Sheet metal bending is the process of applying a force to a sheet of metal to produce a radius. The most common way to achieve this is a press brake. This process can be used in the manufacture of vehicle body panels, fridges, electronic casings, and brackets. Sheet metal bending is best suited for applications with lower production volumes or products using very thin metal for which casting is not effective.
The company is the world’s best aluminum sheet bending machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Sheet metal bending is the forming of metal into different geometries, by using a force to deform the metal. It is referred to as sheet metal bending as a thin sheet of metal is bent once, or multiple times, to form the final geometry. The thickness of sheet metal used can vary. The minimum thickness sheet metal can be bent is approximately 127 mm thick and the maximum will depend on the material type and thickness. Generally, sheet steel is no more than 6 mm thick. As a rule, the bend radius should be equal to or greater than the thickness of the material.
Sheet metal bending is also known as: forming, edging, folding, flanging, press braking, or die bending. The last of the names is used as some sheet metal bending is achieved using a die and punch system. Press braking refers to cases in which a press brake machine is used to bend the sheet metal.
The purpose of sheet metal bending is to form features onto a sheet of metal. This could be for creating body panels, reinforcement struts, floor panels, brackets, or doors. Sheet metal bending is a much faster, cheaper, and more efficient way of producing thin-walled parts, as opposed to machining them.
The use of sheet metal bending is widespread, including: in the construction, automotive, transport, aerospace, and infrastructure industries. Sheet metal bending can be used in every industry to create features such as: lips, joggles, flanges, and indents. Sometimes sheet metal bending is used to increase the stiffness of a sheet metal part.
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.
There are a few different 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:
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.
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.
Align the metal between the tool and die. When the machine is operated, it will bend the sheet of metal at the bend line.
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.
Laser cutting improves the efficiency of sheet metal bending by reducing the time needed to prepare the sheet metal for bending. Laser cutting also provides edges with tight tolerances. These edges can be used as data when using a press brake bending machine. A reduction in the precision of the cut edge would reduce the location accuracy of the bend. To learn more, see our guide on Laser Cutting Manufacturing.
Laser cutting can reduce waste and optimize sheet metal bending in two ways. Laser cutting reduces the number of errors made in cutting; this increases repeatability and reduces variability, resulting in the production of fewer scrap parts. Laser cutting also increases productivity by using an automated process to cut the metal. To learn more, see our guide on How Fiber Lasers Work.
There are a range of metals that can be used in sheet metal bending. Six metals are discussed below:
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.
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.
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.
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.
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.
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.
The time taken to bend sheet metal is subjective to a number of factors. These factors include if the machine is already set up for the bend and the number of bends in that part. If the machine requires the changing of tooling to perform the bends, then it will add extra time for an operative to change the tooling. Additionally, the time taken will increase with the number of bends. If fully automated, with the machine prepared, bending can take a matter of seconds. If machine setup is required, bending may take up to an hour depending on the complexity of the setup.
The final dimensions of a sheet metal part not only rely on the bending of the part but also on the size. If the sheet is cut accurately, it can be bent accurately. Bent sheet metal which has been cut with a laser cutting machine can have a tolerance of +/-0.1 mm.
Sheet metal bending costs will vary depending on the complexity of the sheet metal bending project. A major factor in the price is labor costs. An increase in labor due to unique designs will greatly increase the cost. Conversely, large orders that use an automated process will drive down the price per unit. Additionally, the quality of the bending will factor in the price. This is because if the part has a loose tolerance, the scrap rate is reduced.
No, sheet metal bending is cheaper than die casting initially. This is because sheet metal bending has more standardized tools and takes less time to set up. However, die casting may be much cheaper for large production batches as once the cast is made, die casting can produce many identical parts quickly.
The biggest advantage of using laser cutting for sheet metal bending is the accuracy with which it cuts. The improvement in the accuracy of cutting directly affects the accuracy of the bending. Other advantages of using laser cutting for sheet metal bending include:
To learn more, see our guide on CO2 Lasers.
One drawback of using laser cutting with sheet metal bending is the large initial cost of a laser cutting machine. Although, this cost can be recuperated if there is enough work to use it effectively. Other disadvantages of using a laser cutting machine for sheet metal bending include:
There are a wide variety of products made using sheet metal, including:
The life span of sheet metal bending products will depend on many factors. However, the fact that the product is bent out of sheet metal will not be the limiting factor. Major factors that affect the life span include: strength, fatigue life, corrosion resistance, design suitability, operating environment, and maintenance of the product. With all of these factors to consider, the exact life span is very subjective. However most estimates for the life span of galvanized sheet metal range between 25&#;45 years.
The sheet metal bending process is recognized as producing high-quality parts. The exact quality will depend on: the design, material, manufacturer, and equipment used. However, the bending process is not the limiting factor in the quality of a sheet metal product.
