Finished Tube ID & Torque Calculator
The below calculator can help you determine your finished ID target and recommended torque for expansion.
Calculator
NOTE: The calculated values are estimated based on the available inputs. Actual values may vary due to tube thickness, material, tube sheet thickness, lubrication, operation condition, and/or operator technique. Best practices are to start with a lower torque setting and measure each tube to ensure proper wall reduction and finished ID is achieved.
BWG / Wall Thickness (Inch) Conversion Chart
| Tube Wall BWG | Tube Wall Inches |
|---|---|
| 0 | 0.340 |
| 1 | 0.300 |
| 2 | 0.284 |
| 3 | 0.259 |
| 4 | 0.238 |
| 5 | 0.220 |
| 6 | 0.203 |
| 7 | 0.180 |
| 8 | 0.165 |
| 9 | 0.148 |
| 10 | 0.134 |
| 11 | 0.120 |
| 12 | 0.109 |
| 13 | 0.095 |
| 14 | 0.083 |
| 15 | 0.072 |
| 16 | 0.065 |
| 17 | 0.058 |
| 18 | 0.049 |
| 19 | 0.042 |
| 20 | 0.035 |
| 21 | 0.032 |
| 22 | 0.028 |
| 23 | 0.025 |
| 24 | 0.022 |
| 25 | 0.020 |
| 26 | 0.018 |
Industry Recommended Wall Reductions
| Material | TEMA Standard Target % Wall Reduction | API-660 Target % Wall Reduction |
|---|---|---|
| Aluminum 3003 or 4004 | 4 – 6% | 5 – 7% |
| Aluminum 6061-T | 6 – 9% | 8 – 10% |
| Carbon Steel & low-alloy steel (max 9% Chromium) | 5 – 8% | 8% max* |
| Stainless Steel and high-alloy steel | 5 – 8% | 6% max* |
| Duplex Stainless Steels | 4 – 6% | Not Specified** |
| Titanium (and other nonferrous, work hardening materials) | 4 – 6% | 5% max* |
| Admiralty Brass (and other nonferrous, non-work hardening materials) | 4 – 9% | 8%* |
| Copper & Copper Alloys | 7 – 10% | Not Specified |
Additional Resources
Overcoming Challenges When Expanding Small Tubes
Tube expansion can be challenging regardless of the application. From inconsistent wall thicknesses to exotic materials, a lot of factors can influence the quality of an expansion. In smaller applications, there can be some additional complexity to the process which makes choosing the right expander more critical.
Quick & Easy Replacement of Condenser Expander Roll Sets
Learn how to quickly change out roll sets to avoid drops in productivity.
Selecting An Assisted Tube Rolling System
Assisted tube rolling systems are a great way to increase productivity and decrease cost. Elliott offers 4 quality systems to suit your specific industry and application needs.
The Critical Role of Torque in Tube Expansion: Why the Right Motor Matters
For years, tube expansion relied heavily on the subjectivity of "rolling to size or feel". The issue is that what one operator "sees, hears, or feels" could drastically differ from another, leading to variability and a high potential for error. The advent of torque control revolutionized this process, significantly reducing operator error and ensuring consistent, repeatable results across the board. While torque control is essential for consistency, the success often hinges on one critical factor: selecting the right motor for the job. Understanding why torque matters and the potential pitfalls of choosing the wrong motor is crucial for achieving reliable and lasting tube to tube sheet joints.