Three-point bending is a newer process that uses a die with an adjustable-height bottom tool, moved by a servo motor. While coining can attain high precision, higher costs mean that it is not often used. Coining can produce an inside radius as low as 0.4 T, with a 5 T width of the V opening. In coining, the top tool forces the material into the bottom die with 5 to 30 times the force of air bending, causing permanent deformation through the sheet. In general, air bending is the preferred technique. A disadvantage is that a different tool set is needed for each bend angle, sheet thickness, and material. Advantages of bottoming include greater accuracy and less springback. Larger bend radii require about the same force for bottoming as they do for air bending, however, smaller radii require greater force-up to five times as much-than air bending. The bending radius must be at least 0.8 T to 2 T for sheet steel. The optimum width of the V opening is 6 T (T stands for material thickness) for sheets about 3 mm thick, up to about 12 T for 12 mm thick sheets. Space is left between the sheet and the bottom of the V opening. In bottoming, the sheet is forced against the V opening in the bottom tool. The K-factor approximations given below are more likely to be accurate for air bending than the other types of bending due to the lower forces involved in the forming process. Quality problems associated with this method are countered by angle-measuring systems, clamps and crowning systems adjustable along the x and y axes, and wear-resistant tools. The flexibility and relatively low tonnage required by air bending are helping to make it a popular choice. Bend radius is determined by material elasticity rather than tool shape. Īir bending does not require the bottom tool to have the same radius as the punch. ĭepending on material properties, the sheet may be overbent to compensate for springback. Springback depends on material properties, influencing the resulting bend angle. Angle accuracy is ensured by applying a value to the width of the V opening, ranging from 6 T (six times material thickness) for sheets to 3 mm thick to 12 T for sheets more than 10 mm thick. Īir bending's angle accuracy is approximately ☐.5 deg. Thus, the use of adequate process models is important. Variations in the thickness of the material and wear on the tools can result in defects in parts produced. #Edge blending calculator full#Ī disadvantage of air bending is that, because the sheet does not stay in full contact with the dies, it is not as precise as some other methods, and stroke depth must be kept very accurate. There are also fewer tool changes, thus, higher productivity. Different materials and thicknesses can be bent in varying bend angles, adding the advantage of flexibility to air bending. Some of the newer bottom tools are adjustable, so, by using a single set of top and bottom tools and varying press-stroke depth, different profiles and products can be produced. Because it requires less bend force, air bending tends to use smaller tools than other methods. The punch forms the bend so that the distance between the punch and the side wall of the V is greater than the material thickness (T).Įither a V-shaped or square opening may be used in the bottom die (dies are frequently referred to as tools or tooling). This bending method forms material by pressing a punch (also called the upper or top die) into the material, forcing it into a bottom V-die, which is mounted on the press. The other types of bending listed use specially designed tools or machines to perform the work. Note that some locations do not differentiate between the two different kinds of dies (punches and dies). Dies are usually stationary and located under the material on the bed of the machine. A die with a long rail form tool that has concave or V shaped lengthwise channel that locate the outside profile of the form is called a die. Punches are usually attached to the ram of the machine by clamps and move to produce the bending force. A die with a long rail form tool with a radiused tip that locates the inside profile of the bend is called a punch. The configuration of the tools for these three types of bending are nearly identical. These three are Air Bending, Bottoming and Coining. There are three basic types of bending on a press brake, each is defined by the relationship of the end tool position to the thickness of the material.
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