Knowledge and structure of CNC sheet metal bending ...

The knowledge you need to know before buying a CNC sheet metal bending machine:
Workpiece
The first important thing to consider is the parts you want to produce. The point is to buy a machine that can complete the processing task with the shortest workbench and the smallest tonnage.
Carefully consider the material grade and the maximum processing thickness and length. If most of the work is low carbon steel with a thickness of 16 gauge and a maximum length of 10 feet, then the free bending force does not need to be greater than 50 tons. However, if you are engaged in a large number of bottomed die forming, perhaps a 150-ton machine tool should be considered.
Well, assuming that the thickest material is 1/4 inch, 10 feet free bending requires 165 tons, and bottomed die bending (correction bending) requires at least 600 tons. If most parts are 5 feet or shorter, the tonnage is almost halved, which greatly reduces the cost of purchase. The length of the part is very important for determining the specifications of the new machine.

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Torsion
Under the same load, the deflection of the worktable and sliding block of the 10-foot machine is 4 times that of the 5-foot machine. This means that shorter machines require fewer shim adjustments to produce qualified parts. Reduced shim adjustment and shortened preparation time. Material grade is also a key factor. Compared with low-carbon steel, the load required by stainless steel is usually increased by about 50%, while most grades of soft aluminum are reduced by about 50%. You can get the machine&#;s tonnage table from the sheet metal bending machine manufacturer at any time. The table shows the estimated tonnage required per foot in different thicknesses and different materials.

The bending radius of the part
When free bending is used, the bending radius is 0.156 times the opening distance of the die. During the free bending process, the opening distance of the die should be 8 times the thickness of the metal material. For example, when forming 16 gauge mild steel with 1/2 inch opening distance, the bending radius of the part is about 0.078 inches. If the bending radius is almost as small as the material thickness, a bottomed die must be formed. However, the pressure required for forming a bottomed die is about 4 times greater than that of free bending.
If the bending radius is less than the thickness of the material, a punch with a front-end fillet radius smaller than the thickness of the material must be used, and the imprint bending method must be used. In this way, 10 times the pressure of free bending is required.
As far as free bending is concerned, punch and die are processed at 85° or less (smaller is better). When using this set of molds, pay attention to the gap between the male mold and the female mold at the bottom of the stroke, and the excessive bending that is sufficient to compensate for the springback and keep the material at about 90°.
Generally, the springback angle of the free bending die on the new sheet metal bending machine is &#;2°, and the bending radius is equal to 0.156 times the opening distance of the die.
For the bending of bottomed concave mold, the mold angle is generally 86~90°. At the bottom of the stroke, there should be a gap slightly larger than the thickness of the material between the male and female molds. The forming angle is improved because the bottomed die has a larger bending tonnage (about 4 times that of free bending), which reduces the stress that usually causes springback in the bending radius.
The imprint bending is the same as the bending of the bottomed die, except that the front end of the punch is processed to the required bending radius, and the gap between the punch and the die at the bottom of the stroke is smaller than the material thickness. Since enough pressure (approximately 10 times of free bending) is applied to force the front end of the punch to contact the material, springback is basically avoided.
In order to choose the lowest tonnage specification, it is best to plan for a bending radius larger than the thickness of the material, and use the free bending method as much as possible. When the bending radius is large, it often does not affect the quality of the finished part and its future use.

Precision
Bending accuracy requirements are a factor that needs to be carefully considered. It is this factor that determines whether you need to consider a CNC sheet metal bending machine or a manual sheet metal bending machine. If the bending accuracy requires ±1° and cannot be changed, you must focus on the CNC machine.
The repeatability of the slider of the CNC sheet metal bending machine is ±0. inches, and the precise angle of forming must use such precision and a good mold. The repeatability of the slider of the hand-controlled sheet metal bending machine is ±0.002 inches, and the deviation of ±2~3° is generally produced under the condition of using a suitable mold. In addition, the CNC sheet metal bending machine is ready for quick mold assembly. When you need to bend many small batches of parts, this is an indisputable reason to consider.

Mould
Even if you have shelves full of molds, don&#;t assume that these molds are suitable for the newly purchased machine. The wear of each mold must be checked by measuring the length from the front end of the punch to the shoulder and the length between the shoulder of the female mold.
For conventional molds, the deviation per foot should be about ±0.001 inches, and the total length deviation should not be greater than ±0.005 inches. As for the precision grinding mold, the accuracy per foot should be ±0. inches, and the total accuracy should not be greater than ±0.002 inches. It is best to use fine grinding molds for CNC sheet metal bending machines, and conventional molds for manual sheet metal bending machines.

The side length of the bent part
Assuming that it is bent 90° along a 5×10-foot 10-gauge low-carbon steel plate, the sheet metal bending machine must apply an additional 7.5 tons of pressure to lift the steel plate, and the operator must drop the 280-pound straight edge. Get ready. Several strong workers or even a crane may be required to manufacture this part. Operators of sheet metal bending machines often need to bend long side parts without realizing how strenuous their work is.
Nowadays, there is a kind of supporting device suitable for workshops engaged in this kind of work, and this kind of device can be improved according to the needs of new and old machines. With this device, only one person is required to form long-side parts.

