If you are in an industry where metal fabrication holds a key part of the operation, then you have definitely heard about bending machines.
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Since the bronze age, people have been involved in bending and shaping metals for various purposes. With the range of services that steel fabrication offers, it was evident that we needed to go above forging and hammering. Technology has advanced, and we now have different types of bending machines that apply precision force for bending, rolling, and stamping metal with ease.
Market research says that the automated bending machine market is projected to reach a staggering $3.37 billion by , up from its value of $2.17 billion as of . The numbers show that these machines have greatly influenced various industries like oil and gas, manufacturing, automotive, building, and construction.
We have come up with this comprehensive guide on bending machines. Explore with us their importance while receiving insights on different forms so you can make the right choice.
A bending machine is a versatile tool that is used to bend and shape workpieces as per the purpose of use. It serves as both a press and a bending machine, adapting to various materials and shapes.
For example, certain types of bending machines can directly process sheet metal without the need for additional clamping tools. On the other hand, some bending machines rely on clamping devices to secure the metal sheet during processing.
These machines use specialized bending tools that apply pressure to the metal plate to generate the appropriate form. A dependable bending machine&#;s body and tools are made of strong materials that can handle high amounts of pressure without breaking.
Bending machines are critical in industries such as manufacturing, construction, and automotive. That&#;s because they&#;re capable of offering accurate shaping qualities for a variety of applications.
A bending machine is basically a forging machinery that plays a key role in sheet metal processing, especially for large sheets. Its functions range from bending and stretching to rounding and punching metals. So you can imagine the possibilities it offers across industries- light industry, aviation, shipbuilding, metallurgy, instrumentation, and more!
The workbench, made up of a base and pressure plate, sits on the bracket. The base connects to the clamping plate through a hinge mechanism. Within the base, you&#;ll find essential parts like seat shell housing and coil structure that are covered with protective plates.
All these elements make sure that when metals are placed between them for bending purposes, they can be securely held in place while receiving force from the machine. When the wire is connected to the coil, it creates an attractive force on the pressure plate. This forces the thin plate to be clamped between the pressure plate and the base.
Because the system uses electromagnetic force binding, the pressure plate can be shaped to fit a variety of workpiece needs. It can also process pieces that have side walls. You can replace the bending machine mold and can meet your diverse demands.
We already talked a little about the critical components of a bending machine while mentioning the functions. Let&#;s dig deeper and find out more about those:
The bend die is also known as the bend form or radius die. It&#;s a major part of rotary-draw bending machines. The bend die shapes the tube during the drawing process to achieve the desired bend. You must choose the right type of bend die as it directly affects how well the tubes conform to specific radii.
If you&#;re working with pipe bending applications that require tight bends with small radii, selecting a suitable high-quality bend die becomes even more important.
The clamp die is responsible for pressing the tube onto the bend die. So it ensures that there is no slipping during operation. This particular part provides stability and accuracy to achieve precise bends in metal tubes or pipes.
Suppose you are utilizing a pipe bending machine to make delicate forms or angles on a stainless steel pipe. The clamp die binds it tightly to the bend die to avoid any movement that may result in mistakes.
The primary function of a pressure die is to ensure that the tube or sheet metal accurately follows the bend die&#;s contour. This specific part applies consistent and even pressure throughout the bending operation, resulting in precise bends. Think of it as a guiding hand that ensures uniformity and accuracy in each bend.
A wiper die is positioned right after the bend die, and it primarily prevents the formation of humps in the inner radius.
During the bending process, the material becomes plastic and starts to deform. That creates wrinkles and larger deformations. However, by incorporating a wiper die after the bend die, these issues can be effectively dealt with.
For bending steel and aluminum tubes, the mandrel helps achieve satisfactory results. Its primary objective is to keep the tube from collapsing during bending, ensuring precise and consistent bends every time.
It becomes necessary for more challenging tasks such as bending small radiuses or working with thin tubes or harder materials. Suppose you&#;re trying to bend a delicate tube without a mandrel. The tube collapses under pressure, ruining the entire process. That&#;s where the handy mandrel helps!
From pipe benders to press brakes, a variety of bending machines are available. Each of them has designated functions and purposes for industries that prefer metal fabrication.
A pipe bending machine is a valuable tool used for shaping metal pipes and profiles into different shapes. Typically, these machines are designed to work with square or rectangular profiles made of thick metals.
The process involves stretching the material using friction between the pipes and the bending tools. Pipe benders also perform operations like swaging, flaring, and crimping. To ensure smooth bending, drawing oil can be applied between the pipes and the tools. That&#;ll reduce friction and prolong the life of both.
It&#;s capable of handling different materials such as stainless steel, iron, copper, aluminum, titanium, and carbon steel. With this machine, you receive uniform curves without worrying about external collapses or internal folds. Pipe benders find extensive use in construction projects like buildings, highways, railways, bridges, etc.
It&#;s an incredibly versatile tool that&#;s used to shape sheet metal into specific profiles. When using this machine, the metal sheet is placed on the lower die of the workbench and pressed by punches. The power system drives the movement of the slider, causing the punch to move downwards. That results in precise bends!
