How Sheet Metal Bending Works

Sheet metal bending with a press brake works by aligning and holding the metal to be bent in the press brake tool. Once it is aligned, the press can move down and exert a force onto the metal, forming it into a new shape by producing angles. Press brakes can exert forces well in excess of 100 tons to bend steel upwards of 3 mm thick. 

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There are a few different kinds of machines that can be used to bend sheet metal. The most common is a press brake machine which itself can be mechanical and fully manual (usually used in small machine shops), or it can be computer numerically controlled (CNC) and uses a hydraulic system. The principles used in both machines are the same, but the way the operator interacts is different. This process below will focus on the operation of a CNC press brake machine: 

1. Calculate the Design Parameters

Before using the press brake, calculate the design parameters including force required, bend line (the point where the force is exerted), and the order of bends (if there are multiple). The die used to create the bends must also be decided. 

2. Set Up the Press Brake 

To set up the press brake, input the information calculated into the CNC machine, so it knows how much force to exert on the metal to create the right bend and in which order these bends will be carried out. The right tool and die must be attached to the press and brake, ready for bending. 

3. Align the Part

Align the metal between the tool and die. When the machine is operated, it will bend the sheet of metal at the bend line. 

4. Engage the Press Brake

Engage the press brake so that the force parameters&#;inputted into the CNC press brake at step 2&#;are applied. Once the press brake has bent the metal, the part can be removed and made ready for the next stage of production. 

Metals Used in Sheet Metal Bending

There are a range of metals that can be used in sheet metal bending. Six metals are discussed below:

1. Steel

Steel is a very versatile metal that consists of iron and carbon. Steel is economical and has great strength and durability. There are a range of different steels that can be bent including mild steel and stainless steel. Mild steel is easily bent and used widely, including in a range of automotive applications.

2. Aluminum

Aluminum is a lightweight and cost-effective metal used in the aerospace, electronics, and automotive industries. Aluminum is easy to fabricate and benefits from a high strength-to-weight ratio and high corrosion resistance. 

3. Copper

Copper is a soft metal that allows it to be easily bent and formed. It is also highly conductive, making it perfect for electrical applications. Copper is also naturally antimicrobial and recyclable.

4. Brass

Brass is an alloy consisting of zinc and copper. Brass is used a lot in sheet metal bending because of its aesthetic appeal and ease of fabrication. Because of its aesthetic appeal, it is used in decorative applications including: home hardware, architecture, and instruments. Brass benefits from high machinability, low friction, and corrosion resistance. 

5. Stainless Steel

Stainless steel, like regular mild steel, is made of iron and carbon, but with the addition of chromium and nickel. Due to the extra chromium and nickel, stainless steel is also harder and work hardens as it bends. This means that stainless steel usually requires a press brake rather than bending by hand. Stainless steel, which uses chromium to protect against degradation, is used in medical and food processing equipment. 

6. Galvanized Steel

Galvanized steel, like stainless steel, is highly corrosion-resistant. This is because galvanized steel has a zinc coating. In addition to having an improved service life, galvanized steel components are lower cost than other forms of corrosion-protected steel. 

Aluminum bending

Minifaber&#;s technical office will guide you through every step of the aluminum bending process, from the very beginning until the very end, making sure that you pick the right alloy that best answers your needs.

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How does aluminum bending work?

The process of bending aluminum is made extremely easy by this metal&#;s well-known characteristics. In high purity forms, aluminum is soft, ductile, malleable and light. These features allow to bend aluminum, without the risk of breaking it and causing cracks.

However, in many occasions pure aluminum isn&#;t sufficient (even if it&#;s easier to bend), and it&#;s presented the need for aluminum alloys.

So, which alloys are best suited for bending?

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Bending aluminum alloys

In order to be able to answer that question, we need to consider 3 things:

1.Formability

Aluminum has a wide range of different alloys, with different chemical compositions, which make them applicable in various fields of metal processing. Let&#;s take a look at all the different series of aluminum alloys:

• Series 1: these are the alloys that have 99% of pure aluminum. They are very ductile and have excellent corrosion resistance
• Series 2: here aluminum is mixed with copper. These alloys have limited cold formability and less corrosion resistance than other alloys, which is why they are anodized prior to usage.
• Series 3: here aluminum is mixed with a 1% of manganese. These alloys have good corrosion resistance and very good formability.
• Series 4: these alloys present the addition of silicon, which lowers the melting point, and this is why it&#;s used entirely for manufacturing welding wire.
• Series 5: these alloys are mixed with magnesium. They exhibit a very good combination of high strength, resistance to corrosion, formability, and good weldability.
• Series 6: these alloys are made of a mixture of aluminum, magnesium and silicon. They exhibit great strength, good corrosion resistance, and ease of formability, and are mainly used in architectural applications.
• Series 7: this series includes alloys made of aluminum, zinc and magnesium, and also alloys made of aluminum, zinc and copper. They exhibit very high strength, which makes them very difficult to form.

2.Thickness and bend radius

When bending aluminum, there is something else that needs to be considered: during the process of bending, aluminum hardens and strengthens by reason of the working effect. Therefore, the thickness of the aluminum sheet and the bend radius are also critical factors that must be taken under consideration.

3.Level of elongation

Lastly, a third factor that needs to be considered is the percentage of elongation of each alloy and the difference between yield strength and ultimate tensile strength. On this percentage depends the level of formability of the aluminum alloy.

According to this mechanical rule: the higher the elongation value (meaning, the wider the range between yield and tensile strength), the better the forming ability of the alloy.

So, after applying this rule to the aforementioned alloys&#; characteristics, it looks like the best aluminum series for bending are series 3, 5, and in some cases 6. Series 2 and 7 should be avoided due to the fact that, being extremely strong, they are difficult to form in any way.

Essential machinery for aluminum sheet bending

When it comes to bending aluminum sheets, there are several types of machinery that are specifically designed for this purpose. One of the commonly used machines is the press brake, which utilizes a powerful hydraulic system to exert controlled force on the aluminum sheet, creating precise bends. Another popular option is the roll bending machine, which utilizes a set of rollers to gradually bend the aluminum into the desired shape.

These machines offer versatility in terms of bend angles, thicknesses, and sheet sizes they can handle. Whether you are working with small-scale projects or large industrial applications, Minifaber has the right machinery for to meet the specific requirements of your needs.

If you&#;re interested in Minifaber&#;s aluminum bending process, contact us! We will assist you with a personalized assistance.

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