Selecting the right sheet metal bending tools for your project is not just a matter of preference but a critical decision that can affect the quality, efficiency, and safety of your work. The process of bending sheet metal is a common yet intricate technique used in various industries, including automotive, aerospace, and construction, to create parts with precise angles and shapes. This article provides a comprehensive guide on how to choose the appropriate sheet metal bending tools tailored to your project&#;s specific needs.

Understanding Your Project Requirements

Before diving into the vast pool of sheet metal bending tools, it&#;s essential to thoroughly understand your project&#;s requirements. The nature of the bending process you intend to use, the type of material, its thickness, and the desired bending angle and radius are pivotal factors that will guide your choice.

Type of Bending Process

Different bending processes are available to meet various project requirements. Common methods include air bending, bottoming, coining, and folding. Air bending offers versatility in achieving different angles using the same tool set, though it necessitates precise material control. Familiarity with these techniques will aid in selecting the appropriate sheet metal bending tools.

Material Specifications

The type of metal you&#;re working with&#;be it aluminum, steel, or copper&#;has distinct properties that influence which tools are suitable. Metals vary in strength, ductility, and thickness, all of which affect how they can be bent and what tools can handle the job without damaging the material or the sheet metal bending tools themselves.

Thickness of the Metal

The thickness of your material directly impacts your choice of sheet metal bending tools. Thicker metals require more force to bend and may need stronger, more durable tools, like hydraulic press brakes, to achieve the desired bend without causing strain on the tool or inaccuracies in the workpiece.

Bending Angle and Radius

The specificity of the bending angle and radius you need to achieve will also dictate the type of tool suitable for your project. Tighter radii and more acute angles often require specialized tooling or more precise bending methods to maintain accuracy and prevent material deformation.

Types of Sheet Metal Bending Tools

When selecting sheet metal bending tools for your project, it is crucial to consider various factors. The thickness of the metal plays a significant role in determining the appropriate tools to use. Thicker metals require stronger and more durable tools, such as hydraulic press brakes, to ensure accurate bends without damaging the material or the tools themselves. Additionally, the desired bending angle and radius will also influence the choice of tools. Tighter radii and acute angles may necessitate specialized tooling or more precise bending techniques to maintain accuracy and prevent deformation.

Once you have a clear understanding of your project&#;s requirements, you can explore the various types of sheet metal bending tools available.

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Handheld Tools

For smaller, less complex projects or for fine-tuning bends, handheld tools like seaming pliers and hand brakes can be sufficient. These tools offer simplicity and control for precise, small-scale work.

Press Brakes

Press brakes are among the most versatile and widely used bending tools, capable of handling a broad range of materials and thicknesses. They come in mechanical, hydraulic, and electric varieties, each with its advantages and suited to different scales and types of projects.

Folding Machines

Folding machines, which clamp the sheet metal in place and then fold it to the desired angle using a swinging beam, are ideal for high-precision bends. They are especially useful for parts that require multiple bends in close proximity.

Panel Benders

Panel benders are automated tools that offer high efficiency and precision, particularly suited for large panels or parts with complex bending requirements. They can significantly reduce manual labor and increase production speed.

Tooling Accessories

Choosing the right dies and punches is as crucial as selecting the bending machine itself. These accessories must match the material type and thickness as well as the desired bend radius and angle. Specialized tooling can be necessary for certain materials or bend specifications.

Factors to Consider When Choosing Bending Tools

Several factors should influence your decision when selecting sheet metal bending tools:

Project Complexity

The complexity of your project, including the precision of the bends and the complexity of the part design, will dictate the need for more sophisticated bending tools or accessories.

Volume of Production

Consider the volume of parts you need to produce. High-volume projects may benefit from automated bending machines like panel benders, which can handle large quantities efficiently, while low-volume or one-off projects might be better served by manual or semi-automatic tools.

Budget Constraints

Budget is always a concern, and the cost of sheet metal bending tools can vary widely. Balancing the need for quality, precision, and efficiency with the amount you&#;re willing to invest in equipment is crucial. Remember that higher upfront costs for more advanced tools can lead to long-term savings in time and material costs.

Workspace Limitations

The size and capacity of your workspace can also limit your tool options. Larger machines require more space and might necessitate additional infrastructure, such as reinforced flooring or electrical upgrades.

Maintenance and Safety Considerations

Maintaining your bending tools is vital for ensuring their longevity and performance. Regular maintenance checks, lubrication, and alignment adjustments can prevent breakdowns and ensure consistent accuracy. Safety should never be overlooked; always use protective gear, and ensure that all users are trained on the proper operation of the equipment to prevent accidents.

Tips for Making the Right Choice

To make the best decision, compare products from multiple manufacturers and consult with experts or users who have experience with the tools you&#;re considering. Hands-on demonstrations can also provide valuable insights into how a tool performs in practice. Additionally, consider the tool&#;s adaptability to future projects to ensure it remains useful as your needs evolve.

Conclusion

Understanding the project requirements is crucial when selecting the right sheet metal bending tools. Firstly, assess the thickness and type of metal you will be working with to determine the appropriate tool strength. Secondly, consider the complexity of the bends required and choose between manual or powered tools accordingly. There are various types of sheet metal bending tools available, including bench-mounted brakes, box and pan brakes, and press brakes. Each tool offers different capabilities and versatility, so it is important to match them with your specific project needs. Factors like workspace limitations, budget, and operator experience should also be taken into account when making your final tool selection.

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