Sheet bending is a process in which sheet metal is bent into different shapes and angles using bending and pressing tools. This process is used to produce metal parts with different shapes and curves. Sheet bending is used in various industries such as automotive, metal, construction and electronic industries. In the sheet bending process, the metal sheet is first selected as the raw material. Then, using bending tools such as molds, drills and scissors, the metal sheet is bent at specific points. These tools can be operated manually or by skilled benders using bending machines.
What is the advantage of using sheet bending?
The advantage of using sheet bending in the production of metal parts is the possibility of producing parts with complex shapes and dimensions. Using the sheet bending process, parts with different curves, angles and unique shapes can be produced. Also, this process leads to an increase in the strength and hardness of metal parts. Sheet bending, as one of the main methods of metal forming, is widely used in the metalworking industry, and due to its many possibilities and capabilities, it is widely used in the production of various parts and products.
Types of sheet bending methods
Sheet bending is done in a variety of ways, and below we will name some of its common types for you:
Fixed radius bending
Fixed radius bending is one of the sheet bending methods in which the metal sheet is bent using a mold with a fixed radius. In this method, the metal sheet is regularly placed around the mold and bent to the desired shape using sheet bending tools. The main advantage of using constant radius bending is to produce parts with a uniform and constant bending radius. This method is especially suitable for the production of parts such as pipes, valves and parts that require bending with a fixed diameter or bending radius. Also, due to the simplicity and high accuracy of bending, this method is used in industries that produce parts with simple shapes and bending with a fixed radius.
To perform fixed radius bending, first the desired mold with a specific bending radius is prepared. Then the metal sheet is cut to the appropriate size and placed in the mold. By using bending tools such as crown bending, the sheet is bent into the desired shape. This method can be done manually or by using bending machines.
The most important factor in fixed radius bending is choosing the right bend radius. The choice of the bending radius should be made according to the thickness and mechanical properties of the metal sheet, the needs of the part and the intended use.
Variable radius bending
Variable radius bending is a sheet bending method in which the metal sheet is bent using a mold with a variable radius. In this method, the bend radius can be different for each point of the part, so that it is possible to produce bent parts with complex shapes and curves. The use of variable radius bending as an advanced bending method allows the production of parts with variable radius bending and complex bends. This method is especially used in the production of parts such as vane blades, car parts and parts that need to be bent with different curves and unique shapes.
To perform variable radius bending, first a mold or bending tool with the ability to change the radius is designed. Then the metal sheet is cut to the appropriate size and placed in the mold. By using sheet bending tools and radius control, the sheet is bent to the desired shape with variable radii. In this method, the amount of pressure and movement of the bending tool is controlled to obtain the desired bend radius at any point. The main advantage of variable radius bending is the ability to produce parts with complex curves and variable radii. This method allows for complex bends such as S and C curves and parts with unique shapes.
Multiple bend bending
Multi-point bending is one of the advanced sheet bending methods in which the metal sheet is bent at several points simultaneously. This method is used to produce bent parts with complex shapes and curves that include multiple and complex bends at different points of the part.
The use of multiple bend bending allows the production of parts with complex curves and multiple bends. This method is widely used to produce parts such as complex three-dimensional parts, bent parts with different curves, and parts of the aerospace industry.
To perform multiple bend bending, first a mold or bending tool with multiple bending capability is designed. Then the metal sheet is cut to the appropriate size and placed in the mold. By using sheet bending tools and parallel control of several points, the sheet is bent into the desired shape with different bending works and at different points. In this method, the amount of pressure and movement of the tools are controlled simultaneously to obtain multiple and complex bends in different parts of the piece. The main advantage of multi-bend bending is the ability to produce parts with complex and multiple bends.
bending bending
Press Brake Bending is one of the common and widely used methods in metal sheet bending. In this method, the metal sheet is bent by using bending molds (Press Brake) and by applying force and pressure. Bending means applying a vertical force to the sheet at the bending point and causing bending at that point.
