Technology Traits for Bending Efficiency

A fabricator can minimize processing steps, reduce scrap and process parts faster simply by adding valuable features in the part design. Luckily, these feature-rich designs are an easier reality for today’s manufacturers’ thanks to advancements in press brakes and supporting technologies.

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Machine features can be used to decrease the number of set-ups needed to bend complex parts.

Machine features, programming software and tool availability all play a pivotal role in how efficiently, accurately and cost-effectively the final product is produced.

Many times fabricators claim, “I don’t need that feature on a machine.” “Our parts do not require that tooling,” or, “We program everything at the controller.” These statements may be said in truth, but often it is because the company had to pass up the opportunity to process that higher-level part because they lacked manufacturing capabilities needed for the job.

With the capacity for these services, new opportunities appear which generates future growth and stability. The “leaner” you manufacture a part, the greater the justification to purchase a machine with features that encompass this level of performance. Here, the machine, tooling and programming will provide the greatest advantages in productivity.

The Machine:
Machine features can be used to decrease the number of set-ups needed to bend complex parts. With lower tool displacement, for example, multiple set-ups are condensed to one, greatly reducing cost per part. Part features such as hems, lock-seams, offsets (jogs), large radius single-hit bends and hinges can all benefit from a machine with a shiftable die bed.

For example, the clasped hem (Figure 1) incorporates both air bending and hemming, yet is achieved with a single set-up on the machine. This minimizes tool changeovers since standard and custom tools can be loaded in the machine within the same set-up, helps alleviate operator fatigue throughout the workday, limits incorrect tool placement, drastically reduces program times and grants the ability to run more programs per day.

Combined, the benefits guarantee a more profitable workplace and a higher standard product for the customer.

The tooling:
The right tooling can turn dreadful jobs into shop floor favorites. Feature-specific tooling lets programmers and operators standardize the production process. The result is a repeatable, quality part. For example, when creating a hinge form (Figure 2) the greatest challenges are to determine how the material will interact with the tool, and the location of the first bend.

Almost all hinges are formed in a three-step process (Figure 3) and the first bend is crucial because it dictates the accuracy of the entire part. The tool options will vary depending on the features of your machine. Certain hinge tooling uses lower tool displacement, as mentioned above, while others are designed for a standard die bed. The tooling may also vary based on the range of material thickness and the diameters needed for the part.

In addition, some tooling is designed with a focus on highly cosmetic forms however they often limit the range of applications that are possible. Regardless of the tool style chosen, a digital copy of the tool, a machine control that can handle the tool’s parameters and knowing where key points of that tool are located will help ensure successful completion of the part.

The programming:
Offline programming software is the key component between a great design and a quality product. Software affords the opportunity to “see” what is going to happen before it actually happens. It also allows the programmer to “process” a fabricated part before it even touches the shop floor.

In this way, bend sequences can be proven without the time-consuming process of cutting and testing blanks as is usually required when preparing for complex programs at the machine. In addition, a programmer can caution the operator of bends that may have pinch points before an injury occurs at the machine, which can prove priceless.

Software can also be used as a quoting tool for the company. Program run times, tooling needs, and even machine requirements can be determined for more accurate job quoting. Above all, one of the greatest attributes of offline software is that programming and production processes can function simultaneously, maximizing machine runtime and productivity.

Since programming takes place on a computer, the machine is available for an operator to run production on the shop floor. The result is clear: Increased run time means greater profit. There are many resources and options available in the forming world today. If a manufacturer can capitalize on those opportunities, benefits will appear across all aspects of the manufacturing processes.

The machines, software and tooling choices are available and can be matched to your wants and needs, whether you decide to focus on the product trends that cross your manufacturing floor, or rather to put yourself in the best position to encompass all capabilities. The first step to propelling your production to the next level is simply to know and learn about the technology that is available.