Metal Sheet Bending
CNC bending with an accuracy of 0.3 mm and 0.5 degrees (30 minutes) in the angle of bending.
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Bending is done by manual hammering or via press brakes and similar tools. Modern metal fabricators use press brake with CNC-controlled back-gauges use hard stops to position cut parts in order to place bend lines in the correct position. Off-line programming software now makes programming the CNC-controlled press brakes seamless and very efficient.
CNC bending with Bystronic press brake
With the most modern CNC bending press brake 2017, made by BYSTRONIC company, we can perform complex and precise bends. Our machines are also equipped with the latest technology, 225-tons, 4-meter maximum bend length capacity and 7-Axis CNC Control.
Our machine basic specification is to bend sheet metal work up to 4M long and with a maximum of 225 tons force, it is hydraulic powdered and very fast. The back-gauges behind the machines is to be quick to set up, accurate and very fast to bend all components from the small one to the large parts.
Quality is paramount in all that we do, so embracing new technologies that enhance it is a logical step. Investing in these technologies allows us to keep pace with our customers’ requirements, and with the capability to bend sheet materials up to 4000mm wide, we’re far ahead of many of our peers.
ByVision Control system with the ability of three-dimensional simulation provides ease, precision, and repeatability of a variety of simple or complex bends.
The automatic Hydraulic Crowning system has this capability to make the change in the curvature matrix and bends long curves without any distortion and error with a superior accuracy.
Video shows the machine with a typical sheet metal component being bent. All the CNC programs can be created on the machine ByVision controller or BySoft software and saved directly back to our system server, allowing for recall of the programs for future batches. If a large batch of sheet metal work is needed we have acceptable repeatability in production.
A CNC press brake basically controls 2 bend tools to come together and make a bend in a piece of metal. The top tool is traditionally a V blade or punch and the bottom tool is a V block or die. The angle of any given bend is achieved by increasing the distance that the top tool enters the bottom tool and with the air bending style of tools that we use some parts can have internal bend angles of 30 degrees. If an internal angle is required tighter than this we use a flattening tool to press the two sides of the bends together until they touch if needed which becomes a safe edge or Dutch fold. The length of a bend is determined by a pair of computer controlled back stops called back-gauges, the further out the back stops travels from the bend tools the deeper the bend will be. We have a range of different tools to suit different material thicknesses and to achieve different bent radii.
WE HAVE ByVISION
By programming a series of bend angles and bend depths complex sheet metal work can be bent up. Using both the computer control and BySoft software to create the part in 3D on the machine enables the machine programmer to simulate the finished part, tooling requirements, the correct bend sequence and cut size. The cut size can be used to verify the developed blank size from the 3D model if required to check all the calculations are correct before any materials are cut. The machine controller, can draw a component’s cross section on the screen with their finger and then add dimensions to create a bending program, see a 3D image, simulate the bending sequence and select the correct tooling for the material type and thickness. ByVision controller can be used to calculate bending section cut sizes witch is suitable for simple rectangle sheet metal component blank and to check these against the 3D models software developed blank size for accuracy.
CNC multi-bend
This image shows a curved sheet metal profile. All the bends and the curves have been created on the Bystronic machines using just standard press brake tooling. The curves have been created by using a bending technique called multi-bending or step-bending. The curve is divided into a series of slight bends and flats so that the curve is created as an approximation by flats at a tangent to the desired curve. The closer each bend is together the better the finished curve will look but the longer it will take to bend the sheet metal work. There is normally a compromise between the finished shape and the time spent bending which will affect the costs for the customer. The advantage of this type of bending, called step-bending, over say having a special form tool made is the ability to change the curved profile whenever the customer wants to update a design without any tooling costs, just a few minutes with the control software is all that’s needed.
