Sheet metal bending, a pivotal process in metal forming that dates back to ancient times, involves manipulating sheet metal into desired shapes through the application of force. This technique has evolved significantly with technological advancements, encompassing a range of methods like air bending, V bending, and U bending, each suited to specific applications. Metal bending is a complex process that requires careful consideration of various factors, including material properties, press brakes, tooling, and process parameters. The ability to consistently achieve accurate and high-quality bends is crucial in many industries. Today, commonly used machines for sheet metal bending include press brakes, rotary bending tools, and roll bending equipment, showcasing the versatility and adaptability of this process. These machines have evolved to offer greater precision, efficiency, and automation, allowing for the production of complex components in large volumes. Table of Contents History of Sheet Metal Bending Types of Sheet Metal Bending Importance of Sheet Metal Bending in Manufacturing Sheet Metal Bending Process, Design and Planning Common Materials Used in Sheet Metal Bending Sheet Metal Bending Machines Understanding Sheet Metal Bend Allowance and K-Factor Challenges and Solutions in Sheet Metal Bending Evolution of sheet metal forming Today's modern press brakes are equipped with sophisticated CNC systems, offering enhanced precision and efficiency. While the basic mechanical concept remains the same – bringing a punch to a matrix – the internal mechanisms and electronics have undergone substantial advancements. This evolution has transformed press brakes into high-tech machines capable of producing complex bends with greater accuracy and repeatability. Why Is Sheet Metal Bending Essential in Manufacturing? Sheet metal bending is a cornerstone of manufacturing, transforming flat metal sheets into essential components across various industries. From automotive and aerospace to consumer electronics and construction, its versatility and importance are undeniable. Material selection is crucial in sheet metal fabrication, as it directly impacts the strength, durability, workability, and appearance of the final product. Understanding the composition, characteristics, and interactions of various materials with the press brake is essential for accurate project calculations. Beyond Steel: Exploring Diverse Sheet Metal Options Here's a list of common materials used in sheet metal bending: Steel: The most widely used material due to its strength, durability, and versatility. Aluminum: Lightweight, corrosion-resistant, and easy to work with. Stainless steel: Offers excellent corrosion resistance and formability. Copper: Known for its electrical and thermal conductivity, often used in decorative applications. Brass: A copper-zinc alloy with a golden appearance and good workability. Titanium: Highly durable and lightweight, often used in aerospace and medical applications. Cor-Ten steel: A weathering steel with self-protecting properties. The choice of material depends on factors such as the required mechanical properties, corrosion resistance, cost, and the specific application. Material Composition Key Characteristics Common Applications Steel Iron and carbon alloys High strength, durability, versatility, cost-effective Automotive, construction, appliances Unalloyed Steels Iron and carbon Varying levels of hardness based on carbon content General-purpose applications Alloyed Steels Iron, carbon, and other elements Enhanced properties like corrosion resistance, heat resistance, and specific mechanical characteristics Stainless steel, Cor-Ten steel Stainless Steel Chromium, nickel, and often molybdenum Excellent corrosion resistance, formability, durability Food processing, marine, medical, architectural 300 Series Stainless Steel 304 (18/10), 316 High corrosion resistance, formability Commercial kitchens, appliances, food processing 400 Series Stainless Steel 430, 410 Good corrosion resistance, mechanical properties Appliance panels, cutting tools, industrial equipment Cor-Ten Steel Weathering steel Self-protecting from corrosion, high tensile strength Outdoor structures, architectural elements Aluminum Lightweight, corrosion-resistant, easily processed Aerospace, automotive, consumer electronics Copper High electrical and thermal conductivity, corrosion resistance Electrical wiring, heat exchangers, decorative elements Brass Copper and zinc Malleable, corrosion-resistant, attractive appearance Decorative components, musical instruments, plumbing fixtures Titanium Lightweight, highly durable, corrosion-resistant Aerospace, medical, military Want to learn more about sheet metal materials and their applications? Read our comprehensive guide on how to choose the right material for the bending process Principle of Sheet metal Bending Process Sheet metal bending involves a series of steps, beginning with design and planning. Factors such as material type, thickness, and desired bend angles are considered to select the appropriate sheet metal and bending method. The process then involves material preparation, alignment, and