Sheet metal bending is a standard method to convert sheets into different shapes, angles, and curves with the application of force. This process has been going on since ancient times, and now, it has technological advancements with the passage of time.
One important factor of this process is that it does not affect the surface finish, strength, or toughness of the material. In the modern era, a variety of methods are used to perform bending, such as U bending, roll bending, and rotary bending, which are very suitable for specific applications.
This article will cover some of the most commonly used bending methods and their applications.
Sheet metal air bending is one of the most prevalent sheet metal bending methods. The basic idea is to shape-force the surface of a workpiece into a V, U, or whatever else you can imagine. In this method a strong tool required that can punch through metal.
The tips of these tools and the die shoulders might be different from one another. The ultimate shape of a sheet metal workpiece is formed by these components. The most important thing is that the curved piece of metal does not come into contact with the die’s walls.
This strategy is very versatile since it allows you to create multiple angles with the same tool combinations. A wide variety of bends at varying degrees are required for general manufacturing. Creating prototypes and performing simple procedures that do not require the dies to be changed.
2.Bottoming/Bottom Bending
Another method is the bottom bending, combining a punch with a v-shaped bottom die within a brake press. Basically, the punching tool compacts the sheet metal all the way to the die bottom so that a bend takes on the shape of die selecting the correct die: Each bend angle requires selecting a different die.
However this method requires a different bottom die for every possible bend radius and the process needs higher press forces.
Commonly used bottom bending:
The sectors, with a high precision demand like aerospace and automotive manufacturing, manufacture these parts and components.
In mass production environments, repetitive processes need to be done accurately and consistently.
When exact measurements need to be taken for your components.
3.Coining
A considerable punching force that is more than the sheet’s yield strength is applied to a metal sheet when it is being pressed through a die. This causes the metal sheet to be pressed into the die, which brings the cavity to its full capacity.
The method is based on the principle of applying up to thirty times the amount of pressure that is applied during air-bending to the bottom dies in order to force a sheet of metal into this way. Some applications of coining are given below:
- Producing components for aviation and automobiles that require a high level of precision parts.
- In order to manufacture electrical connections and other components
- Producing medical instruments and equipment that are not only precise but also of excellent quality
4.Folding
Folding, as the name suggests, involves precisely bending workpieces at an angle. The process requires the use of a clamping beam tool to position and hold a metal sheet in order to perform the function properly.
The material is then folded as a result of this specific process, which involves swinging an object around a pivot point.
Manufacturing components that are utilized in the construction and architectural components of buildings, such as roofing panels. Constructing cabinet and enclosure panels.
5.Hemming/Flattening
In order to enhance the results of prior bending operations, you employ flattening as a supportive method. Flattening, for instance, is a technique that may be utilized to smooth out a fold. You can find yourself in this situation when you wish to do numerous folding procedures.
Typically, this technique is utilized to make the edges of enclosures, door panels, and car parts even. The process of flattening seams is often produced by connecting a pair of metal sheets together.
6.Joggling/Joggle Bending
Segmented bending, or joggling, shapes sheet metal sections with stringers and formers. The method is useful for bending long workpieces repeatedly.
The procedure involves forcing a sheet metal workpiece through an equipment unit. Formers bend metal 20°–30°. Release, flip, and bend the portion again.
This method is frequently utilized:
In the process of fabricating airplanes and making flush seams and overlap frames.
The automobile, panel manufacturing and construction industries.
In the construction industry, including roofing and siding, the goal is to prevent leaks from occurring.
7.Roll Bending
With the use of the roll-bending process, sheet metals may be bent into rolls, tubes, cones, or curved forms. In this sheet metal forming process, rollers feed and bend metal stock to the appropriate curvature.
Roll bending is commonly used in the production of plumbing and architecture materials such as tubes and pipes. Architectural decorations and window frames. Ship and aircraft fuselage construction.
8.Rotary Bending
The rotary bending technique is a complicated method that can make pipes with a wide variety of center-line radiuses.
This technique is based on the bending of a tube using an inside mandrel to match the precise outer diameter.
An interior, solid support keeps a tube from collapsing while it is propelled forward and continuously rotated by a rotary die. The approach is flexible.
A tube may be rotated at 180° maximum. This method is applied in the automotive, aerospace, architectural, and electronics industries.
9.Three-Point Bending
When compared to other methods, three-point bending facilitates the creation of bends that are extremely precise by the application of controlled force, resulting in a bigger radius.
Utilizes a press brake or a three-point bending machine, together with a punch and a pair of variable supporting anvils.
This particular technique is applied in a variety of sectors, including the aerospace, automobile, fabrication, and construction industries.
10.U-Bending
With U-bending, you can shape metal sheets into U-shapes by arranging them with parallel sides and a curved base in a certain way.
In U-bending, the tools needed to perform the press are a U-shaped die, a punch, and a press brake.
The u-bending method is utilized by a variety of sectors, including the preparation of supports for structural components.
Manufacturing components for automobiles, such as brackets and channels, etc. Creating enclosures for electrical components through fabrication. Creating components of furniture such as supports.
11.Wipe Bending/Wiping
The wipe bending technique uses a pressure pad to hold the sheet metal against a wipe die. The punch then pushes on the edge of the sheet that extends over the die and pressure pad, forcing it to bend over the end of the die.
This approach provides a mechanical advantage, requiring less force to achieve desired bends.
Wipe bending is generally used in making electrical components, automotive components, refrigerators, and microwave components.
Conclusion
The importance of sheet metal components can be gauged from the way sheet metal components are being widely used in industries. After reading this guide, you can easily choose a more suitable method for your product. If you want to learn about sheet metal bending products, feel free to contact us. Our experienced staff is always ready to guide you through the process of bending.