This type of machine can bend not only metal sheets but also pipes at any desired angle. Sheet metal bending machines are ideal for processing larger workpieces that may be too challenging for other machines to handle. The clamping shaft securely holds each workpiece in place. At the same time, folding arms swing in an arc motion to achieve perfect flange angles.
The pyramid-type mechanical marvel called the plate rolling machine is designed for bending and forming metal plates. It&#;s equipped with a motor and gear system, and the bottom roller powers its rotation. Meanwhile, the upper roller can be manually adjusted up and down to achieve the desired bending radius.
One notable feature of the steel plate bending machine is its double-sided pre-clamping device. It&#;s a unique structure that allows both bottom rollers to clamp the workpiece securely in place. Also, there are hydraulic cylinders that lock down the upper roller firmly via these two lower rollers.
When it comes to bending metal plates, the press brake is the go-to machine for press brake bending. It offers accuracy and speed while processing workpieces in bulk. You can find different types of press brakes available, and they are usually powered by hydraulic or mechanical systems.
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The secret behind the precision lies within the three shafts of its rear gauge. They provide control over stroke length and bending angle. So whether you need precise bends for automotive parts or intricate shapes for architectural elements, a press brake can handle it all with ease.
A mechanical bending machine allows for precision customization according to your specifications. That&#;s because it does not use stationary dies like traditional bending machines.
The accuracy of a mechanical bending machine relies on factors such as material properties and the degree of bend required. With different types available, let&#;s explore two popular options:
Want to achieve optimal results? When choosing a mechanical bending machine, always ensure it aligns with your specific requirements.
The hydraulic bending machine consists of a workbench, support, clamping plate, and pressure plate. The clamping action can be controlled manually or automatically using a foot pedal. Inside the machine&#;s base, there is a movable coil. The coil is energized by a wire attached to a hydraulic cylinder.
One of the advantages of using this type of bending machine is its flexibility and portability. It offers cost-effective solutions compared to conventional machines while easily handling both small and large pipes. In industries like automotive, chemical production, and more &#; where precision bending plays an important role &#; hydraulic bending machines are highly sought after for their versatility.
Another variation, known as the hydraulic press brake, utilizes mechanical blocks operated by hydraulics instead of coils. It ensures effortless bends in metal parts.
A bending machine offers numerous advantages that make it an essential tool in the metal fabrication industry. Here are some key benefits:
Apart from these popular methods, there are wiping, roll bending, roll forming, and stretch bending that are handy and effective for specific roles!
Understanding the different types of bending machines will greatly benefit any industry that requires metal fabrication. From pipe bending machines to press brakes and plate rolling machines, each machine serves a specific purpose in creating precise bends and shapes.
Fab-Line Machinery specializes in providing high-quality metal fabricating machinery, including press brakes, that can meet your unique requirements. We offer a range of products so you can easily find the perfect solution for your bending needs.
Upgrade your manufacturing process with state-of-the-art bending machines from Fab-Line Machinery today! Contact us now or browse through our website to see how we can assist you in maximizing efficiency and productivity with top-notch bend solutions!
When it comes to investing in a bending machine, I understand how crucial it is to choose the right one for my needs. In this article, &#;6 Tips for Choosing the Right Bending Machine,&#; I&#;ll share my insights on what factors to consider, from machine specifications to functionality. Whether I&#;m working with different materials or varying thicknesses, these tips will help ensure that I make an informed decision, ultimately enhancing my production efficiency and quality. Join me as I delve into the essential considerations for selecting the perfect bending machine for my projects.
Bending machine is a machine for bending sheet metal, which is very common in industrial production. With gradual development and growth of modern industry, the user&#;s need for bending machines has gradually risen, but with the increase in demand, the industry has gradually emerged some bending machines of varying quality, and the quality of these machines also determine the future production process smooth or frustrating.
So how to properly select quality bending machines? It is best to start by carefully considering what model to buy in terms of the end-use of the machine, the known deflection variables that may occur in the machine, and the bending radius of the part. When choosing a bending machine, you as the decision-maker also need to know in detail about the machine&#;s performance, processing range, processing features, processing accuracy, etc. The selection process is non-trivial, because once you choose improperly, your subsequent production costs will climb, and the bending machine will not recover the expected costs. To this end, Haas CNC has organized the following to help you buy the most preferred bending machine.
The first important thing to consider is the parts you want to produce, to fully estimate the standard size of the parts you want to produce goods, the shape of the structure, etc. to make a full accounting, the point is to buy a machine that can complete the processing task with the shortest table and the smallest tonnage, so as to achieve the purpose of practical and economical.
Consider carefully the sheet metal and the maximum thickness and length of processing. If the main production product material is mild steel, its thickness is within 3 mm, the maximum length does not exceed mm, then the free bending force does not need to be greater than 80 tons. However, if there is a large amount of bottom bending in the operation, then perhaps you should consider purchasing a bending machine of about 150 tons.