the actual bending operation. Finally, the finished product is inspected and verified to ensure it meets the design specifications. Types of sheet metal bending methods A deformation process is a technological process that involves modifying the dimensions of a material through the application of controlled external stresses. In the case of sheet metal, deformation processes can be divided into five main groups. Air bending It is the typical deformation of press brakes. It represents the most versatile processing and involves the use of a die with a V-shaped groove and a punch. The points of contact with the sheet metal are three: 1) vertex of the punch; 2) left vertex of the die; 3) right vertex of the die. The versatility of three-point bending lies in the possibility of working on small and discontinuous batches together with large productions with a practically infinite range of thicknesses; in fact, conceptually, there is no actual limit to the thickness in bending. In fact, assuming that it is possible to have a machine with adequate performance and by widening the size of the die, it is possible to bend any thickness of sheet metal. Sheet metal bending is carried out by vertically approaching the tools up to the desired height and identified by the numerical control of the machine. Behind this simple concept, many technological and design solutions have been developed by manufacturers over time. Some of these are now completely outdated in favor of others that guarantee greater precision, speed, safety and lower environmental impact. Pros Versatility: Suitable for various metal types and thicknesses. Reduced tool wear: Less contact with the die reduces wear and extends tool life. Flexibility: Allows for a wide range of bend angles with a single set of tools Cons Less precision: The bend angle can be influenced by the material’s springback. Dependence on material properties: Variations in metal thickness or strength can affect bend consistency. Forming or coining Through a wide range of possibilities (such as deep drawing, hydroforming, etc.), this type of processing involves the use of dies that give a specific shape to the sheet metal and are designed exclusively for this purpose. It is a process that is not particularly versatile but that guarantees great repeatability. Forming is in fact the most adopted solution by companies that need to produce large volumes. Pros: High Precision: Yields exact bend angles with minimal springback. Consistent Results: Ideal for repetitive, high-volume production with uniform quality. Clean Edges: Produces sharp, well-defined bends. Cons: Tool Stress: Exerts significant pressure on tools, leading to potential wear. Material Limitation: Less effective for very thick or hard materials. Higher Cost: Often more expensive due to increased tooling demands. Folding It involves the deformation of long strips of sheet metal through their forced passage through a long series of rollers that gradually modify their shape. Folding requires a dedicated system, such as folding machines, often of large dimensions, but allows obtaining complex profiles thanks to the possibility of adding further processing during the process, such as cutting, punching, welding, threading and much more. Panel bending It is carried out by applying a lateral force through a moving blade, which deforms the panel until the desired shape is reached. Its use is dedicated to thin thicknesses, typically up to a maximum of 3 mm. Panel benders are very complex machines and relatively recent, having been born around the 1970s; they guarantee high productivity and versatility in the face of a high initial investment. What is the desired outcome of this bending operation? When we ask, 'What am I trying to achieve with this bend?', we're diving into the heart of sheet metal forming: managing variables. Several factors influence a metal’s ability to bend without breaking or losing its structural integrity Every bend has specific requirements, including desired angle, radius, and surface finish. These requirements, combined with the properties of the sheet metal itself, the tooling used, and the machine settings, all contribute to the final outcome. Understanding these variables is essential for producing consistent, high-quality bends. Here a list of the 5 most important factors that determine the bendability of metal. For the full list, please refer to this table. Material Composition and Finishings Any type of surface treatment or pattern on the sheet metal can make bending more challenging. Perforations or raised patterns on the sheet metal can make bending even more difficult. The uneven distribution of material along the bend line (i.e., the area that will be deformed) creates asymmetrical stresses that cause the part to slip during the bending process, making it particularly difficult to achieve a correct flange length. The same inconsistency is also reflected in the bend angles, which vary continuously, making it difficult to standardize the process. This means that when the material has an uneven surface (like perforations or textures), it causes uneven forces during bending. This can make the