Computer numerical control (CNC) bending and panel bending help fabricate a variety of metal components. When determining whether this fabrication method is ideal for a particular product, it&#;s important to understand what panel bending is and how it works. At Metal Works of High Point, we offer a range of CNC metal forming services for our clients&#; unique specifications. Learn more about CNC panel bending here.
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What Is Panel Bending?
Panel bending is one of many methods used for sheet metal fabrication. Automated and semi-automated processes such as CNC panel bending, which use CAD and CAM drawings, produce metal pieces with tight tolerances. Panel bending systems rely on specially designed panel bender machines. The process differs from regular bending, which usually takes place on press brakes or progressive dies.
Depending on the application&#;s specific needs, the CNC bending process may involve different types of panel bends, including:
In sharp bends, the radius is smaller than the minimum bend radius, while the center of the radius is creased to produce a sharp bend.
A custom bend radius depends on the customer&#;s unique specifications.
A step bend comprises a large bend radius divided into several smaller bends, which form a slightly larger radius.
These bends consist of sheet metal edges bent to 180°, creating a hem at the edge.
Advantages of Panel Bending
Panel bending offers numerous benefits that make it a suitable fabrication method for many applications. The process works particularly well for larger components, as it&#;s generally more economical and can meet tighter tolerances than other methods. Additionally, panel bending processes only require a single operator. The alternative would be a two-person press brake operation that&#;s more expensive, increases the likelihood of errors, and doesn&#;t allow for tight tolerances.
Press Brakes vs. Panel Benders
Press brakes and panel benders have some key differences to keep in mind. While press brakes use a punch and die set to shape materials, CNC panel benders use part manipulators along with bladed bending units. Understanding the differences between press brakes and panel benders can help you determine which to use for a given application.
The panel bending process involves the following steps:
The manipulator fixes the workpiece in place in front of the panel bender.
The panel bender&#;s blades bend the workpiece by applying force either upward or downward.
The operator turns the workpiece as needed to bend different sides.
Once bending is complete, the operator removes the finished material from the panel bender.
Dimensions and Design Considerations for Panel Bending
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With each panel bending project, there are certain design considerations and dimensions that influence the workpiece&#;s outcome.
Bend Line
The bend line is a straight line on either side of a panel bend that shows the start and end of a bend.
Bend Radius
The bend radius is the distance between the axis of the bend and the bend&#;s interior surface. The most frequently used radius is a 90° angle. To save time and money, Metal Works can bend up or down on the same plane for more efficient production.
Parts often need to be overbent to achieve the ideal radius and bend angle due to residual stress in the material following bending, which is known as springback. The minimum bend value depends on the specific material and application, but the bend radius in most applications should be at least equal to the material thickness, which helps prevent fracturing.
Bend Angle
The bend angle, or inside bend radius, is the angle from the bent flange to its starting position before bending. The inside bend radius plus the sheet thickness will give you the outside bend radius.
Neutral Axis
The neutral axis is the part of the metal sheet that remains uncompressed and unstretched. It stays at a constant length.
K-factor
This defines where the neutral axis is within the bending material. The formula for calculating the K-factor involves dividing the neutral axis (T) by the sheet thickness (t). The value of the K-factor tends to be higher than 0.25 but below 0.5.
Bend Allowance
The bend allowance is the bend&#;s arc length or the neutral axis length between the bend lines. You can use bend allowance to calculate the total flat length, specifically by adding the bend allowance to the flange lengths.
Bend Relief
Applications use bend reliefs if a bend extends on an edge. The bend relief must not be deeper than the combination of the bend radius and material thickness. To prevent tearing, the bending process requires a relief notch.
Bend Height
The bend height (H) needs to be a minimum of four times the thickness (t) of the sheet added to the bend radius (r). Otherwise, a bend height that&#;s too small will lead to part deformation. The formula for calculating bend height is as follows: H = 4t + r.
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Bending Near Holes
Panel bending near holes on a workpiece can result in hole deformation.
CNC Panel Bending From Metal Works
The experts at Metal Works of High Point offer CNC metal forming and bending services tailored to the needs of your application. We use press brakes and panel benders to achieve the best possible results with each project.
We have experience with a wide range of industries, including material handling, appliances, telecommunications, transportation, contract furniture, construction and aerial lifts, and power generation. You can learn more about our past work through our case studies.
Since our establishment in , Metal Works of High Point has developed into a leading provider of turnkey contract metal fabrication solutions for a diverse portfolio of clients. We work to give our clients high-quality custom components with an emphasis on top-tier customer service, respect, and honesty behind each project. Whenever our clients work with us, they benefit from personalized and consistently responsive service, along with state-of-the-art technology and high skill levels.
In addition to CNC bending and metal forming, we offer a host of other solutions, including laser cutting, welding, and finishing. We adhere to our five core values of honesty and integrity, dependability, respect, innovation, and commitment to excellence. In giving our clients the best, we aim to improve delivery times and cut down on costs while maintaining the highest level of quality. To ensure this, we invest in the most advanced technology available and employee training.
Want to learn more about how our capabilities can serve your application? Contact us today. If you&#;re in need of custom metal fabrication services and want to get started with us, you can request a quote.
Considering adding a panel bending machine to your sheet metal fabrication operation? Whether you are bending metal for the automotive industry, medical applications, aerospace devices, or anything else, there are tons of advantages of panel bending machine models.
