worth evaluating when the part requires a defined sequence rather than only a single expansion or reduction.

Published Stern Brown features and buyer benefits

• IMS touchscreen software: enables creation, copying and execution of end-forming programs and visualization of the part.
• Single- or multiple-station programming: allows a defined sequence of tools for the application.
• Program memory listed up to 10,000 programs: supports a library of repeat jobs, subject to the supplied controller.
• Variable-speed manual jogging and on-screen tool selection: supports setup and prototype development by trained personnel using the approved safety procedure.
• Remote design and network download on request: can support program preparation and transfer; confirm licenses, options and network arrangements.
• Powered tool stations: the 25 and 50 list 15 stations; the 80 and 160 list 12.
• Rotating tool stations: published features describe 360-degree tooling capability for suitable forming and machining operations.
• Indexed tool positioning at the machine center: supports switching between operations within the intended sequence.
• Digital absolute brushless motor control: provides electrically controlled positioning functions; obtain the exact model’s axis list.
• Ball-screw and bearing working-motion components designed for heavy loads: contribute to controlled tool movement.
• Clamping units capable of tandem or independent operation: provide workholding arrangements to evaluate for the part.
• Manual pre-clamping lever: assists setup for appropriate part shapes.
• Webcam support for remote assistance: can help service personnel assess a problem, subject to connection and service arrangements.

The published operation list includes expansion, reduction, beading, facing, chamfering, closing, threading, tapping and flaring. These require the appropriate model and tooling. Do not assume flanging, rotary swaging or every thread form is included merely because the machine is described as an end former.

Compare the published size range

Capacity note: these are separate published maxima, not a guarantee that maximum diameter, wall and depth can be combined in one part. Material strength, final geometry, clamping and tool design affect capacity. A larger model number does not mean every travel or depth specification increases.

Drive-system clarification: electrically controlled axes do not establish that every machine function is electrically actuated. Published Stern Brown descriptions differ: the range overview uses electric wording, while U.S. model sheets describe electro-hydraulic equipment and hydraulic functions. Ask CML USA to confirm the forming, clamping, indexing and machining drives for the exact quoted configuration. Do not treat the complete series as uniformly all-electric based on the range label alone.

When should you buy a hydraulic end-forming machine?

Evaluate hydraulic equipment when the application benefits from controllable forming force, appropriate stroke and versatile tooling at a justified installed cost. The Era Press is one example of a hydraulic platform that combines tube forming with suitable general press work.

A hydraulic machine can be a strong fit when:

• The shop needs expansion, reduction or other approved press operations across a varied workload.
• The operation can be performed efficiently with a limited number of forming stages.
• The required force and stroke fit the machine and tooling.
• The expected batch sizes do not justify a more elaborate multi-station system.
• The shop can maintain the required hydraulic fluid, filters, seals and components.

Hydraulic does not mean unprogrammable or inherently inaccurate. Era Press offers programmable cylinder positioning, and hydraulic or mixed-drive equipment can have sophisticated control. Compare the achieved part and complete cycle rather than assuming a technology label determines quality.

Evaluate idle power, heat, oil maintenance and environmental requirements on the actual machine. The EP60’s published motor shutdown feature illustrates why blanket assumptions about every hydraulic machine’s idle consumption are misleading.

When should you buy electric end-forming equipment?

Evaluate servo-electric forming when programmable motion, repeat setup, coordinated movements and integration offer a demonstrated benefit within the required force and duty cycle. Electric drives can support repeatable positioning and motion profiles and may reduce hydraulic-system maintenance where they replace hydraulic actuation.

Electric equipment may be attractive when:

• Many part numbers require repeatable stored process settings.
• The process benefits from controlled motion profiles or coordinated axes.
• The production plan favors automated sequences and integration.
• Actual energy measurements show an advantage for the intended workload.
• Reducing dependence on hydraulic power systems is a defined site objective.

Electric does not mean unlimited thrust, zero maintenance, zero lubricant or automatic quality verification. Confirm available force throughout the working stroke, duty cycle, tooling, maintenance and any auxiliary hydraulics or pneumatics. Ask whether force monitoring or force-position records are included; CNC positioning alone does not establish those features.

When does a mixed-drive machine make sense?

A machine may combine electric positioning or tool rotation with hydraulic forming or clamping. That arrangement can suit an application requiring both programmable motion and hydraulic force. Specify the function of each drive and evaluate the complete result. Do not reject or select a machine merely because a brochure uses “electric,” “hydraulic” or “electro-hydraulic.”

What to look for in tooling and workholding

The tooling determines how the metal is supported and moved. Request a proposed sequence, not just an equipment quote. Large changes in shape may need progressive stages rather than one aggressive stroke. The supplier should explain how the process controls material flow, thinning, buckling and tool release.

Review grip length, clamp force, holding resistance and surface protection. Clamping must resist forming loads without unwanted crushing, slippage or marking. For non-round or already bent tube, verify orientation and clearance. Ask whether internal support is needed and how tooling wear affects the finished dimensions.

Clarify every included tool: holders, jaws, punches, reduction cups, segmented tools, forming tools, machining tools and gauges. Published station counts do not mean the machine arrives with a complete set of application-specific tools. Likewise, standard press accessories do not establish that a particular tube-end geometry is covered.