part slip, leading to inaccurate bend angles and inconsistent flange lengths. How to solve it One possible way to counteract this problem to a significant extent is to install a wider die. Bending with wider dies means that the deformation occurs over a larger area and is therefore gentler. However, such a measure is not always sufficient and is completely useless in ensuring consistent flange lengths. Using a wider die can help distribute the forces more evenly, but it won't solve the problem completely, especially when there are significant differences in the material thickness on either side of the bend line. Unfortunately, in the presence of holes, raised patterns, or other functional features, there are asymmetries between one side and the other side of the bend line that make the use of a wider die useless. Features like holes or raised patterns create uneven stresses that can overcome the holding force of the die, causing the part to slip. These asymmetries during deformation create asymmetrical stresses, often greater than the clamping force. This causes the sheets to slide in search of an equilibrium, and the most evident consequence of this variability factor is inconsistent and varying flange lengths. The uneven stresses caused by the features on the material can lead to the sheet metal sliding during bending, resulting in inconsistent flange lengths. Thickness Variation Thickness variation is generally the most common variable in bending operations and is also quite common in plain, unfinished sheet metal. Why? Simply put, the processes used to produce sheet metal, especially for thicker gauges, cannot guarantee absolute precision. In fact, each sheet exhibits dimensional deviations, which, although within the expected tolerances at the time of purchase, impact the consistency of angles during bending. The thicker the material, the more noticeable the problem becomes. A decrease in the actual thickness of the workpiece leads to an increase in the angle α. The reason for this annoying issue is purely geometric and, unlike other variable factors, it doesn't affect the earlier stages of the production process. The maximum downward travel of the upper beam coincides with the lowest point reached by the punch inside the die and is called the 'Lower Dead Point' (LDP). The CNC controls identify the LDP using an internal algorithm that calculates it based on the following data: sheet thickness, material, tool height, and desired angle (angle α). The CNC machine converts the desired bend angle into a specific movement of the punch. The accuracy of this conversion depends on how advanced the machine's software is and the overall quality of the machine. Even a small difference in thickness can cause a significant change in the bend angle, especially for angles close to 90 degrees. These variations might seem insignificant in earlier stages like cutting or nesting, but can have a big impact on the final bend angle. Grain Direction The orientation of the metal’s grain can significantly impact its bendability. This variable is also known as anisotropy, and it is a physical property that affects how sheet metal behaves when bent in the longitudinal or transverse direction. This characteristic is imparted to the raw material during the rolling process, particularly in cold rolling. The rolling process causes three dimensional changes in the starting semi-finished product according to the following proportions: Along the length, very significantly; Along the width, to a medium-low extent; Along the thickness, very slightly and gradually. This means that the internal fibers of the material are forced to follow the direction of the most modified dimension and, therefore, are arranged perpendicular to the rolling mill rollers. This causes the sheet metal to respond differently to bending when done transversely or parallel to the rolling direction. An anisotropic material, in fact, has different mechanical strengths depending on the orientation. For example, alloys like AISI 430 stainless steel and aluminum exhibit significant anisotropy. This variable affects the consistency of bend angles and, in some cases, even the developments. The bend radius, in fact, is the element that most affects standardization: the stronger a material is, the larger the naturally occurring inner radius will be. The more yielding a material is, that is, the less resistant, the smaller the bend radius will be. For this reason, the same sheet, which guarantees its maximum mechanical performance when bent transversely to the rolling direction, generates two different radii. Temperature The sole environmental variable that significantly influences the sheet metal bending process is temperature. While temperature fluctuations are often overlooked in controlled environments, they can have a noticeable impact on both the bending machine and the sheet metal itself. For example, extreme temperature changes, such as those experienced on very hot or cold days, can affect the machine's hydraulic system and the material's properties. Similarly, when working with freshly cut metal that is still at a different temperature than the ambient