Professional Documents
Culture Documents
Automatic Bending Machine Report-1
Automatic Bending Machine Report-1
processes that shape a piece of sheet metal into the desired part through
piece of metal much thinner is considered to be "foil" and any thicker is referred to as
a "plate". The thickness of a piece of sheet metal is often referred to as its gauge, a
number typically ranging from 3 to 38. A higher gauge indicates a thinner piece of
sheet metal, with exact dimensions that depend on the material. Sheet metal stock is
Aluminum
Stainless steel
Brass
Steel
Bronze
Tin
Copper
Titanium
Magnesium
Zinc
Nickel
Sheet metal can be cut, bent, and stretched into a nearly any shape.
1
geometric shape. Deformation processes can bend the sheet numerous
The size of sheet metal parts can range from a small washer or bracket, to
the applied force causes the material to plastically deform, but not to fail.
Such processes are able to bend or stretch the sheet into the desired
shape. Cutting processes are those in which the applied force causes the
Forming
Bending
Roll forming
2
Spinning
Deep Drawing
Stretch forming
Shearing
Blanking
Bending
Plasma cutting
to a piece of sheet metal to modify its geometry rather than remove any
material. The applied force stresses the metal beyond its yield strength,
causing the material to plastically deform, but not to fail. By doing so,
the sheet can be bent or stretched into a variety of complex shapes. Sheet
piece of sheet metal, causing it to bend at an angle and form the desired
3
complex part. Bent parts can be quite small, such as a bracket, or up to 20
which the sheet metal stock is fed through a series of roll stations. Each
the sheet. The shape and size of the roller die may be unique to that
The roller dies may be above and below the sheet, along the sides, at an
angle, etc. As the sheet is forced through the roller dies in each roll
station, it plastically deforms and bends. Each roll station performs one
stage in the complete bending of the sheet to form the desired part. The
roller dies are lubricated to reduce friction between the die and the sheet,
thus reducing the tool wear. Also, lubricant can allow for a higher
number of roll stations, and radius of each bend. The roll forming line
4
can also include other sheet metal fabrication operations before or after
The roll forming process can be used to form a sheet into a wide
closed tube-like shape can be created as well. Because the final form is
achieved through a series of bends, the part does not require a uniform or
very long sheet metal parts with typical widths of 1-20 inches and
5
be formed, some up to 5 ft. wide and 0.25 inches thick. The roll forming
inches. Typical roll formed parts include panels, tracks, shelving, etc.
1.2 SPINNING
while forces are applied to one side. A sheet metal disc is rotated at high
speeds while rollers press the sheet against a tool, called a mandrel, to
form the shape of the desired part. Spun metal parts have a rotationally
requires a blank, mandrel, and roller tool. The blank is the disc-shaped
piece of sheet metal that is pre-cut from sheet stock and will be formed
into the part. The mandrel is a solid form of the internal shape of the part,
against which the blank will be pressed. For more complex parts, such as
6
those with reentrant surfaces, multi-piece mandrels can be used. Because
the mandrel does not experience much wear in this process, it can be
utilizes a metal mandrel. The mandrel and blank are clamped together
and secured between the headstock and tailstock of the lathe to be rotated
at high speeds by the spindle. While the blank and mandrel rotate, force
is applied to the sheet by a tool, causing the sheet to bend and form
around the mandrel. The tool may make several passes to complete the
lever. Rollers are available in different diameters and thicknesses and are
usually made from steel or brass. The rollers are inexpensive and
7
Fig. 1.2 Spinning Lathe
roller tool pushes against the blank until it conforms to the contour of the
mandrel. The resulting spun part will have a diameter smaller than the
blank, but will maintain a constant thickness. In shear spinning, the roller
not only bends the blank against the mandrel, it also applies a downward
force while it moves, stretching the material over the mandrel. By doing
so, the outer diameter of the spun part will remain equal to the original
blank diameter, but the thickness of the part walls will be thinner.
8
Fig. 1.3 Conventional Spinning vs. Shear Spinning
stretched into the desired part shape. A tool pushes downward on the
sheet metal, forcing it into a die cavity in the shape of the desired part.
