Bending machines are integral to the manufacturing industry and are available in various types and sizes. With further classification based on features, characteristics, and applications, selecting the right tool for your business can be daunting.
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To aid in your decision-making process, we&#;ll explore six major types of bending machines and their applications in modern manufacturing. Let&#;s dive in!
Bending machines are industrial tools used to shape metal parts at different angles. These machines apply pressure evenly, reducing the risk of metal fatigue and breakage during the bending process. They are compatible with numerous materials such as steel, copper, aluminum, and even tough ones like titanium.
The art of bending, an essential technique in manufacturing, has been practiced since the early metal ages. From shaping basic tools to crafting intricate metal works, bending has remained a fundamental skill throughout history. Even now, metal bending machines are in high demand across aerospace, construction, and automotive industries.
According to FMI, sales of metal sheet bending machines are expected to grow to $1,344.60 million by , up from the current valuation of $1,020.1 million in .
Other than major industries, bending machines are used everywhere, from hospital furnishings to boat and swimming pool furnishings, road signs and posters, bathroom furnishings, taps, and faucets, to prams and pushchairs.
Now, let&#;s delve into the advantages of bending machines:
Generally, bending machines are categorized into six main types, as listed below. However, they can also be further classified based on specific characteristics, features, or applications. For instance, there are wire-bending machines specialized for wire manipulation. We will discuss each type in detail in a later section.
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There are different types of bending machines catering to various metal shapes, such as small pipes, large tubes, rebar, thick metal plates, or regular sheet metal, covering a wide variety of applications.
Each bending machine serves particular functions involving various metal fabrication processes. Here is a brief overview of how bending machines function in modern industry.
Sheet metal bending machines are specifically designed to bend metal sheets of various thicknesses into intricate shapes. Common tasks include bending, curving, and folding metal plates at different angles.
In the manufacturing industry, sheet metal bending machines are commonly paired with metal cutting machines. The newly cut metal sheets are then shaped into 3D designs, resulting in a smoother workflow.
A steel plate bending machine is also used for the &#;Heming&#; process, which reinforces metal edges and removes the burs. Primarily applied in the food packaging industry.
Not all sheet metal bending machines are the same. Here is a further classification of machines based on bending techniques. Each has unique features and excels at certain applications.
Depending on the nature of the business, the fabricator can choose the most relevant one.
Although sheet metal bending machines vary from maker to maker, generally, they operate on these parameters.
Pipe bending machines can bend any type of cylindrical or rectangular metal pipe, tube, rod, or channel into the desired shape. They do so in such a way that the pipe&#;s internal diameter or dimensions remain constant throughout the entire length. However, there is still a risk of collapse and crimping due to excessive compressive force on the inside. High-quality machines are designed to factor in this risk.
Pipe bending machines aren&#;t one size fits all, so they are further classified into four different types based on their applications and features.
Yields most consistent and solid bends with the help of three rollers arranged in a pyramid shape. Best suited for sharp circular bends and thicker materials.
Use high compressive force of ram to the focal point, bending pipes at much sharper angles.
Utilizes two sideways pressure pistons to hold the pipe together and compress it against a circular bending die. Most suited for bending large-diameter pipes.
Similar to compression bending, the rotary one clamps the metal pipe, and the lever pulls it along a static die, curving it in the process. Most suited for small to diameter pipes and tubes.
No matter what the type, the pipe bending machines operate on roughly the following parameters.
Press brake machines bend industrial metal plates and sheets but differ in the process compared to traditional sheet metal benders discussed above. These machines have punch and die components with powerful brakes that stop the punch from going all the way to the die underneath. Such a mechanism helps in creating more complex shapes and designs.
A highly advanced computer numerical control manages the extent of downward force and the braking point, resulting in a diverse range of angles, shapes, and finishes.
The incredible downward force must be countered with an equally powerful braking system. That&#;s why these machines are further classified based on braking technology.
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The plate rolling machine is a heavy industrial metal sheet bending machine that can bend thick metal plates. Unlike the press brake and sheet metal bender, its capacity to handle large workpieces is its defining feature.
Plate rollers are either fully automatic or semi-automatic, and any standard machine can handle up to 3-inch (76 mm) thick plates. However, with hot rolling, they can bend even 4-inch (102 mm) thick plates.
It uses three roller systems arranged in the familiar pyramid shape, with the top one providing the main force while the bottom two provide counter-reactions. The difference lies in the powerful motor system that runs the rollers, making such heavy-duty fabrication possible. However, the process is slower and requires multiple passes to achieve the desired angle.
The mechanical bending machine is a traditional industrial tool that relies on motors, wheels, pulleys, levers, and gears to bend metal workpieces, as opposed to pneumatic, hydraulic, or electrical systems. Both automatic and manual operating machines are available in the market and dominate small to medium-scale businesses.
