Stainless steel's unique properties, such as its corrosion resistance, which we explain in detail in this guide to materials in sheet metal working, make it a popular choice. Stainless steel is used in industries ranging from food processing to construction and medical equipment. However, working with stainless steel in the sheet metal bending process presents a number of unique challenges. To understand these challenges and how companies are overcoming them, we interviewed two specialists in stainless steel fabrication. The Challenges of Bending Stainless Steel Stainless steel parts are prized for their high resistance to corrosion, hygiene, and visually appealing finishes. However, these same qualities can create problems during processing, particularly bending. Stainless steel sheets aren't your typical flat sheet, says Davide Chinellato, Production Manager at Inox Piave di San Fior. They often undergo various processes that can lead to deformation and thickness variations. The key is achieving consistent, uniform bends along the entire length of the piece. Beyond bend quality, processing speed is crucial. Today's press brakes need to be extremely fast while maintaining safety compliance, Chinellato adds. This was a challenge in the past, as safety features often slowed production. VICLA machines, however, deliver complete safety without sacrificing performance. Stainless steel's properties necessitate meticulous handling to avoid visible defects in the finished product. Marco Nervi, owner of C.L.A. LAVORAZIONE INOX, a company specializing in raw stainless steel machining, emphasizes this point: For instance, bending requires a perfectly straight and continuous bend throughout the entire piece. If the bending machine's force isn't consistent, you might end up with a slightly open or closed bend. Choosing the Right Bending Machine Selecting the right press brake is critical for achieving flawless parts on the first try. Companies managing numerous orders with departments working in sync require machinery that guarantees precision, repeatability, and reliability. Inox Piave, for example, opted for a unique press brake configuration to handle their one-of-a-kind parts. The machine, developed over a year, features a special backguage explains Chinellato. Essentially, it has a single crossbeam for general movement of the stops, plus four independent stops for customized adjustments. The Advantages of Hybrid Bending Machines Both companies chose a hybrid press brake due to its numerous benefits. Firstly, it offers consistent repeatability thanks to a compact system with reduced piping and a direct drive connection between the pump and motor. Secondly, there's speed. Hybrid press brakes leverage cutting-edge technology to deliver high thrust. The system combines an electric axis with a hydraulic clutch and a brushless electric motor, providing both high force and fast travel speeds. Finally, hybrid machines offer greater versatility compared to all-electric models. As Chinellato explains, For the bending we do, an all-electric option wouldn't deliver the necessary performance. That's another reason we chose VICLA's hybrid technology. Selecting the Right Tools Cost is another crucial factor when working with stainless steel, as Nervi explains: Material costs have risen in recent years, especially in the first half of 2022 when finding materials was difficult. This, combined with the material's delicate nature, makes waste reduction essential. Even minor marks can render a stainless steel component unusable, particularly in applications like furniture where aesthetics are paramount. Materials like AISI 304 stainless steel, iron, galvanized steel, copper, brass, aluminum (including diamond plate and painted varieties) all require meticulous handling to avoid visible defects. Choosing the right bending machine is crucial, but so is using tools that won't damage the material, such as protective films placed between the sheet metal and the die. We have written a guide that illustrates the main types of dies and punches most used in bending. The K-Factor in Sheet Metal Bending The K-factor is a critical aspect in sheet metal processing, including stainless steel. It's essential for achieving accurate bends. The K-factor represents the ratio of the material thickness to the neutral radius, directly impacting the final bend result. For a deeper dive into the K-factor and its influence on stainless steel processing, please refer to our article on the sheet metal K-factor.
When we talk about tandem press brakes, we refer to a particular configuration that involves the connection of two machines into one, but there are also solutions that combine three bending machines (tridem) or 4 bending machines (quadrem). In this type of configuration, the machines can have the same length and the same nominal bending power or different lengths and nominal bending powers can be provided. What are the characteristics to consider when choosing a tandem configuration? Let's find out together in this complete guide. What are tandem press brakes? When two press brakes are used in tandem, a single CNC controls both machines. However, each machine can also be used independently for added flexibility What are tandem bending machines used for? To bend long profiles, it is not necessary to have a large bending machine. Sometimes it is enough - and much more beneficial - to choose a tandem configuration, because it allows for greater versatility and productivity. Specifically, tandem bending machines can be used in synchronised or single mode. In the first case, both machines can be programmed by the numerical control of the master machine, which sends the signals to the secondary machine, allowing synchronized management with a single CNC. It is crucial that both machines are perfectly calibrated, as any problem on one machine will affect the operation of both. In any case, machine builders already prepare the optimal configuration of the machines during assembly, so if the operator follows all the instructions given during installation, it is very difficult for problems to arise in the future. In the case of separate use of the machines, each machine is independent, equipped with its own photocells and a safety guard. With this solution it is possible to carry out different processes in each machine, with the advantage of