Keep reading to learn about the top 8 benefits of sheet metal panel benders including increased productivity, precision, versatility, short setup times, improved workflow integration, and more.
First, though, let&#;s examine what a panel bending machine is and what it&#;s used for.
A panel bending machine, also called a panel bender, is a machine that bends and molds sheet metal or metal panels into different shapes. Generally, they use an upper and lower die to bend the sheet metal to the desired angle.
This minimizes time and generates consistent results for metal fabrication. Not only that, but the advantages of panel bending machines make them useful for various industries including construction, medical equipment, aerospace, furniture, consumer goods, signage, automotive, and more.
In fact, they are great options for virtually any metal fabrication operation that works with sheet metal, especially considering they can bend a wide variety of metal types and thicknesses.
While there are different types of panel benders including manual panel benders and semi-automatic panel bending machines, CNC panel bender options are at the cutting edge of technology. That&#;s because they use Computer Numerical Control (CNC) operators to allow for high repeatability, precise bends, and simple & safe operation.
Take the Accurl SMART BEC Panel Bending Center for example. With a highly customizable design, universal tooling, and the ability to bend various complex shapes, this versatile option is highly advanced. The automation features streamline productivity while the reliability means it can sustain your business operations for longer, with minimal maintenance.
Regardless of the sheet metal panel benders you choose from, these machines offer a wide variety of different benefits that you&#;ll want to consider.
The main benefits of a panel bending machine are productivity, precision, versatility, rapid setup times, cost savings, flexibility, enhanced safety, and improved workflow automation, which is why they are perfect for CNC bending in sheet metal fabrication.
1. Increased Productivity
Panel bending machines streamline the bending process, elevating productivity while still maintaining the highest possible quality of bends as well as the integrity of the material. Not only that but with CNC control, you can drastically reduce manual labor. That means higher efficiency and easier operation that coexists with your entire operations.
Even better, with modern automation, you can accelerate productivity even more. For example, with Accurl&#;s advanced BEC line of panel benders, you can automate even the most complex shapes, boosting efficiency with consistent results and a max bending speed of 0.5 s/bending.
To put it simply, a CNC panel can maximize productivity while still giving you precise bends. That brings us to the next major advantage of panel bending machine options.
2. Precision and Accuracy
A panel bender can deliver accurate results, bending metal sheets into complex shapes with ease. With precise tooling and CNC controls, you can achieve unmatched precision with almost any advanced CNC panel bender.
That&#;s why they are critical components of operations that require utmost precision like medical equipment or aerospace devices. However, you don&#;t have to require top-quality precision for this to be a valuable benefit to your operation.
Precision can mean less material waste, stronger output integrity, and consistent quality for whatever you are manufacturing and fabricating. Combined with the first benefit of speed and efficiency, this is an extremely important factor for almost any business.
3. Versatility in Bending Operations
Panel bending machines are highly versatile, offering precision and abilities for various bending operations. They can bend complex or simple shapes with ease, delivering almost any result you need.
As we&#;ll investigate later, they also have unmatched versatility for a wide variety of materials and thicknesses, integrate with various different machines, and more. There are also different sizes available with different output limitations, speeds, and settings so you can find the perfect machine for your operations.
4. Reduced Setup Times
One of the slowest and most time-consuming aspects of a metal fabrication operation is the setup. However, CNC panel bending machines minimize setup times, offering easy tooling, automation, and simplified controls to streamline the entire process.
For example, the quick tooling changes mean that even for operations that use a single machine for various shapes and bends, the setup time is fast and easy. Plus, with modern automation, you can easily increase output for years to come.
5. Cost Savings
There are various ways that modern panel bending machines can reduce costs for your business, including:
6. Flexibility in Material Handling
Many panel benders work with a wide variety of different materials, thicknesses, and grades. In fact, cutting-edge machines do so with minimal adjustment required, thereby reducing wasted time and handling versatile operations with ease.
Whether you have a thick piece of aluminum, or slim stainless steel, panel bending machines can optimize the process and deliver unmatched results for your operations. That&#;s why CNC Bending in Sheet Metal Fabrication is so important and perfect for businesses of all sizes whether you&#;re a small manufacturer of furniture or a corporate partner of the world&#;s largest aerospace firms.
7. Enhanced Safety Features
With modern-day panel bending machines, safety is always a priority. With automated shut-offs, CNC control, and other safety features built into the machines, your employees and operators will be protected. Not only that but the materials will be protected as well.
Light curtains, interlocks, and emergency stop buttons reduce the risk of catastrophic injury and create a happier, safer workplace. That means happier employees that are more likely to be productive without having to worry about potential accidents.
8. Improved Workflow Integration
Panel bending machines integrate seamlessly into modern workflow systems as well as your existing machinery and operations. Accurl machines, for example, are compatibility with CAD/CAM software, allowing for design-to-production workflows and end-to-end integrations.
That also means they are perfect for long-term use in your metal fabrication area, being able to scale with your operations and working alongside both older and newer machinery like laser cutters, press brakes, and more.
Now that you see the countless advantages of panel bending machine options, make sure you weigh different models, their costs, and their features before making a decision. Check the specifications for precision and accuracy, inquire about safety features, and examine the type of control. If you want to learn more about advanced Accurl CNC sheet metal panel benders, click here. Then, request a free quote to see if our options are right for you.
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