Yes, sheet metal parts are extremely durable. Sheet metal is especially durable when made out of a corrosion-resistant material such as stainless or galvanized steel. The continuous nature of sheet metal eliminates stress points, increasing a part&#;s longevity.
Want more information on commercial appliances panel bender? Feel free to contact us.
This article presented sheet metal bending, explained it, and discussed its purpose and advantages. To learn more about sheet metal bending, contact a Xometry representative.
Xometry provides a wide range of manufacturing capabilities, including sheet cutting and other value-added services for all of your prototyping and production needs. Visit our website to learn more or to request a free, no-obligation quote.
The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry&#;s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.
Minifaber boasts a fifty years expertise in the field of metal sheet bending: a process of metal cold working that takes place by means of a machine, called a bender. The mold of the bender exerts pressure on the flat plate, to obtain different shapes.
Together with the shearing and molding process, sheet metal bending is used on metal surfaces to obtain semi-finished products and can be carried out on surfaces of different types: our specialization is the bending of aluminum, stainless steel, iron and copper.
What will you find on this page?
Every metal responds differently to the metal sheet bending operation, which is why every single one of them needs to be treated carefully, according to its mechanical and physical properties, to avoid cracking.
In order to be able to provide a quality metal sheet bending service, we rely on 7 technologically advanced bending machines and a well-prepared Technical Staff, that is going to transform your idea into a feasible project and, ultimately, into a real-life finished or semi-finished product.
Would you like to know more about our metal sheet bending service?
Contact us for more information
The bending of an aluminum sheet is one of the simplest processes, thanks to the well-known properties that characterize the aluminum: softness, malleability and lightness allow to bend it without risk of breaking or causing cracks. Learn more about the aluminum bending process and how we do it here at Minifaber.
Also known as press braking, flanging, folding and edging, bending is one of the most commonly employed cold working methods in the sheet metal industry. The most characteristic property of steel is its hardness: for the bending of steel, therefore, it is essential to respect precise measures, that allow obtaining an always optimal result. Steel bending and stainless steel bending are slightly different processes: in Minifaber we carry out both of them with the utmost precision.
It is the second most popular metal after aluminum: it is easy, therefore, to understand how the range of its applications is incredibly vast. To cover all those needs, we perform iron bending processes. Iron sheet bending deforms the iron sheet, but it does not change its thickness. The process must always be performed by professionals because of the characteristics of the metal:
Stainless steel is particularly required in sectors such as food, pharmaceuticals and cosmetics, due to its high corrosion resistance: in this way, it is possible to maintain high levels of hygiene. Learn more about how we bend steel and stainless steel.
The high electrical and thermal conductivity of copper makes it one of the most requested metals for applications such as those of the building sector. In fact, copper possesses a few characteristics that make it a top choice for bending operations, despite its high cost. For these specific requests, in the microfiber the bending of the copper is joined to the bending of the other metals. Due to our specialization in cold metal working, in Minifaber we successfully provide a copper bending service that allows you to obtain the exact product you want!
Sheet bending requires the application of a force to sheet metal that bends at an angle and forms the desired shape. But this is only the general process: if we get more in detail, we will find:
Depending on the sheet metal type, Minifaber chooses the most suitable process. First of all, we cooperate with the clients to determine the needed product. Then, we study the feasibility stages to the realization of the semi-finished or finished product, and we choose the right machine and sheet metal bending process between air bending, U-bending and rotary bending.
V-bending and air bending are so called because the workpiece does not fully touch the parts of the tool. In the air bending process, the workpiece rests on 2 points and the punch pushes the bend. It is still usually done with a press brake, but there is no need for a side die.
The air-air sheet metal bending process offers great flexibility. With this method, between 90 and 180 degrees can be achieved. In case the load is released and the springback of the material results in an incorrect angle, it is simple to adjust it by applying more pressure.
Of course, this results in less precision than other types of sheet metal process. At the same time, the great advantage of air bending is that retooling is not necessary for bending at different angles.
The U-bend is very similar to the V-bend. There is a die and a punch, this time both cylindrical in shape, that result in the bending of the sheet metal. This is a very simple method for bending, for example, steel U-channels, but it is not so common as such profiles can also be produced by other, more flexible methods.
Roller bending process is used to make tubes or cones of different shapes using cylinder molds. Depending on the capacity of the machine and the number of rolls, one or more bends can be made simultaneously.
To bend the part on both ends and the center section, an additional operation is required. This sheet metal bending process is performed on a hydraulic press or press brake. Otherwise, the edges will be flat.
Sheet metal bending is carried out through CNC machines that can bend either a big quantity or a single piece of metal with the same and utmost precision.
Depending on your needs, this technological machinery can realize different kinds of bends such as standard ones, U-bending or rotary bending. Minifaber can choose among 7 bending machines ranging from 30 to 180 tonnes depending on the product to obtain.
Contact us to discuss your requirements of appliance doors bending machine. Our experienced sales team can help you identify the options that best suit your needs.