optimizing production in the best possible way. In fact, many metalwork fabrication, in addition to the bending of heavy and long profiles, supports the bending of shorter pieces. Moving a huge machine to bend smaller profiles would be costly in terms of time, energy and productivity. With a tandem setup, however, you can easily switch to single mode and operate each machine completely autonomously. So that's one of the great advantages of the tandem setup! We'll talk about the other benefits - and limitations - in a moment, but first we'll focus on some equally important aspects. What processes can be done? Most of the bending that requires a tandem configuration concerns long sheets that require high powers. The processed products belong to the most varied sectors, including: industrial bodywork, trailers, agricultural equipment, aircraft parts, modular spaces and storage solutions. Most tandem bending machines have deeper recess dimensions (e.g. around 1000 mm) in order to allow more agile bending of wide profiles. To enable this, machine tool manufacturers such as VICLA design a larger, thicker and more solid structure that can compensate for the increased stresses that result from having a larger groove. Another interesting aspect is that, compared to a large bending machine, tandem bending machines generally do not need a pit for the lower bench housing What are the characteristics to consider when choosing a tandem? When choosing a tandem configuration, it is important to consider the bending force: it is widely believed that using two bending machines in combination allows you to double the bending force at every point of the machine, but this is a mistake. The total force, given by the combination of the force of each machine, applies only in the case of bending along the entire length. Let's take a concrete example. Let's take two bending machines of 4 meters and 250 tons each. In a tandem configuration, the total force is equal to 500 tons, but only if you are working on a profile that requires the entire length. On the other hand, in the case of a shorter profile, for example less than 4 meters, the total power will be 250 tons! Another aspect to evaluate is the configuration: tandem bending machines allow you to have almost the same customizations as a single bending machine, with one caveat: while, for example, it is possible to have a different number of axes for each machine, the configuration of the stomp and the bench, for obvious reasons, will necessarily have to be identical in both machines. Here is a list of the customizations you can do: Oversized recess Increased stroke Larger opening Intermediate heights Clamps for all types of tools Sheet metal escorts Motorized front supports What are the advantages of tandem compared to using a single machine with the same length and power? When choosing whether to have a tandem, it is important to consider the following advantages: Flexibility: we have repeatedly specified the great versatility of a tandem, but it is worth repeating it once again. Such a configuration allows two machines to be used together or separately, with the great advantage that a workshop does not need to equip itself with additional machines. It also allows you to adapt to business changes effectively, always ensuring future business options. Last, but not least, is the speed of execution: thanks to the reduced size, the bending machines configured in tandem are more streamlined in movements than a larger bending machine and this allows to obtain a fast work cycle. Lower risks: buying a tandem allows you to halve the risks compared to buying a large bending machine, which will be more exposed to the risk of production stoppages. In a tandem, on the other hand, it will still be possible to produce parts on the working machine. Lower ancillary costs: Before purchasing, it is always important to evaluate all the costs related to the new project. How do transportation costs differ for one large machine compared to two smaller machines? Will special permits be required? Will additional foundation preparation work be required for one type of configuration over another? Understanding all the associated costs is the only way to accurately calculate your return on investment. What are the limitations of a tandem? We often talk about the benefits, but little about the limitations. Let's look at some factors that can influence the decision to buy a tandem: We have already said that the versatility of tandems consists in being able to bend long pieces without having to equip themselves with imposing machines that require more space and additional bending at the foundations. However, it's worth noting that a tandem setup still has limitations. One of them is related to the recess: although it is possible to increase the depth, it could still interfere with the bending of certain parts. Another consideration is the cost of the machine. Depending on the case, buying a large car can prove to be more expensive than choosing a tandem, however, the opposite is also true. In fact, a tandem consists of two machines and therefore each component is doubled (two CNCs, 4 cylinders, etc.). This does not mean that a tandem is less convenient than a single car, but it is certainly one of the many aspects to consider when buying. Now let's see what the other criteria are to consider before buying a machine. What criteria should be adopted when purchasing a new machine? Before proceeding with the purchase of a tandem or a large bending machine, it is essential to consider all the variables at play, first and foremost your production needs. What are the processes you need to do? How much do they cost you? What is the level of sustainability in continuing to process the parts through the current production process? These are fundamental questions to pay close attention to. How to achieve higher productivity and save costs? What are the markets that offer the latest products? What are the changes in the production field in recent years? Buying tandems seems like a serious financial solution. Start with a clear estimate of the status of your work and get the answers to questions about how to increase the productivity of your operations and get the most profit possible. Our consultants at your disposal Would you like personalized advice to find the right machine for you? Contact us now.
