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Bending Guide

The document provides a comprehensive overview of various metal bending methods, including air bending, bottom bending, and coining, each with its specific applications and characteristics. It also details press brake bending, types of press brakes, key components, and tonnage calculation for effective bending operations. Additionally, common bending problems such as springback and cracking are addressed with suggested solutions.

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alirezaac2012.1375
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11 views2 pages

Bending Guide

The document provides a comprehensive overview of various metal bending methods, including air bending, bottom bending, and coining, each with its specific applications and characteristics. It also details press brake bending, types of press brakes, key components, and tonnage calculation for effective bending operations. Additionally, common bending problems such as springback and cracking are addressed with suggested solutions.

Uploaded by

alirezaac2012.1375
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Comprehensive Guide to Metal Bending & Press Brake Bending

1. Bending Methods

1. Air Bending (V-Bending) - Most common, flexible angles, but has springback.
2. Bottom Bending - More precise, less springback than air bending.
3. Coining - Highly precise, eliminates springback, but requires high force.
4. Roll Bending - Used for large-radius bends, cylindrical shapes.
5. Rotary Bending - Avoids surface damage, good for coated materials.
6. Wipe Bending - Creates sharp bends, often used for flanges.
7. Folding - Used for thin panels, avoids tool marks.
8. Step Bending (Bump Bending) - Creates large radii using multiple small bends.
9. U-Bending - Forms U-shaped channels.
10. V-Die Bending with Special Dies - Used for custom geometries.
11. Heat-Assisted Bending - Reduces cracking risk in hard materials.
12. Stretch Bending - Used in aerospace for smooth curves.
13. Tube & Pipe Bending - Uses mandrel, rotary draw, or compression bending.

2. Press Brake Bending

Press brakes are machines used for bending sheet metal. They come in:
- Mechanical Press Brakes (Fast but less flexible)
- Hydraulic Press Brakes (Precise, suitable for thick sheets)
- CNC Press Brakes (Highly automated, best for complex parts)
- Pneumatic & Servo-Electric Press Brakes (For thin sheets, high-speed bending)

Key components include:


- Ram, Punch, Die, Backgauge, CNC Controller.

Types of bending on press brakes:


- Air Bending, Bottom Bending, Coining, Offset Bending, Hemming.

Tonnage Calculation Formula:


F = (1.42 × UTS × t² × w) / V
Where: UTS = Material Strength (MPa), t = Thickness (mm), w = Width (mm), V = Die Opening
(mm).

Tooling types include V-Dies, Gooseneck Dies, Hemming Dies, Offset Dies, Radius Dies.

3. Common Bending Problems & Solutions

- Springback: Overbend or use bottom bending.


- Cracking: Increase bend radius or use heat-assisted bending.
- Bend Angle Inaccuracy: Calibrate machine, use CNC adjustments.
- Material Slipping: Use textured tooling or clamps.

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