Since it uses bending molds, bending bending makes it possible to produce parts with large bends and curvatures. This method is used to produce parts such as diagonal parts, arcs, specific protrusions and parts with large curves.
To carry out bending work, first a bending mold (Press Brake) is designed, which includes two upper and lower parts. The metal sheet is cut to the required length and placed between the two parts of the mold. Then, by using a press brake device and applying force and pressure to the sheet, bending occurs and the metal sheet is bent. In this method, force and pressure are applied vertically at the bending point and cause bending and deformation of the sheet. The main advantage of bending bending is the possibility of producing parts with large and precise bends and curves. Bending molds are adjustable, so you can adjust the shape and radius of the bend and easily produce parts with desired bends and curves.
Direct bending
Direct bending is one of the sheet bending methods in which the metal sheet is bent directly without using a mold or bending tool. In this method, the sheet metal is bent into the desired shape using direct bending tools, such as hand tools or sheet bending machines.
Direct bending is used as a quick and economical method for bending parts since it is done without using a bending die. This method is suitable for producing simple parts with basic bends and curves and parts that need bending with simple shapes.
To perform direct bending, first the metal sheet is cut to the desired length. The sheet metal is then bent into the desired shape using direct bending tools, such as spring bending, crown bending, or computer-aided bending (CNC) machines. This method can be done manually or using sheet bending machines.
The main advantage of direct bending is its speed and economy. In this method, there is no need to design and prepare a mold or a bending tool, and therefore, bent parts can be produced in less time and at a lower cost. Also, this method provides the possibility of bending parts in different dimensions and sizes.
Who is Khemkar Maher?
A skilled bender or a professional bender is a person with high experience and skill in the field of metal bending. A skilled bender is an expert who has the ability to bend metal parts accurately and according to the needs of customers. Skilled benders have a deep understanding of metal properties, different bending methods, sheet bending tools and machinery.
What are the duties of skilled benders?
Highly skilled benders have the following duties:
1. Reading and interpreting technical drawings and plans
Reading and interpreting technical drawings and plans is very important for skilled benders; Because the accurate and complete information in the drawings helps them to bend the parts correctly and with high precision. The skills required to read and interpret technical drawings and plans are as follows:
Knowledge of drawing elements: Skilled benders must be familiar with the various elements used in technical drawings and plans. This includes industry standard lines, symbols, symbols, scales, symbols and notations.
Reading Dimensions: Skilled benders must be able to read and interpret dimensions on drawings. It includes longitudinal dimensions, angular dimensions and diagonal dimensions. They should be able to use the scale on the map and determine the dimensions correctly.
Recognizing drawings and surfaces: In technical drawings and plans, information may be seen as three-dimensional drawings or surfaces. Skilled benders should be able to understand these drawings and levels well and bend parts according to them.
Understanding the materials and properties of metals: Skilled benders must be familiar with the various materials used in technical drawings and plans in order to perform metal bending work with high quality.
2. Adjusting and using bending machines
Setting up and using sheet metal bending machines is a key skill for skilled benders; Because bending machines provide high precision and the ability to perform complex bending operations. The steps of setting and using bending machines are as follows:
Adjusting the bending tool: First, you need to choose the right bending tool based on the needs of the part. Then place the tool correctly in the sheet bending machinery and set the axes and coefficients necessary to perform the bending operation.
Adjusting machine parameters: sheet bending machines usually have adjustable parameters such as speed, pressure, time and bending angle. You must set these parameters correctly so that the bending operation is done accurately and optimally.
Examining and preparing technical drawings and plans: Before starting to bend the sheet, read the related technical drawings and plans carefully. Make sure you understand exactly what kind of bending is to be done and where on the part.
Safety and protection settings: Before starting to use sheet metal bending machines, make sure that all safety and protection settings are applied.