The ever-increasing demand for skilled pressbrake operators, who possess both practical know-how and a deep understanding of the theoretical aspects of bending, has solidified our commitment to providing comprehensive training opportunities. In collaboration with an Italian school, we are proud to offer a unique theoretical/practical BENDING CLASS. The program attracted a diverse group of participants, including experienced, as well as young PB operators eager to learn, and drawing department personnel seeking to enhance their knowledge. The enthusiasm for learning and the need for technical expertise were palpable throughout the course. Many companies have recognized the importance of investing in training to unlock the full potential of their workforce and technology. By empowering their employees with the necessary skills and knowledge, they can achieve a significant competitive advantage. The ongoing industrial change requires making the production cycle increasingly efficient, keeping production costs low without compromising quality and safety. Factors such as the growing demand for product customization, on one hand, and the difficulty of finding qualified labor, on the other, are pushing companies to reorganize their production departments to remain competitive. One of the fundamental elements on which companies are trying to act to contrast the shortage of labor is to enhance internal resources by training, stimulating, and retaining them. Training plays a key role because it allows us to acquire an awareness of the difficulties and the most practical aspects of bending thanks to which it is possible to make the process more streamlined and solve many problems upstream of production. A highly skilled press brake operator or fabricator who possesses a deep understanding of both the practical and theoretical aspects of sheet metal working is an invaluable asset to any company. In fact, a qualified and adequately trained operator will play a key role in making the production cycle increasingly efficient, contributing to increasing the quality level in the repetitiveness of the processing processes. A second interesting aspect related to personnel training is its flexibility. Companies are increasingly aware that to improve the efficiency of the production chain, synergy is needed between the technical office and the production department. In fact, the technical office must have precise information on the characteristics and limits of press brakes in order to design and draw efficiently, avoiding errors and waste. It happens too often, in fact, that the technical office develops developments with tolerances that are too hard, if not impossible to achieve considering the equipment (press brake and tools) in the bending department. Knowing the theoretical bases behind the sheet metal forming process can help designers and draftsmen to have a complete overview of all the necessary elements in the design and drawing of parts. It is precisely to encourage the sharing of knowledge that at VICLA we have chosen to move in two directions: on the one hand, by organizing training days, full of detailed diagrams and valuable insights that stimulate lively debates; on the other hand, by creating a bending manual – as for now, available only in Italian - which summarizes the theoretical and operational bases of sheet metal working. The manual contains numerous tips and practical advice to take press bending to its maximum possible performance, as well as an in-depth overview of the evolution of press brakes and new technological solutions to improve the quality of finished products. For 10 years now, the machine tool industry has been witnessing an incredible revolution, says Marcello Ballacchino, owner of VICLA together with his partner Corrado Nucci. I am referring to the automation of processes, the advent of robotics and the development of machines with a high energy coefficient. And then we must not forget the great theme of the Digital Factory. This new way of conceiving production is projecting the entire sector into the future. Hence, VICLA's mission to continue to look ahead, to anticipate requests and meet the needs of customers. The Bending Day was a valuable opportunity to share our passion for sheet metal working and to forge stronger relationships with our customers We can't wait to replicate this experience!
Sheet metal bending often represents the bottleneck of the entire production process, because sheet metal, which is a living material, can take on infinite shapes and sizes and this, sometimes, is the cause of little-known and complex problems to solve. It must be said that, sometimes, problems do not arise in front of the machine, but very often are caused by an upstream error in the technical office. It is for this reason that you should learn to identify sources of error early on and correct them upstream, when it is still possible to intervene in the entire bending process. What are the most common problems when bending sheet metal? Simplifying, we can distinguish between two categories: punctures and vent curls. For each, there are different approaches you can take to eliminate or limit the problem. Here's a summary of what we'll be talking about: Punctures near the bend line Partial punctures Pre-drilling with smaller diameter Vent Cuts Reducing the width of the matrix Changing the Folding Mode Using tangential bend dies Vent Curls Vent Cuts Bending Mode Changes Tangential bend dies A book would not be enough to describe in detail every single point and the possibilities of solution. Today we will limit ourselves to talking about sheet metal drilling and what are the first two solutions you can adopt. We'll be delving into the rest of the game in the coming weeks. Drilling near the bend line Punctures in the vicinity of the bend line are an extremely common problem. The presence of holes near the bend axis can create a deformation that changes the shape and position of the hole. The best solution would certainly be to avoid designing bent sheet metal elements with holes too close to the bend lines. However, if you do not have this possibility, there are several strategies that can be adopted both by the technical department of the company that physically makes the piece, and by the operators. Partial drilling Mainly used in heavy metalwork fabrication, partial drilling involves not completing the entire shape of the hole. This makes it possible to preserve a surface useful to be supported by the matrix during deformation with the consequent stability of the perforated shape. The hole will be completed by further processing, such as with a hand plasma. As you can imagine, this technique is best used in the presence of high thicknesses and small quantities of pieces. Pre-drilling with smaller diameter All in all, similar to partial drilling, pre-drilling with a smaller diameter involves a non-complete drilling of the template to be removed during cutting. In this case, a small hole is drilled and sufficient to avoid any deformation during bending. Unlike the partial drilling technique, pre-drilling with a smaller diameter is faster and suitable for even medium-thin thicknesses and medium-large batches. In the next article, we'll continue to dive deeper into the approaches you can use to handle holes near bend lines. If you haven't already done so, we recommend subscribing to the VICLA newsletter!