The tensile forces applied to the sheet cause it to plastically deform into a
more than half of the diameter of the part. These parts can have a variety
effective with ductile metals, such as aluminum, brass, copper, and mild
9
steel. Examples of parts formed with deep drawing include automotive
bodies and fuel tanks, cans, cups, kitchen sinks, and pots and pans.
and die. The blank is a piece of sheet metal, typically a disc or rectangle,
which is pre-cut from stock material and will be formed into the part. The
blank is clamped down by the blank holder over the die, which has a
cavity in the external shape of the part. A tool called a punch moves
downward into the blank and draws, or stretches, the material into the die
apply enough force to the blank. Both the die and punch experience wear
from the forces applied to the sheet metal and are therefore made from
tool steel or carbon steel. The process of drawing the part sometimes
punch forces the part into a different die, stretching the part to a greater
depth each time. After a part is completely drawn, the punch and blank
holder can be raised and the part removed from the die. The portion of
the sheet metal that was clamped under the blank holder may form a
10
Fig. 1.4 Deep Drawing
11
1.4 STRETCH FORMING
press, in which a piece of sheet metal is securely gripped along its edges
by gripping jaws. The gripping jaws are each attached to a carriage that is
used in this process is a stretch form block, called a form die, which is a
solid contoured piece against which the sheet metal will be pressed. The
most common stretch presses are oriented vertically, in which the form
die rests on a press table that can be raised into the sheet by a hydraulic
ram. As the form die is driven into the sheet, which is gripped tightly at
its edges, the tensile forces increase and the sheet plastically deforms into
a new shape. Horizontal stretch presses mount the form die sideways on
a stationary press table, while the gripping jaws pull the sheet
12
Fig. 1.6 Stretch Forming
Stretch formed parts are typically large and possess large radius
bends. The shapes that can be produced vary from a simple curved
capable of shaping parts with very high accuracy and smooth surfaces.
aluminum, steel, and titanium. Typical stretch formed parts are large
enclosures.
13
Capabilities
Typical Feasible
Shapes: Flat
Thin-walled: Cylindrical Thin-walled: Complex
Thin-walled: Cubic
Part size: Area: Up to 80 ft
Weight: 0.5 oz - 100 lb
Materials: Metals Lead
Alloy Steel Magnesium
Carbon Steel Nickel
Stainless Steel Tin
Aluminum Titanium
Copper Zinc
Surface finish - 32 - 125 in 16 - 250 in
Ra:
Tolerance: 0.01 in. 0.002 in.
Max wall 0.08 - 0.5 in. 0.001 - 1.0 in.
thickness:
Quantity: 1000 - 100000 1 - 1000000
Lead time: Weeks H
Advantages:ur Can form complex shapes
s Many material options
High production rate
Low labor cost
Short lead time possible
Disadvantages: Limited to constant part thickness
Part may require several operations and machines
Large amount of scrap
Applications: Brackets, panels, cans, utensils
Table 1.1 Capabilities
14
Cutting processes are those in which a piece of sheet metal is
processes. When a great enough shearing force is applied, the shear stress
in the material will exceed the ultimate shear strength and the material
will fail and separate at the cut location. This shearing force is applied by
two tools, one above and one below the sheet. Whether these tools are a
punch and die or upper and lower blades, the tool above the sheet
delivers a quick downward blow to the sheet metal that rests over the
lower tool. A small clearance is present between the edges of the upper
and lower tools, which facilitates the fracture of the material. The size of
upon several factors, such as the specific shearing process, material, and
sheet thickness.