3. Selection and use of bending tools
Choosing and using the correct bending tools is very important for skilled benders. Suitable bending tools make the bending of parts more accurate and efficient. The steps of choosing and using bending tools are as follows:
Knowing the type of part: First, you should carefully examine the part you are going to bend. Knowing the material of the part (such as metal, plastic, etc.) and its structure will help you choose the right bending tool.
Selection of bending tool: After knowing the part, you must choose the right bending tool to perform the bending operation. This includes dies, dies, crowns, springs and other sheet metal bending tools. The tool must be precisely adapted to the required size and shape of the part.
Adjusting the bending tool: Before starting to use the sheet bending tool, you need to adjust it properly. This includes setting the appropriate angle, distance and pressure for bending. Additionally, you should make sure that the tool is properly secured and stable.
Use of bending tool: according to the drawing and technical plan of the part, use the bending tool on the part with precision and proper technique.
4. Quality control and measurement
Quality control and measurement in the bending industry is very important to ensure the precision and accuracy of the bent parts. This process is carried out in order to ensure the compliance of parts with specified standards as well as quality control and measurement. The steps of quality control and measurement in the bending industry are as follows:
Dimension check: The dimensions of the bent pieces should be checked using suitable measuring tools with precision and accuracy. Tools such as rulers, arrows, calipers and micrometers are used.
Bending angle measurement: In some cases, bending angles are also measured. This includes the use of protractors and protractors.
Checking the surface quality: The surface quality of bent parts is also checked. Tools such as microscopes and light meters are used to identify defects and defects on the surface of the parts.
Non-destructive tests: Some bent parts are used to ensure the quality and accuracy of their internal structure, non-destructive tests such as permeability test, ultrasonic test and radiographic imaging test.
What is a press brake tool?
The brake press tool is one of the tools used in the sheet bending industry. This tool is used to create bending or crowning in sheets and plate parts. The brake press consists of a matrix and a punch. The matrix in the press brake tool is a fixed template in which the desired shape is placed. The matrix can be a direct die or a crown die. A straight die is used to create a uniform bend in the sheet, while a crown die is used to create bends of different shapes and with more detail.
The punch is a needle-like piece that is placed on top of the matrix. By using the compressive force, the punch is pressed against the sheet and as a result, bending is created in the sheet. The shape of the punch can be different depending on the need and the shape of the desired bend.
To use the break press tool, first the desired sheet is placed between the matrix and the punch. Then, using a press machine, pressing force is applied to press the punch to the sheet and create a bend in the sheet. The force, time and speed of the press are different according to the standards set for each type of sheet and product.
The brake press tool is used in the sheet bending industry to produce parts with various and accurate bends.
How is the press brake service performed by the BEYELER brake machine?
Beyeler brake machine is one of the famous brake press machines in sheet bending industry. This machine is produced and supplied by Beyeler company and uses advanced technology to create bends in the sheets. The Beyeler brake machine has the ability to perform various bends with high precision.
Press brake services using a Beyeler brake machine are generally provided by workshops and bending companies. These services include the following:
1. Bending of various parts
The Beyeler bending machine is capable of bending and crowning different parts with the desired shape and dimensions. This includes bending industrial parts, automotive parts, machinery parts and other metal parts.
2. Crown production with different shapes
The production of crowns with different shapes is one of the other capabilities of the Beyeler brake machine. This includes crowning with curved, spherical, conical and other shapes.
3. Sheet bending with high precision
By using the Beyeler brake machine, it is possible to bend the parts with high precision and with strict control over the bending dimensions and angles. This is very important for the production of parts that require high precision in dimensions and shape.
4. Mass production of parts
The Beyeler brake machine is suitable for mass production of parts using molds and matrices. This allows manufacturers to produce large quantities of parts at high speed and with excellent quality.
Conclusion
Sheet bending is one of the important methods in the metalworking industry, where skilled benders can turn metal sheets into the desired shape and bend by means of a sheet bending tool. This process is very important in the production of metal parts; Because by using sheet bending, parts with different shapes and precise dimensions can be produced.