Two weeks ago we discussed how important it is to know the recurring problems of sheet metal bending and we saw what the first two cases are, i.e. partial drilling and pre-drilling with a smaller diameter. Today we are going to delve a little deeper into the theme of drilling, introducing vent cuts and we will end by talking about the use of tangential bend dies. Are you ready? Tagli di sfogo It consists of providing a cut at the bend line that allows the flap to be bent up to the apex of the notch. The cut can then be restored by welding or left open depending on the end use of the piece. This method, where permitted, also guarantees absolutely outstanding results. It consists of making cut strokes or real windows that interrupt the bend line at the holes. In the presence of a high thickness, simple cuts cause tears on the ends of the bend line break. This phenomenon may not be a problem, even more so if the external radius is restored through welding and grinding. However, in the presence of elements subject to fatigue and high loads, it is advisable to operate in a different way, for example as in this image, where, thanks to an H-shaped cut, tears and potential crack triggers are completely avoided. Die width reduction The reduction of the width of the matrix is a technique that finds its best application when it is already provided for in the technical office. At the drawing or planning stage, if there is the appropriate knowledge, it is already possible to understand whether the deformation of the holes can be avoided with this system and whether the workshop has the right tooling for the purpose. If so, the technical department will necessarily have to generate a development suitable for the new condition. This also means that it is a good rule of thumb to state on the drawing which is the die to be used in production to obtain the correct part. Reducing the width of a die, as already described, causes a smaller bending radius in the sheet metal with the consequence of obtaining a part with a smaller finished size than desired. Changing the bending mode As already discussed in this volume, there are three folding methods, each with its own peculiarities: air folding, matrix bottom and coining. Depending on which mode it is adopted, there is a different constancy in the shape of the holes during bending. Working in air, in fact, the sheet metal is totally free and suspended on the die and this approach is the least favorable condition to preserve the holes from deformation. For this reason, it is more suitable to use an 88° homologated matrix for hollow bottom mode. In this case, the internal faces of the die, coming into contact with the sheet metal, reaffirm the deformations bringing the holes back to their initial shape. If high precision is required, it is advisable to consider the use of this technique already when determining the development of a part. Using tangential bend dies For several years now, special dies have been offered on the market equipped with milled semi-rollers and housed on special seats. The position of these rollers is maintained by springs that allow them to move and return to their initial horizontal position. Tangential or oscillating bend dies have many advantages in the face of a rather high purchase cost and a wider width than traditional dies that makes it more complex to make closely spaced Z folds. In the next article we will complete the topic of the most common problems by talking about venting curls. If you haven't already done so, we recommend subscribing to the VICLA newsletter! Is this your first time reading this blog? Download our press bending manual and subscribe to the newsletter!
During the bending process, the machine is subjected to a tension that causes a deformation of the structure and, consequently, also of the sheet metal; to compensate for this kind of stress, the crowning system comes into play. When we bend the sheet metal with a press brake, the upper crossbar always tends to curve upwards. The crowning system lifts the die to maintain a constant distance between punch and die. Without it, the result of the bending angle would be irregular. To put it in a nutshell, in a press brake with incorrect crowning or without crowning, the bending result will have a more open or closed bending angle. For this reason, it is of fundamental importance to choose the correct crowning system for your press brake. What are the main crowning systems? There are several crowning systems, some of which are exclusive patents of very few manufacturers such as VICLA. Today you will discover the three main systems and which, among them, really helps you to achieve perfect folds without having to waste material and money on tests and verifications of the part. If you want to read immediately what it is, you can go directly to the paragraph where it talks about active hydraulic crowning. Wedge-style crowning system The wedge-style crowning system is an adjustment that takes place beforehand and can be modified on the basis of the characteristics of the sheet metal. It consists of two rows of wedges across the length of the bed; one row is fixed and the other is movable; moreover, it involves a series of profiles with different inclinations, characterized by a stronger marking in the center and less on the sides. The wedge in the middle of the bed has a higher slope than the wedges under the pistons, and the angle of the slope decreases toward the ram from the middle of the bed. On one of the sides of the machine there is a gear motor: when activated, the movable wedge creates a curve with the high point at the center of the bed and the low points at either end of the bed below the pistons to create a spline curve in the table. The wedge bench always requires an intervention by the operator; In fact, the profiles, when viewed from the side, show an oblique contact plane that allows the expert bender to adjust the rib and make it localized. This system, while very useful, has one major drawback. With the wedge table, changes to the linearity of the bench cannot take place during bending, but must necessarily be made beforehand. In fact, this crowning system is also called pre-crowning, precisely because the adjustment takes place before starting to bend the sheet metal. Sheet metal bending and crowning: how much do you need to compensate? Compensation is one of the crimper's big pet peeves. While it is true that there are theoretical tables and formulas to calculate compensation, it is equally true that sheet metal is an unpredictable material. It happens very frequently that the theory clashes with the variable behavior of sheet metal. What can be done in these cases? Surely the first step to take is to know all the factors that determine the behavior of the sheet metal. It will help you understand how to compensate for them and not waste time and material on tests and verifications. Sometimes, however, even knowing the material is not enough and the company could run into many problems deriving from non-uniform parts: material cost, late deliveries, high waste. Getting the result right the first time becomes essential for companies that want to remain competitive in the market. Crowning systems: hydraulic crowning Hydraulic crowning is a system historically used by many manufacturers. Inside the bench, in the table that bears the stress and supports