Confirm replacement-tool availability, expected wear items, sharpening or refurbishment where applicable, and how long a normal changeover takes. Evaluate tooling cost across the intended part family rather than treating it as an afterthought.

Prepare the tube correctly

A consistent end form starts with consistent incoming stock. Cut length, squareness, burr condition, material variation and seam condition can influence the result. Prepare tube ends according to the approved process and remove debris that could affect tooling or the finished connection.

Use compatible lubrication where specified and establish any required cleaning afterward. Lubricant that helps forming may be unacceptable in a later welding, brazing, coating or fluid-system operation unless removed. Define the entire production route.

Decide whether forming precedes or follows bending based on tooling access, clamping space and the effect of subsequent operations. Validate the complete sequence rather than assuming the two processes can be rearranged without consequences.

Measure the benefits using accepted production

Track complete cycle time, operator handling, first-off approval, scrap, rework and downstream assembly time. A faster ram stroke does not necessarily produce more accepted assemblies. A multi-station process may justify its investment by eliminating transfers even when one individual forming movement is not faster.

Compare total cost per accepted part: installed equipment, tooling, setup, labor, consumables, maintenance, energy, inspection and rejects. Credit reduced fitting purchases or joining operations only where the product design and process trial demonstrate that they can actually be eliminated.

Applications can include furniture, displays, sign structures, HVAC and cooling, fluid lines, automotive components, agricultural machinery and other fabricated tube products. A general application list does not establish approval for a pressure system, aerospace component or any regulated service. Apply the actual drawing and qualification requirements.

Request a trial that proves the complete part

Use your intended production material and representative tooling. Agree on the final geometry, tolerances and inspection method before the trial. Check a representative batch, not only one successful sample.

• Inspect formed diameter, length, concentricity, transition shape and surface condition.
• Evaluate wall integrity and section the part where necessary.
• Check cracks, folds, wrinkles, thinning and unwanted tool marks.
• Test fit with the actual mating component.
• Perform required leak, pressure, retention or fatigue tests through the appropriate qualified process.
• Record the complete cycle and operator involvement.
• Demonstrate a tooling change and repeat setup where relevant.

Separate factory acceptance before shipment from site acceptance after installation. Agree on operator training, process documentation, maintenance instructions and support responsibilities. Do not change approved guarding or reach into the work zone to improve cycle time.

Installation, service and quotation checklist

Plan machine access, material supports, tooling storage, operator space and protective devices. Confirm electrical service and any other utilities for the exact configuration. Determine who handles freight, unloading, rigging, connection, commissioning and cell integration.

Send CML USA:

• Starting tube dimensions, material grade, wall and condition.
• Finished drawing, mating-part details and end-form depth.
• Required expansion, reduction, bead, flare, flange or machining operations.
• Dimensional, surface, cleanliness and test requirements.
• Part length, bend geometry and available grip area.
• Prototype, batch and annual quantities.
• Required tooling changeovers and future part families.
• Handling or automation needs.
• Site utilities, installation constraints and timing.

Ask the quotation to separate machine, tooling, software, options, gauges, training, installation, freight and service. Confirm warranty scope, spare parts, remote assistance and current lead time. Do not equate a published specification with a promise of immediate stock or an included option.

Frequently asked questions

Is more tonnage always better?

No. The machine needs sufficient force, but the right tooling, material support, stroke and sequence determine the result. Excessive force can damage a part or tool rather than improve forming.

Should I choose an Era Press or Stern Brown?

Evaluate Era Press for programmable hydraulic forming and suitable general press work. Evaluate Stern Brown when a multi-station CNC forming and machining sequence can improve the complete process. Have the same drawing and acceptance requirements assessed for each proposed solution.

Does CNC mean full electric?

No. CNC describes numerical control, not every actuator. Request a function-by-function drive description. Published Stern Brown descriptions require configuration confirmation rather than a blanket all-electric claim.

Can end forming eliminate welding or fittings?

Sometimes, if the approved design permits a formed connection in place of a separate component or operation. Validate the joint’s functional, sealing and structural requirements before claiming the substitution.

Will one tooling set cover every diameter and material?

No. Tooling must match the starting tube, final shape and material. Some tooling systems offer flexibility, but the supplier must confirm the actual range and changeover requirements.

Choose a proven process for the connection you need

The right end former is the one that consistently makes an acceptable part at a justified cost. Era Press brings programmable hydraulic pressing and application-specific tooling versatility. Stern Brown brings multi-station CNC sequencing and forming-and-machining capabilities. Their value becomes clear when measured against the drawing, tooling plan and complete production route.

Request an end-forming application review with your material, starting dimensions and final connection drawing.

Related guides and published references

If the part also needs bends, read the Full-Electric CNC Tube Bender Buyer’s Guide. For stock preparation, explore the cold saw vs. band saw comparison.

• Ercolina Era Press product information
• Era Press catalog and tooling information
• Stern Brown 25 specifications
• Stern Brown 50 specifications
• Stern Brown 80 specifications
• Stern Brown 160 specifications

Published descriptions and options must be confirmed for the machine offered. This guide is not an operating procedure, a finished-part guarantee or approval for a particular connection standard.