Extensive Guide To Sheet Metal Bending Methods
Sheet metal bending is among the most common sheet metal fabrication processes. At Creatingway, we use this process to deform a material into any angular shape requested. Other names for this process include die-bending, edging, flanging, folding, and press braking. The process entails applying force on a workpiece. However, this force should exceed the material’s yield strength for plastic deformation to occur. This allows a lasting result on the bend forming on the material.
The Common Bending Methods For Sheet Metal Fabricating
What’re The Bending methods?
There exist several bending methods available at Creatingway. Each method possesses its own advantage. You have to decide which suits your project more, whether accurate or simple. However, accuracy is preferable due to its practicability. On the other hand, simpler methods are flexible to use and require a lesser variety of tools to get results. The use of CAD software appropriately makes it easier for the entire process. This lessens the possibility of errors occurring during production.
The common bending methods include:
- Step bending
- Roll bending
- Rotary bending
V-bending is a common metal bending method that uses a die and punch. However, this method has three subgroups. They include coining, bottoming, and air bending. The subgroup of bottoming and air bending make up most of the bending tasks.
Coining allows for a much more accurate result obtainable. For example, if you require a 45-degree angle, we only require a die and punch of the exact same angle. The effect of spring back does not occur with this method. It is because we use the die to penetrate through the metal sheet and cause a dent into the workpiece.
Bottoming involves the use of a punch press on a metal sheet. Another name for the process is bottom striking or bottom pressing. We press the material on the surface of the die which in turn takes the angle of the die. This angle is the determiner of the final angle of the workpiece. Furthermore, the die’s radius is dependent on the inner radius of the angled sheet. However, we use more force to manipulate the inner liner while compressing. The advantage of using more force is lesser chances of experiencing a spring-back effect thus providing better precision.
Air bending has the workpiece not fully touching the tooling parts entirely. In this process, we place the workpiece on two points while pushing the punch to bend it. When compared to the rest, air bending is much more flexible. For instance, we can obtain results of between 90 and 180 degrees with a 90-degree die and punch. Despite this advantage, it is less accurate. It experiences a spring-back effect upon releasing the load. However, we can simply readjust this by applying extra pressure on the workpiece.
U-bending shares a similar working principle to V-bending. We use a die and punch in the process but they are U-shaped, causing a similar bend. This makes it straightforward in how we bend steel U-channels. However, there exist other more flexible methods to produces such profiles.
Step bending involves using V-bending but in a repetitive manner. The process utilizes multiple V-bends in succession to obtain a workpiece with a large radius. A finer quality is dependent on the number of steps and bends between them. Additionally, it is a cheaper option due to the ease of setting it up especially with small batches.
At Creatingway, we utilize roll bending to make cones and tubes into different shapes. On request, we can make a large radius bends using this method. The process has two driving rolls and an adjustable roll. The third movable roll moves along the workpiece through frictional forces. However, when if both ends need to be bent along with the mid-section, it requires an additional operation to achieve this. We thus use a press brake or hydraulic press for this operation. It also avoids the details of the edge being flat.
Rotary bending has an advantage over V-bending or wipes bending. It commonly utilizes two rolls with an option of a single roll use. The process does not cause scratches on the workpiece surface. The secret is in its use of special polymer tools that avoid tool markings on the sheet metal. They can make sharp bend corners of up to 90 degrees. This ability nullifies the spring-back effect thus increasing the accuracy of the final result. Additionally, it is more flexible than other methods thus allowing the production of U-channels with close flanges.
You need to work with a reputable CNC fabrication company to meet production demands and deadlines. Contact Creatingway now to get the best service for your sheet metal bending options.
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