the dies, high-pressure and low-flow cylinders are inserted. Like real hydraulic jacks, they push the center of the bench upwards, thus compensating for the deformation of the stomp. The effect you get is the perfect parallelism between the punch line and the die line. With hydraulic crowning, you get a workpiece with a constant bend between the center and the sides. Even in this case, however, it may happen that, due to the variability factors of the sheet metal, the system returns a value that is not optimal. In fact, the numerical control calculates the compensation on the basis of the description of the piece to be produced and on the calculation calibrated to the structure of the sheet metal machine. Linear bends of sheet metal at the first attempt: active hydraulic crowning The only way to successfully manage crowning is to use technology that measures the actual deformation and corrects it in real-time. VICLA, for this reason, can guarantee active crowning, which, in fact, represents the evolution of the system and the ultimate in terms of repeatability and precision. With VICLA's Clever Crowning active crowning system, you can be sure that no matter how different the material is, you will always achieve a perfectly linear crease. How does the active crowning system work? VICLA's Clever Crowning active crowning is a sophisticated and extremely intelligent system that provides for a modification of the linearity of the bench, calculated exactly on the basis of the real need. The press brake, in fact, thanks to special sensors inserted at the strategic bending points, is able to understand exactly how many hundredths of a millimeter the extent of the crossbar bending is. It is no longer a parametric calculation, but a real value that establishes the exact pressure that the cylinders must use to compensate for the bench and achieve the perfect bends along the entire length of the profile. This solution does not require corrections because it is positioned completely automatically, always guaranteeing excellent results. In short, it is a real revolution in the bending process that improves work in the workshop in many ways: you get excellent results even with inexperienced staff, as the system calculates everything automatically; reduce material waste, as the system applies the exact compensation in real time; reduce production times because you no longer need pre-crowning and part checks. All the systems currently offered on the market, hydraulic or mechanical wedge, require corrective intervention by the operator. They are therefore semi-automatic systems, in which the positioning is theoretically determined by the NC but is subsequently corrected by the operator. With VICLA's Clever Crowning active crowning system, on the other hand, the NC measures the changes to be made in real time without you having to intervene with subsequent adjustments. This option is available on the hybrid press brake. SUPERIOR and allows you to achieve exceptional performance. Now that you know how to achieve perfect folds without wasting time and material, discover the other benefits of VICLA press brakes.
During the last 10 years, industries across all sectors have actively participated in a significant shift towards automation, with solutions for every aspect of production, from automated warehouse management lines to robotic bending cells. Robot integration revolutionized the sheet metal bending process on press brakes. Automated press brakes represent for sure an advanced solution for industrial automation, increasing the quality and efficiency of work. Thanks to the advantages of state-of-the-art programming, press brake bending cell can work continuously, providing constant, repeatable and high-quality results, without the variability associated to human operators. How does a bending cell work? A robotic bending cell is an integrated system that combines a robot and a press brake. This solution allows to automate the entire bending cycle. In particular, automation includes: Part picking by the robot, which is equipped with suction cups or magnets Thickness control and centering plate Bending phase (includes performming of re-grips or turnovers) Palletizing Faster production cycles thanks to robotic bending The lack of qualified staff has developed an increased need of automated production. Without any doubt, the scarcity of qualified labor can be considered one of the main factors that has required this change in the workshop organization. Robotic bending cells are designed to perform a variety of operations. The use of automated solutions allow companies to make the production cycle more efficient, while keeping production costs low, without compromising quality. The robotic bending cell automates the entire bending cycle, from part picking to final palletization, ensuring high-quality and consistent results. Let's take a real example: the bending department of a company can organize the work on a continuous cycle. You might optimise effectively the work by using the robotic cell during the night to perform all the simplest and repetitive processes, while operators can focus exclusively on the most complex and challenging phases of processing, especially those in which a robot cannot compete with the creativity and added value of an experienced bender. The operator, released from doing repetitive tasks, can put its attention on other activities, such as preparing for the next processing phases, or can be trained on machine maintenance. With this kind of organization the company can fully exploit the potential of automation for the simplest working phases, where the human contribution is less appreciated. On the other hand, companies can employ human capital on more remunerative tasks, fostering the development of new skills and creating the conditions to retain the most valuable resources. MATRIX: robotized cells without limits To meet these needs, VICLA has designed MATRIX, the fully customizable robotic cell that perfectly meets the real needs of customers. It is a highly performing integrated system, easy to program and designed to meet the needs of the individual customer. VICLA stands out for the high level of customization of both the robot and the press brake, which can be configured in terms of power and length, while the integration with the robot is designed according to the customer's needs. The cell configuration is highly versatile and allows to easily switch from automatic to standalone mode when needed. The design is compact and can be configured according to the space available. The robot can pick a wide variety of sizes, even the smallest, thanks to different gripper options. It is possible to equip the robotic cell with a mobile or press brake-integrated (ATC) tool changer and obtain a fully automated bending system. The high-tech sensors ensure a consistently accurate bending angle. The angle control, the adaptive crowning system, and the Flex device ensure perfect linearity even on non-uniform materials. Matrix offers a suite that combines bending software and robot programming in a single environment, also allowing to import drawings, collect real-time data, monitoring production. These features make the Matrix bending cell particularly reliable and productive, thus helping to meet the shortage of skilled labor. Due to the fact that it is fully customizable, VICLA offers various