A Beginners Guide to Square Tube Vs Round Tube

December 20, 2020

An introduction to square tube bending and round tube bending:

Bending is the process where cross-section fibers of the square tube or round tube bear tension on the outside of the bend area. And besides compression on the inside of the bend area. Moreover when the material surpasses its ultimate tensile stress tube will rip along the outer side surface.

First, scroll down and find out the details about the square tube and round tube then drag the cursor more and learn the differences.

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What is the square tube?

The square tube has a flat shape therefore it has bolts and other objects attached to it. For instance, the uses include assembling development, railings, and signposts.

square tube

Their estimation performs through external measurements and their wall thickness. Square Tube is accessible in Aluminum, Stainless Steel, Hot Rolled Steel, and Cold Rolled Steel.

Manufacturing of square tube:

Square tube manufactures from curls and afterward passes through dies. However, welding is done from within to frame their shape. Square tube is largely used for upkeep and underlying purposes.

Strength of square tube:

The unbent pieces of the square tube have great strength. Therefore it is used in the building and construction industry a lot. However, the only drawback is the vertical surfaces that distribute tension across square tubes. Thus, the tube loses some strength when comes under pressure.

Mold ability:

When square tube comes under pressure, it loses its strength. Thus, it is less reliable than a round tube. However, the square shape tube can be easily cut and weld to settle down in unique shapes.

What is a round tube?

The round tube has round barrel-shaped shapes that are hollow. Round cylinders have a wide variety of underlying and compositional applications. In contrast to pipes, tubes measures by their external width and their wall thickness. A few instances of round tube applications include car parts, railings, and yard furniture.


The shape of the tube becomes the reason for less material in production and making it weigh less. Furthermore, the coil of metal turns into sheets and forms a circle before welding to produce a cost-effective tube.


The round shape has a continuous shape which helps to distribute the pressure evenly when stress applied. Just as rectangular tubing has no weak points and it has consistent strength. Hence it is a good alternative to a rectangular tube.


The round shape helps the metal to flow properly in all directions as to its being bent. The shape reduces the risk of concaving.

Now let’s find out about the bending process.

Factors influencing bending process:

Here are some tips that can influence the bending of the square and round tube.


Lubricant helps to remove friction between tooling material and material to be bent. When there is a friction reduction the material easily flows through the bending machine.

Material size:

The larger materials are unable to bend at a shorter radius and have greater chances of distortion. On the other hand, smaller materials easily bend at a larger radius. Therefore knowledge of the size of the material is necessary for planning and solving the bending problems.

Bending method:

This is a vital factor in controlling bending. An effectively chosen strategy can assist in creating steady tolerances. To select what is the equipment requirement of the bending process first a bending method is chosen. Likewise, a material having a small size requires two types of bending rotary and compression. So for this reason wiper dies and mandrels can be incorporate easily.


After the designing of the parts, one has to choose the bending procedure size and tools required for this process. For instance, the tools are clamp block, follower block, mandrel. Maybe all tools or a combination of these tools are used.

The thickness of the wall:

Bending is the process of stretching outside diameter of round or square material bend, whereas compression of inner diameter.  The wall thickness influence the process in a way; the thicker the wall the tighter is the bend radius. This allows for more stretchability and less distortion.

Types of bending:

Roll type bending:

The roll type bending is the process of entailing three rollers in a pyramid shape either vertically or for larger materials horizontally. Furthermore, the roll moves in the direction that the machine provides. The rolls move to produce very large radii. Sometimes, the two upper roll moves to produce a certain angle. The bottom rolls are movable, and the upper roll is stationary.

If spirals are what you need then roll bending is an excellent choice. In a workpiece that has a one-width pitch and a huge radius, the operator can lift the roller after one insurgency to create a ceaseless loop. A few applications, incorporating those with a bigger spiral pitch, requires an extra roll that directs the roller outward as the loop forms.

Compression type bending:

The compression bending system fastens the workpiece to the rearmost tangent point. The tube compresses through rollers against the central bend die. Symmetrical workpieces are appropriate for this type of bending. Compression type bending commonly produces household products.

Rotary bending:

The most precise way of bending is rotary draw bending. It is used to achieve tight radii. Moreover, the process provides control over wall thinning. Rotary bending allows flows of material through mandrel in the inner diameter of the tube and the use of precision tooling on the outside diameter.

A rotary draw facility upholds the flat surface. A cinch pass on the clamps workpiece around a twist die; a mandrel, here and there with a progression of articulating balls on the end to help the cylinder inside around the corner; and a wiper pass on that contacts the workpiece.

Ram bending:

It is the oldest technique of bending. The ram-type bending uses a hydraulic ram the clamps back the tube against rollers. This strategy is popular in square tubing applications, the ramming equipment uses it in a way that it compresses and distort the inner radii of the bend.  This forestalls wrinkling and changes the outside surface of the bend to the inward surface, and delivers a concave surface.

The modern era of bending:

In the early day's hammers, tongs and anvils were used for the bending process. But nowadays turning on a bender will open a gateway to knowledge and technology of this time.

In today's world knowledge of the past is blended with modern tools to achieve efficient bending.

You May Also Read: Rectangular Tube and Square Tube Bending Process

Square tube bending vs round tube bending:

Without any hesitation, we can say that round tube bending is the ideal way of bending. Just as the round tube wins the race because of high strength and good formability, its manufacturing process is easier than square tubing. But you cannot make a firm decision here about which shape is the best because every design has specific requirements.

But the main concern is always about which shape is cost-effective so you can surely go for round tubing. However, the square tubing is essential when the main requirement is the tube shape.

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