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Though mechanical, it still provides accurate and precise bends of metal sheets, pipes, and tubes. Nowadays, they are primarily used for work that is more complex or requires more attention to detail.
A CNC hydraulic machine is a versatile industrial bending tool that has many advantages over other bending machines we discussed above. Thanks to the power of hydraulics, this CNC bending machine can transmit exponentially higher force onto the workpiece.
The higher power of hydraulic actuation is guided by CNC systems, making the operations safe and accurate. Manual hydraulic bending machines are also available in the market; however, they are more labor-intensive.
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Now that we&#;ve covered the basic types of bending machines let&#;s explore some essential factors to consider when choosing the best product for your business.
Evaluate the machine&#;s ability to achieve precise bend angles and lengths for accurate part production. You can order sample products from the manufacturer.
Select a machine suitable for the material&#;s ductility to ease the bending process.
Always select a machine with multiple tool stacks for increased flexibility and efficiency.
Consider the machine&#;s throughput and efficiency to meet production demands effectively.
Assess the level of automation and control features for optimized operation and reduced setup time. However, higher automation levels also increase the upfront cost of the machine.
Look into the machine&#;s maintenance requirements and the availability of support services to ensure smooth operation over time.
Check the manufacturer&#;s warranty for coverage of essential components and common issues, ensuring peace of mind and investment protection. Inquire about the accidental damage policy during shipping.
Consider shipping expenses, especially for overseas purchases. Compare options and factor in additional fees to determine the total cost.
Evaluate the manufacturer&#;s reputation for helping with technical issues, having spare parts, and doing maintenance. Good support reduces downtime and makes the machine last longer.
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We&#;ve covered all the major types of bending machines, their operating parameters, and general applications. Additionally, we&#;ve discussed important factors for business owners to consider when purchasing a suitable machine. Be sure to thoroughly discuss these points with manufacturers for greater success in the future.
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Sheet metal bending with a press brake works by aligning and holding the metal to be bent in the press brake tool. Once it is aligned, the press can move down and exert a force onto the metal, forming it into a new shape by producing angles. Press brakes can exert forces well in excess of 100 tons to bend steel upwards of 3 mm thick.
There are a few different kinds of machines that can be used to bend sheet metal. The most common is a press brake machine which itself can be mechanical and fully manual (usually used in small machine shops), or it can be computer numerically controlled (CNC) and uses a hydraulic system. The principles used in both machines are the same, but the way the operator interacts is different. This process below will focus on the operation of a CNC press brake machine:
Before using the press brake, calculate the design parameters including force required, bend line (the point where the force is exerted), and the order of bends (if there are multiple). The die used to create the bends must also be decided.
To set up the press brake, input the information calculated into the CNC machine, so it knows how much force to exert on the metal to create the right bend and in which order these bends will be carried out. The right tool and die must be attached to the press and brake, ready for bending.
Align the metal between the tool and die. When the machine is operated, it will bend the sheet of metal at the bend line.
Engage the press brake so that the force parameters&#;inputted into the CNC press brake at step 2&#;are applied. Once the press brake has bent the metal, the part can be removed and made ready for the next stage of production.
There are a range of metals that can be used in sheet metal bending. Six metals are discussed below:
Steel is a very versatile metal that consists of iron and carbon. Steel is economical and has great strength and durability. There are a range of different steels that can be bent including mild steel and stainless steel. Mild steel is easily bent and used widely, including in a range of automotive applications.
Aluminum is a lightweight and cost-effective metal used in the aerospace, electronics, and automotive industries. Aluminum is easy to fabricate and benefits from a high strength-to-weight ratio and high corrosion resistance.
Copper is a soft metal that allows it to be easily bent and formed. It is also highly conductive, making it perfect for electrical applications. Copper is also naturally antimicrobial and recyclable.
Brass is an alloy consisting of zinc and copper. Brass is used a lot in sheet metal bending because of its aesthetic appeal and ease of fabrication. Because of its aesthetic appeal, it is used in decorative applications including: home hardware, architecture, and instruments. Brass benefits from high machinability, low friction, and corrosion resistance.
Stainless steel, like regular mild steel, is made of iron and carbon, but with the addition of chromium and nickel. Due to the extra chromium and nickel, stainless steel is also harder and work hardens as it bends. This means that stainless steel usually requires a press brake rather than bending by hand. Stainless steel, which uses chromium to protect against degradation, is used in medical and food processing equipment.
Galvanized steel, like stainless steel, is highly corrosion-resistant. This is because galvanized steel has a zinc coating. In addition to having an improved service life, galvanized steel components are lower cost than other forms of corrosion-protected steel.
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