custom-designed configurations. The customer can therefore choose a solution with a gantry robot, a rail robot or a fixed platform robot. Let's see together the advantages of each type. Robotized cell .Matrix Baseline Integrated robotic cell that combines a press brake and a floor-mounted robot. The robot can be configured to move on a rail, thus obtaining a seventh axis, or it can be positioned on a fixed support platform. A bending cell with a rail robot offers a lot of advantages; let's see some of them: Increased flexibility: if the robot is equipped with a seventh axis on a rail, it can serve multiple workstations, allowing for different operations without the need for operator supervision on the machine and the execution of tasks at different points in the production line. Downtime reduction: thanks to the ability to move along the rails, robots can reduce downtime associated with the movement of materials or components within the work area, improving overall production efficiency. Increased productivity: robots moving on rails can avoid the downtime typical of production, optimizing cycle times during the day and the night by serving production lines 24/7, saving time increasing productivity. Better use of space: thanks to their mobility, rail robots can be used more efficiently because they work in a larger space, allowing for better organization of the production area and a strong reduction in the footprint of the machines. First piece right: each process is first designed remotely and feasibility is checked using specific software. The robot checks and positions the part exactly where it needs to be bent, and specific devices are used to verify the position and material, which ensures the right first piece from the beginning. Matrix Skyline: for a more efficient use of space Integrated robotic solution that combines a press brake and a robot mounted on a gantry. This configuration is the best solution when it would not be possible to install a rail-mounted robot due to space limitations. Thanks to the use of an overhead gantry for the robot, the working area is free of obstacles, allowing for greater flexibility and versatility. Unlike the version with a floor-mounted robot, this system does not require to place the bending brake on lifting blocks, making it a more versatile solution even when used in standalone mode. Robotized bending with automatic tool changer Robotic bending can be integrated with an automatic tool changer that automatically performs even the most complex setups, handles dies up to 70 mm V width, round tools and also allows 180° rotation of the tool. VICLA ATC - Single or Twin - can reduce setup times by 4 or 5 times compared to manual operations. This system, combined with a bending robot, is the most suitable solution for saving time in the bending cycle, combined with flexibility and production speed. Robotised solutions from laser to bending Matrix Tailor is an innovative system that enables the complete automation of laser cutting and metal bending. Its uniqueness lies in the use of two or more 8-axis gantry robots, where the eighth axis is dedicated to bending. This solution allows the robots to be used not only for bending, but also for sorting and palletizing the laser cut parts. The automation covers several aspects, including: automatic sorting, part transportation from laser machine to bending machine using by AGV (Automated guided vehicles) robots and bending phase. The flexibility and versatility of this solution become even more evident when considering that the system can be designed for 24/7 production. During the day, production can be managed by operators and/or robots, while at night the system can operate automatically. In this way, robots can work with or without human intervention, even carrying out entire shifts fully automatically.
A robotic bending cell is a system that integrates a robot and a bending press, designed to perform operations of picking, bending, and depositing metal sheet profiles. It is a solution born out of the need for companies to make the production cycle more efficient while keeping production costs low without compromising quality. The modern era of mechanical processes is characterized by a common thread: an increase in the level of quality in the repeatability of machining processes. In the field of sheet metal processing, continually improving productivity is one of the current major challenges, especially considering the growing variability in shapes, sizes, and quantities of pieces demanded by the market. What are the possible solutions? As always, there is no one-size-fits-all formula, but there are options that better suit each individual company. Today, we will talk about robotic bending and how it can enhance corporate productivity. Robots and Innovations in Industrial Bending: Latest Developments Bending automation has made significant strides compared to a few years ago, considering collaborative robots (cobots) or automated tool changer. Before the advent of cobots and anthropomorphic robots, a Cartesian robot was used. This is a robotic arm that moves along a large steel frame positioned in front of the bending press. Technological evolution in recent years has allowed freeing the robot from the elevated horizontal sliding beam, giving rise to the anthropomorphic bending robot. Automation of Bending The sheet metal processing sector is experiencing remarkable technological evolution, especially in the field of press bending. Traditionally, the bending phase has always been considered the bottleneck of the entire process because it is where the most significant waste occurs, both in terms of material and time. Automated solutions act on two fronts: speeding up the bending cycle and reducing human error. The automated bending cell relieves operators from strenuous, repetitive, and unstimulating work, allowing them to focus on other tasks. VICLA automatic tool changer allows machine setup without operator intervention. Programmable remotely or on the machine, it accelerates the bending cycle. Advantages of Robotic Bending In the new smart factory, the programming phase of different processing stages is managed by the technical office, which becomes the true operational center of the workshop. With everything controlled from a single location, the bad habit of having programs in the machine more accurate than the technical drawings or relying solely on the notes of the benders ceases. Reduces Costs By reducing the discretion of the human factor, costs can be reduced. Positive impacts include a reduction in material waste and a decrease in the production cycle (operators can focus on optimizing other production cycles). Additionally, the work of people involved in other areas is expedited. Lifts operators from repetitive, strenuous, and risky activities Another aspect not to be overlooked is the safeguarding of the health of operators who, freed from taxing and dangerous activities, can engage in other tasks. Operators can cease manual handling of large sheets, eliminate the risk of finger crushing during the bending phase, especially for very small pieces, and reduce risks and fatigue from manual tool changes. Improves Job Estimation Automation allows precise measurement of the time, material, and energy required to produce a piece. This enables more accurate quotations and eliminates the discretion