Certain factors have to be considered while designing and processing parts. Actually, not every part is suitable for bending. This is a very important fact, that each designer and operator should take into account.
Prior to designing designers should look into the tool inventory of their workshop. Start designing after you have identified the tooling used for it and bending flanges, for instance, whether Z bending is available. Consider the characteristics of your machine as well, concerning its lengths, tonnages, whether it carries back-gauge, crown automation or angular measuring systems. The features mentioned determine the efficiency of bending.
Operators must make sure that they master the complete information about the parts transferred from the bending software to the controlling system, for example, the tooling is required to bend the parts and the tool positioning upon the machine. Updated press brake machines are capable of providing three-dimensional modeling of the bending programs. This enables operators to be aware of part processing ways through the bend operation.
Escaping Bending Errors
Mostly, bending errors occur if incorrect tooling is used by operators. Every possible tool must be known to the operator. The tool tolerance has to be verified each time the tool is placed on the machine. It is crucial to be certain about the proper state of the tool as well as about the specification provided by the manufacturer. All the data and bending instructions are taken directly from the off-line software, so it is impossible to determine if the correct tooling was installed on the machine. The operators need to find out the types of bend installation required. Otherwise, the part making process will not turn efficient.
Processing parts properly is critical to escape bending errors. Operators can apply 3D modeling of the bending program to know how to efficiently process parts in the bend operation. All molding elements upon the parts must be identified by stand-alone software, and the modeling indicates whether bending of these elements on parts is possible or a collision with punches and dies will occur prior to the machine operation. In case it appears impossible to bend parts with no collision, the designers should configure the sizes of parts again or move some elements.
Most commonly, bending symmetric stainless steel with protective films can cause failures. It may happen that an operator starts bending protective-filmed parts over the wrong face.
Certain sheet metals need vertical bending in relation to the metal structure. Bending collateral to the metal structure will lead to cracking or to the breakage of the bend radii outer side in case of low bend force of the sheet.
Materials are also decisive in the successful bend process. Materials vary in bending allowance and inner radii. Ignoring this fact will force operators to process one more unwrapped part through laser or punch. Thus, considering the material types is compulsory prior to process unwrapped parts, especially when several operations are needed.
Part precision depends on the bending tolerance and subtraction of the bend. The inbuilt data bank of bending tolerances and deviations must be considered by operators as well. This data bank offers automatic control of each bend parameter. It also saves and refers to the former bend data about certain tooling or material. Such important factors as the types of materials, their thicknesses, bending angles, V-die and its angles, punching radii make up the bending tolerances. Select proper bending allowances and you will gain high precision for your parts.
Correct angularity is no less crucial. While making plain and high-flange U-profiles, in case of great angular variation beneath, the size in the upper part of the profile varies as well. It is possible to make calculations to gain the least variation possible. Multiply the allowance tang of angles by the height of flanges. Press brakes featured with angular measurement provides accuracy and simplicity for this process. This feature eliminates the necessity to bend manually for testing purposes as well as to make corrections and checking the details within the framework of a serial run, scraps are decreased and the participation of operators comes to the minimum. Nearly every manufacturer of press brakes offer certain forms of the angular measuring system.
Providing precision for holes may be a little challenging. This can bring about part breakage or misalignment. This is particularly the case for multi-bent holes. Multiple bending demands higher bend tolerances. Ensuring multi-bend dimensional precision may deliver some difficulties. Consequently, this situation will lead to some troubles to align holes. Operators are advised to escape severe tolerance properties of parts with multiple-bends to reduce the degree of misalignment.
If holes appear extremely near the bending line, this means they are in the deformation area, which will cause the hole to deform as well.
While bending big parts some difficulties with handling can arise, bending at the utmost lengths of parts will enhance the panel, making it rigid and facilitating the work for operators.
In case it is impossible, it is recommended using punching formation features to reinforce the inner side of Z-profiles, as it also strengthens parts.
Such features of machines as a programmable sheet follower or front support helps operators to handle with big parts. The programmable sheet follower provides certainty that speeds of parts synchronize fully with the machine beams.
Bend automation has become a trend. It is becoming more and more common for manufacturers to robotize bend applications. Each designer must be aware of who is going to bend the part. They have to adjust the part designs based on the fact who will carry out bending. Things can be moved by operators in a way that robot gripper fingers cannot. For instance, grippers might fail to firmly hold parts with multiple holes.
Advanced options of software have made it easy to design parts, and later to bend them properly. Proper unfold parts are developed through software according to a model. Moreover, the software assigns correct bending allowances, bending deductions, sends these to the laser, and finally to the press brakes to bend.
Upgraded software offers simplicity and convenience eliminating human errors. Designers can make parts, then connect them to the software to be sure whether they can be bent. If a crash or collision occurs, designers are free to make an adjustment to get around the problem, rather than gain new tooling or send the trouble to the workshop.
Nowadays more intricate parts are created by designers through multiple bending, which reduces welding and assembling demands. Rather than making 2 or 3 parts, later assembled, designers go beyond and create parts including the entire complex of elements into one.