If the plate to be bent in production is mild steel, the thickest has 6 mm, the length of mm within the free bending, then you should consider buying a bending machine of 100 tons or more. If the bending needs to be corrected bending, then a larger tonnage of the bending machine.
If the majority of the workpiece is bent mm or shorter, then consider the number of bending machine tonnage is almost halved, which can greatly reduce the acquisition cost. Therefore, the length of the processed part product is quite important to determine the model specifications.
Bending machine in the bending process, especially when bending long size of the workpiece, deflection will occur. The longer the workpiece, the greater the deflection. Under the same load, the deflection of the table and slide of a mm model is four times greater than that of a mm model.
This means that shorter machines require less shim adjustment to produce quality parts, and less shim adjustment reduces lead time. However, most current CNC hydraulic bending machines have been designed for production with the addition of a hydraulic deflection compensation function, reducing the need for production operators to adjust the machine while improving bending accuracy and productivity. Hydraulic deflection compensation function is controlled by the CNC system, hydraulic oil through the magnetic service valve into the compensation cylinder, to carry out the table upward, while the deflection compensation force increases with the increase in bending force, thus playing a role in deflection compensation.
The material of the processing plate is also a key factor. Compared to mild steel, stainless steel typically requires about 50% more load, while most materials are about 50% less than soft aluminum. The relevant standard bending pressure parameters can be obtained from the bending machine manufacturer. The table shows the bending force required per mm length at different thicknesses and different plates.
The bending corner radius of the workpiece is also a factor to be considered during the bending of the product. When using free bending, the bending radius is 0.156 times the size of the V-groove opening.
In free bending, the V-groove opening should be 8 times the thickness of the sheet metal. For example, if a 12 mm V-groove opening is used to bend 1.5 mm mild steel, the bending radius of the part is approximately R = 1.9 mm. If the bending radius is close to or less than the thickness of the sheet, under molding must be performed. However, the pressure required for bottom bending is about four times greater than that for free bending. When free bending is performed, attention is paid to the gap between the upper and lower dies at the bottom of the stroke, and to the use of compensating springback to keep the sheet overbent at about 90°. Typically, the free bending die produces a rebound angle of &#; 2° on a new bending machine and a bending radius equal to 0.156 times the opening of the lower die. Therefore the die angle for free up and down die bending process is generally 86 ~ 90°. At the bottom end of the stroke, there should be a gap between the upper and lower dies that is slightly larger than the thickness of the sheet.
The forming angle is improved because the larger tonnage of the bottom press bend (about 4 times that of the free press bend) reduces the stresses that normally cause springback within the bending radius. Impression bending is the same as bottom bending, except that the front end of the upper die is machined to the desired bend radius and the upper and lower die gap at the bottom of the stroke is less than the sheet thickness. Springback is largely avoided by applying sufficient pressure (about 10 times that of a free bend) to force the front end of the upper die to contact the sheet. In order to choose the lowest tonnage specification, it is best to plan for a bending radius greater than the plate thickness and to use free bending whenever possible. A larger bending radius often does not affect the quality of the finished part and its future use.
Bending accuracy is a factor that needs to be carefully considered, this factor determines whether you are buying a CNC bending machine or an ordinary bending machine. Selection of bending machine to involve the precision of the mechanical system hard indicators used, because from a scientific point of view, the error is inevitable, and can only go as far as possible to reduce the error. Some workpiece itself and some simple parts in a small range of errors are acceptable, then there is no need to pursue high-precision bending machine; and some workpiece must be highly accurate, which requires a high degree of precision bending machine, more recommended to buy CNC bending machine.
If the bending accuracy requirements ± 0.5 ° and can not be arbitrarily changed, you must look at the CNC bending machine. CNC bending machine slider repeatability is generally guaranteed at ± 0.01 mm, forming accurate angles must be used with such precision and good quality tooling. Ordinary bending machine slider repeat accuracy of ± 0.5 mm, and in the use of suitable mold conditions will still produce ± 2 ~ 3 ° deviation. In addition, CNC bending machines are equipped with quick clamping and quick die change systems, making CNC bending machines an unquestionable choice when you need to bend many small parts.
Bending dies also have a direct impact on bending accuracy, so check the wear of the dies frequently by measuring the length from the front of the upper die to the shoulder of the table and the length between the lower die and the shoulder of the table.
For conventional dies, the deviation should be ± 0.01 mm per 10 mm, and the total length deviation should not be greater than ± 0.15 mm. As for fine grinding dies, the accuracy should be ± 0.005 mm per 100 mm, and the total accuracy should not be greater than ± 0.05 mm. It is best to use the fine grinding dies for CNC bending machines and conventional dies for ordinary bending machines.
As a user or manufacturer of equipment in the purchase of bending machines, the main thing is to purchase an economic and practical bending machine, which of course is to take into account many factors at the same time according to their actual situation. The above points are only a brief overview of some one-sided issues, the best way is to choose a professional bending machine manufacturer, so that they provide you with several sets of plans according to your actual situation alternative, so that the resolution plan up more reasonable and effective.
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