of the human factor. How often does one base the price on skilled operators who are not always the same ones producing the piece? Additionally, knowing in advance the timing, energy, and material, the company can make accurate forecasts of costs and revenues for the current year, improving the overall management of cash flows. Robotic Bending vs. Manual Work It is a common misconception to believe that automated bending will lead to the end of thousands of jobs. The same was said of the advent of the PC, but facts have shown that the introduction of new technology tends to have more positive than negative effects. Bending automation will drive the development of human skills. New skills will range from machine maintenance to programming. Thanks to the time saved, versatile figures capable of performing multiple tasks could emerge— for example, a laser cutter or a welder could learn to manage a robotic bending station much more quickly than a manual machine. So, will benders lose their jobs? Absolutely not! A robot can never replace the work of a highly skilled bender, also because not everything can be automated. There are indeed processes so complex that they must necessarily be carried out by the human hand. Control Systems in Robotic Bending: Optimization and Precision As advanced as bending robots may be, they cannot understand if they are working correctly and if the piece is successful. To avoid unpleasant situations where the system worked all night and one ends up with a series of pieces that have errors and inconsistencies, it is necessary to equip oneself with sensors and bending control systems. The first is angle control. It consists of a system of laser readers running parallel to the bending bench. This solution guarantees the set angle without any additional correction. Another useful precaution that ensures the correct positioning of components is the rear register sensor system. Other very useful devices are inserted inside the bending bench and serve to detect and compensate for natural flexions due to the bending effort. Adaptive bending device (VICLA Clever Crowning) Ensures excellent results and requires no in-depth technical knowledge; adjusts compensation without any need for operator intervention; guarantees a perfectly linear bend even on non-uniform materials (e.g., mixed perforated/solid material). Device for controlling structural flexions of shoulders (VICLA Flex) allows maintaining the same bending depth regardless of the sheet metal's length. The CNC receives data from the pressure sensors of the cylinders, which are then interpolated to establish the correction to be made. Limits of Robotic Bending As with any other machinery, it would be wrong to think that a robotic bending cell can do anything. These are application limits that must be known and explored before proceeding with the machinery purchase, so as not to end up dissatisfied with the investment made. Looking at the issue from another perspective, the question to ask is: what factors should be considered when choosing an automatic bending system? What kind of work do you do? The essential prerequisite is that the work is repeatable, so it cannot include prototyping. This is because it makes no sense to invest time in programming a product that will be made only once and never again. If a workshop regularly produces different parts for customers, however, the program can be easily recalled, and it might make sense to invest in a robotic bending cell. Furthermore, to get the maximum benefit from an automated system, it is crucial to ensure maximizing the variety of operations that can be performed on it. What are the best jobs for a robotic bender? Surprisingly, it covers a fairly wide range of applications: repeated high-volume jobs; low-volume jobs that are repeated; heavy jobs can all make sense. Evaluate all costs The cost of an automated system is certainly important, and it is undeniable that, for the same price, one could purchase one or more independent bending machines. However, the significant limitation of this reasoning is that, for each bending machine, an operator is needed. Are we sure the game is worth the candle? When introducing an automated bending system, it is possible to optimize human resources as well. An experienced operator can manage an independent bending machine while monitoring a robotic cell. Organize work and space In addition to choosing the right-sized tooling, a workshop must also consider how the parts will be removed from the cell. Will they be assembled into kits, placed on a conveyor belt, removed via a chute, or stacked on pallets? Decisions like these will influence the length and width requirements of the cell. Always Monitor Production It is a misconception to believe that merely programming in the technical office, hitting start, and waiting for the system to do all the work is sufficient. This oversimplification disregards the variables involved in sheet metal processing. With a traditional bending machine, the operator can manually intervene to manipulate the piece and avoid potential collisions. In the case of a robotic system, the automated bending machine will only perform what it is programmed for, so the tool configuration must be precise. A tool out of place could cause significant damage. It is crucial for the operator of the bending machine to ensure that every part is in its proper position because the robot cannot reposition the part to accommodate a misplaced tool. In conclusion, working with a robotic bending machine requires meticulous attention to detail. 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In sheet metal working, batches are increasingly small, complex and non-homogeneous. More and more efficient technologies are needed, while also trying to maintain compatibility with existing machines and services. This is why Nuova Inox decided to focus on VICLA'S ATC automatic tool changer combined with two .SUPERIOR press brakes. Nuova Inox Srl, based in Rovato (near Brescia, North Italy), is a metal carpentry company for medium-light components. Founded in 1989, the company began with the management of small metal products and immediately stood out for its excellent ability to machine stainless steel, becoming a reference point in this field in just a few years. Nuova Inox has always believed in technological innovation, investing in facilities and auto-mation, it has also implemented a next generation management system which, combined with 4.0 technologies, makes the service qualitatively better with useful information for the customer. The strengths of the Lombardy-based company, which employs around 50 people, are its speed of response to requests, efficiency in the execution of orders, and timely deliveries. The work is based on customer projects which generally require the production of sub-as-semblies of machine carpentry in their vari ous sectors, especially packaging, food and medical, given the Lombardy-based company's specialisation in stainless steel and construction steel. A comprehensive service The entire activity is based on various stag es, starting from engineering, which is the stage where the design of a manufactured article is received in preparation for its real-isation, as Fabiano Fieni, General Manager of Nuova inox, pointed out: The intervention of the engineering department serves to make any corrections to