environment, temperature variations can introduce inconsistencies in the bending process. Even in highly automated production lines, temperature remains a critical factor to consider. In bending machines, temperature fluctuations can affect the machine's performance from the moment it is turned on to after numerous bending cycles. What are Critical Design Considerations for Sheet Metal Bending? Effective sheet metal bending requires careful design considerations. To achieve the desired outcome without compromising the material's integrity, it's essential to focus on the following key aspects: Material Selection: choose a material that suits the project's functional and aesthetic requirements, considering its bendability. Bend Radius: ensure the bend radius is appropriate for the material thickness to prevent cracking or deformation. Grain Direction: align the bend line with the metal grain to reduce the risk of cracking. Bend Angle Accuracy: consider the material's springback characteristics to achieve the desired bend angle. Hole Placement: avoid placing holes near the bend line to prevent distortion or weakening. Edge Condition: ensure smooth edges on the sheet metal to avoid irregularities in the bend. Calculating Bend Allowance and K-factor The K factor is a crucial parameter in sheet metal bending, but it can be tricky to determine, as it depends on factors like material, thickness, inner radius, and bend angle. The k-factor is fundamental to designing precise sheet metal products. It allows you to anticipate the bend deduction for a large variety of angles without having to rely on a chart. There are numerous ways to explain it, but let's just say the k-factor is the percentage that reflects how the neutral axis move toward the inside surface during the bending process. In other words, the k-factor is nothing more than a multiplier that can give you an accurate value for the relocated neutral axis. And if you know the bend allowance, you can extract the k-factor from it. Once you know the k-factor, you can use it to predict the bend allowance for various angles. Read our guide to understand more about k-factor. What is sheet metal bend allowance? Bend allowance is a critical value in sheet metal fabrication. It refers to the additional length of material required to account for the stretching that occurs when a sheet metal part is bent. Essentially, it's the extra length you need to add to a flat sheet to achieve the desired bend angle. The neutral fiber is an imaginary line within the material that experiences neither tension nor compression during bending. It's along this line that the material neither stretches nor compresses. Bend allowance is the extra length you need to account for when bending a piece of metal, to ensure that the final part is the correct size. Why is bend allowance important? Accurate dimensions: without the correct bend allowance, your finished part will be too short. Consistent results: a well-calculated bend allowance ensures that all parts are identical. Reduced waste: by accurately calculating the bend allowance, you can minimize material waste. Using Software for Calculations of Bend Allowance and K-Factor You can use our online calculator to accurately calculating k factor and sheet metal bend allowance. Troubleshooting Common Sheet Metal Bending Issues Understanding and addressing common sheet metal bending problems can significantly improve the quality and efficiency of the fabrication process. Here are some frequent issues and potential solutions: Springback: to prevent the material from returning to its original shape after bending, slightly overbend or use a material with a lower yield strength. Cracking: avoid bending the metal beyond its elastic limit. Using a proper bend radius and annealing the material can help prevent cracking. Warping: to avoid uneven stresses and prevent warping, ensure uniform thickness and use symmetric bending techniques. This can include punctures and vent curls. If you eager to learn how to avoid them, read our dedicated guide on how to deal with puntures and vent curls in sheet metal bending. Scratches or Surface Marks: protect the material with films and maintain clean tooling to prevent surface damage. Inaccurate Bend Angles: regular maintenance and calibration of the bending machine are crucial to ensure accurate angles.
The choice of the right material is fundamental for any sheet metal fabrication project. Understanding the composition and characteristics of these materials, how they interact with the press brake, and the variables of the sheet metal itself, is essential for accurate development calculations. Different materials offer unique characteristics that can significantly influence the strength, durability, workability, and aesthetic appearance of the final product. Steel Throughout history, steel has always been employed in a highly versatile manner. This material has been indispensable for technological innovation worldwide. In fact, without its availability and low cost, the Industrial Revolution would not have been possible. Over time, steel production techniques have been perfected. When discussing steel, it's useful to