Sheet metal bending is an essential process for modern machine building. It bends a flat sheet of metal in a V-shaped form, where the V can vary in terms of the angle. CNC press-brakes are a modern way to achieve accuracy with complex parts.
With heavy machinery however the work pieces of flat steel are often too thick (6 mm or more) and to large and heavy for regular bending. Therefore, manufacturers separate cubical or other angle-shaped parts in singular simple details (sides) and then weld them together (picture 1.)
As we can see the two parts are brought together and can be welded with one seam from the outer side, or two seams from both sides. This method however, inflicts significant amount of heat in the work piece, which after cool down results in deformation. Furthermore, this method requires much more manual labor and time, which makes it quite pricy.
In modern press-braking there is heavy machinery capable of bending greater thickness thru different methods.
Air bending is a bending method in which the work piece is positioned over a V-shaped block, called a die. A punch then presses down the piece from above and curves it in to the die. During this process the press brake has to overcome not only the tensile stress of the material, but also the compressive stress. Once the punch moves up and releases the piece, the residual stress causes the piece to Spring back to its initial positon.
The spring back effect can be best depicted on the next image:
The tricky part with air bending is to achieve the required angle and radius of the bend. With normal press-brakes, bending different materials always results differently in terms of spring back and respectively angle correction. Quite often reaching the required angle (45°, 60°,90°,120° or other) becomes tedious as the operator has to perform tests with several pieces to reach the angle and radius.
This problem is smartly solved with laser measurement systems that modern CNC-press brakes apply in their technology. Basically during the bending, a laser beam measures the angle after a single bend and inputs correction for this material. After that it bends again to reach the requirements.
You can check our heavy-part bending capacity on our next video:
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