the incoming design with the intention of improving its characteristics, implementing better technical solutions to minimise the time needed for realisation. We are well organised to offer a complete service: after the technical department, there is the sheet metal and tube laser cutting department with different working ranges and thicknesses, able to meet most requirements. Then we have the bending division, in which we have recent ly concentrated our resources. More and more often we are producing small batches. these are not even prototypes for large or ders, they are really components of special machines custom-built by our customer, completely different automatic machines, true unique pieces which are very unlikely to be replicated except in very few examples Nuova Inox's services are completed by the punching, welding, assembly and finishing departments, when necessary, not forgetting deburring, which is also useful for company safety. Compatibility first and foremost The specialisation and care put into production have brought Nuova Inox great success in the market, but have also required careful optimisation of work, especially in the bending phase. The lat ter is particularly affected by both set-up times and the management of a vast number of unique codes associated with each job, including non-repeatable ones. There was a need to reduce the time as much as possible on these components of different lengths and thicknesses: the bending set becomes laborious and par ticularly difficult to manage, due to several consecutive settings and a different bending logic from the standard. With a view to reinforcing the department by purchasing more press brakes, this phase had to be made smoother: We examined the mar ket proposals. The first machines with automatic tool changers had already appeared, but we had requirements which could not be overlooked: interchangeability with our existing dies ( matrices and punches already present in the workshop), the fact of having a single magazine serving two machines and a bending CAM program which could manage the entire fleet of machines in the bending department and, finally, having machines equipped with the angle control device. At the time, our needs were met by VICLA, a company specialising in designing and building press brakes, shears and robotic cells in Italy. We therefore purchased two VICLA SUPERIOR 170 and 250 ton press brakes (3 and 4 metres respec-tively, both equipped with an automatic sheet metal loader and angle control de-vice) and a VICLA ATC tool change system to service both machines Speed and precision VICLA'S ATC automatic tool changer is designed precisely to minimise set-ups when these operations follow one after the oth-er; the system can reduce them by 4 or 5 times compared to manual operations. It also eliminates downtime between one phase and the next, allowing you to go di rectly from cutting to bending the part with out having to wait for traditional set-up times. In the new cell, office programming is now managed, a non-trivial operation in this new operational strategy, which begins with 3D 'solid mathematics and ends with bent products. The VICLA SUPERIOR hybrid press brake represents the top of the range from VICLA: brushless engines with a high energy coefficient, active crowning, flex system, angle control and double guided ram. This family of machines is available in difierent configurations (lengths, pressure forces and controls); all are characterised by an extremely solid structure made of high quality steel, capable of absorbing and eliminating mechanical stress and guaranteeing excellent bending precision. For example, the double guide preserves the stability and perpendicularity of the upper crossbar with respect to the work surface: this allows bending precision to be maintained with different tools and intermedi-ates, guaranteeing that the centring carried out at the test is maintained over time. A value not to be forgotten At Nuova inox we have seen that an operator's decades of bending experience is really an added value: we have seen, General Manager Fabiano Fieni concluded, that not infrequently these professionals are capable of inventing' a equivalent or better bending strategy than the one suggested by the soft. ware itself. But not evervone is such an ex-pert, and so cam programming combined with automation is very useful in routine op-erations, through which even beginners can become productive, indeed, they can take advantage of CAM to build on the results and therefore learn! We have put in place a system consisting of press brakes, stor age, ergonomics, set-up time reduction and safety, without neglecting the 4.0 approach and the tracking of the various steps. We are confident that this set-up in the company will allow us to consolidate our carpentry business through improvement of production capacity. As for the future, we look for ward to automation for welding and finish-ing, always ready to innovate”.
Let’s further discuss the fundamental aspects that need to be analysed before choosing a press brake. Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends... Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based. So what are the key elements to examine before signing a contract for press brake supply? #1: the Structure The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product. Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles. The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy. #2: the Double Guide The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing. This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced. #3: the Cylinders Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part. VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left. #4: the Hybrid System If in the past there were few types of bending machines, nowadays the market offers different choices: hydraulic press brakes; electrical press brakes; hybrid press brakes. These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system. Be careful, though! It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines. The results in numbers of this technological innovation are significant, as seen on the graph. #5: the Clever Crowning The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well-processed part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length. What are the advantages of this intelligent system? Mainly three: it ensures great results even in the presence of an inexperienced operator; it uniforms the bending angle without any need for operator intervention; it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material). #6: the Flex Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet. Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon yawn and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out. #7: the Back The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities: Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance; Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence; New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength; Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference. Ultimately We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of: reducing operating costs; maximising productivity; achieving the most in terms of processing quality. By doing so, even the end client can count on a standardised and reliable supply.