distinguish between two main families: Unalloyed steels: Composed of iron and carbon alloys. Alloyed steels: Alloys containing elements in addition to iron and carbon. Beyond the presence of elements, there are different types of steel based on the percentage of carbon present. In general, the higher the carbon content, the greater the hardness. When referring to mild or hard steels, we're talking about the carbon concentration. Generally, steel can be classified into these categories: Extra mild: 0.5-0.25% carbon Mild: 0.15 – 0.25% carbon Semi-mild: 0.25 – 0.40% carbon Semi-hard: 0.40 – 0.60% carbon Hard: 0.60% - 0.70% carbon Very hard: 0.70% - 0.80% carbon Extra hard: 0.80 – 0.85% carbon Alloyed Steels We've mentioned that alloyed steels are metals that mix other elements besides iron and carbon. One of the most famous is undoubtedly stainless steel. Stainless Steel Stainless steel is composed of a high percentage of chromium, which makes the material highly resistant to corrosion and temperature; chromium also provides great malleability, making stainless steel a material used in countless applications. In press braking, various types of stainless steel are used, each with specific characteristics that make them suitable for particular applications. The most commonly used types of stainless steel are: 300 Series Stainless Steel Stainless Steel 304: This is the most common and versatile type of stainless steel and is also known as 18/10 stainless steel due to the percentages of chromium and nickel present in the alloy. It's known for its excellent corrosion resistance and formability. This material is often used in applications requiring high corrosion resistance, such as commercial kitchens, appliances, and food processing equipment. Stainless Steel 316: In addition to nickel and chromium, it also contains molybdenum, which further improves corrosion resistance, particularly against saline and chemical environments. It's widely used in marine, chemical, pharmaceutical, and medical applications where the environment is particularly aggressive. 400 Series Stainless Steel Stainless Steel 430: This is a type of ferritic steel with good corrosion resistance and good mechanical properties. It's often used for internal applications such as appliance panels and architectural cladding. However, compared to the 300 series, it has lower corrosion resistance and lower malleability. Stainless Steel 410: It offers a good balance between corrosion resistance and hardness. It's used for applications requiring high wear resistance and moderate corrosion resistance, such as cutting tools, blades, and industrial equipment. Cor-Ten Steel Cor-Ten steel, also known as weathering steel, is a special alloy with a brownish-red color. The name COR-TEN comes from the combination of corrosion resistance and tensile strength, highlighting its main characteristics of corrosion resistance and tensile strength. The primary property of Cor-Ten steel is its rare and unique ability to self-protect naturally from corrosion, an oxidative reaction that responds to environmental stresses and leads to the development of a surface oxide patina that, if scratched or removed, constantly regenerates over time. Aluminum Aluminum is another highly popular material in sheet metal fabrication due to its lightweight nature, corrosion resistance, and ease of processing. It finds applications across a broad spectrum, from aerospace to automotive and even household appliances. Aluminum can be anodized to further enhance its corrosion resistance and aesthetic appeal. Copper Copper is renowned for its exceptional electrical and thermal conductivity, making it perfect for electrical and heating applications. It also exhibits good corrosion resistance and can develop a protective patina, lending it a unique and appealing appearance. However, copper is relatively expensive and often used in specialized applications. Brass Brass, an alloy of copper and zinc, is valued for its ease of processing, corrosion resistance, and golden appearance. It's widely used in decorative components, musical instruments, and plumbing fixtures. Its malleability allows for the creation of intricate and precise details, making it ideal for precision work. Titanium Titanium is a highly durable and lightweight material known for its exceptional corrosion resistance and ability to maintain its structural integrity even at high temperatures. It's employed in industries demanding superior performance, such as aerospace, medical, and military. The downside is that titanium is expensive and requires specialized processing techniques. The choice of material for sheet metal fabrication depends on a variety of factors, including the desired mechanical properties, corrosion resistance, cost, and the specific application. Each material offers unique advantages and can significantly influence the production process and the performance of the final product. Understanding the characteristics and interactions of these materials is essential for successful sheet metal fabrication projects.
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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