progresses and are visible on the edge of the sheared material. When the
punch or blade impacts the sheet, the clearance between the tools allows
the sheet to plastically deform and "rollover" the edge. As the tool
15
penetrates the sheet further, the shearing results in a vertical burnished
zone of material. Finally, the shear stress is too great and the material
fractures at an angle with a small burr formed at the edge. The height of
each of these portions of the cut depends on several factors, including the
Sheared edge
open path to separate a portion of material and some with a closed path to
16
cutout and remove that material. By using many of these processes
together, sheet metal parts can be fabricated with cutouts and profiles of
Conventional blanking
Fine blanking
Piercing
Slotting
Perforating
Notching
Nibbling
Lancing
Slitting
Parting
Cutoff
Trimming
Shaving
Dinking
17
Shearing
shearing force to cut sheet metal. However, the term "shearing" by itself
sheet parallel to an existing edge which is held square, but angled cuts
can be made as well. For this reason, shearing is primarily used to cut
sheet stock into smaller sizes in preparation for other processes. Shearing
a squaring shear or power shear, that can be operated manually (by hand
machine includes a table with support arms to hold the sheet, stops or
guides to secure the sheet, upper and lower straight-edge blades, and a
18
between the upper and lower blade, which are then forced together
against the sheet, cutting the material. In most devices, the lower blade
remains stationary while the upper blade is forced downward. The upper
blade is slightly offset from the lower blade, approximately 5-10% of the
sheet thickness. Also, the upper blade is usually angled so that the cut
progresses from one end to the other, thus reducing the required force.
The blades used in these machines typically have a square edge rather
19
Shearing
Blanking
shearing force. In this process, the piece removed, called the blank, is not
scrap but rather the desired part. Blanking can be used to cutout parts in
almost any 2D shape, but is most commonly used to cut workpieces with
Often times multiple sheets are blanked in a single operation. Final parts
20
that are produced using blanking include gears, jewelry, and watch or
blanking punch, and blanking die. The sheet metal stock is placed over
the die in the blanking press. The die, instead of having a cavity, has a
cutout in the shape of the desired part and must be custom made unless a
standard shape is being formed. Above the sheet, resides the blanking
punch which is a tool in the shape of the desired part. Both the die and
punch are typically made from tool steel or carbide. The hydraulic press
drives the punch downward at high speed into the sheet. A small
punch and die. When the punch impacts the sheet, the metal in this
clearance quickly bends and then fractures. The blank which has been
sheared from the stock now falls freely into the gap in the die. This
21
Blanking
Fine blanking
22
quality parts can be blanked that do not require any secondary operations.
However, the additional equipment and tooling does add to the initial
cost and makes fine blanking better suited to high volume production.
conventional blanking. The sheet stock is still placed over a blanking die
inside a hydraulic press and a blanking punch will impact the sheet to
3 forces. The first is a downward holding force applied to the top of the
sheet. A clamping system holds a guide plate tightly against the sheet and
that surrounds the perimeter of the blanking location. The second force is
later ejects the blank. These two forces reduce bending of the sheet and
improve the flatness of the blank. The final force is provided by the
blanking punch impacting the sheet and shearing the blank into the die
opening. In fine blanking, the clearance between the punch and the die is
23
speeds. As a result, instead of the material fracturing to free the blank, the
blank flows and is extruded from the sheet, providing a smoother edge.
Fine blanking
Punching
called the slug, is scrap and leaves behind the desired internal feature in
the sheet, such as a hole or slot. Bendingcan be used to produce holes and
24
cutouts of various shapes and sizes. The most common punched holes are
thereof. The edges of these punched features will have some burrs from
punch, and die. The sheet metal stock is positioned between the punch
and die inside the punch press. The die, located underneath the sheet, has
a cutout in the shape of the desired feature. Above the sheet, the press
holds the punch, which is a tool in the shape of the desired feature.
Punches and dies of standard shapes are typically used, but custom
standard or custom, is usually made from tool steel or carbide. The punch
press drives the punch downward at high speed through the sheet and
into the die below. There is a small clearance between the edge of the
punch and the die, causing the material to quickly bend and fracture. The
slug that is punched out of the sheet falls freely through the tapered
press, but today computer numerical controlled (CNC) punch presses are
25
or electrically powered and deliver around 600 punches per minute. Also,
many CNC punch presses utilize a turret that can hold up to 100 different
Punching
tool pierces the sheet metal, forming a single hole. However, a variety of
26
Piercing - The typical punching
operation.
the punch.
feature.
27
Lancing - Creating a partial cut in the
between parts.
angled, or curved.
28
Shaving - Shearing away minimal
metal.
sheet metal. A cornice brake only allows for simple bends and creases,
while a box-and-pan brake also allows one to form box and pan shapes. [1]
29
Description
placed, and a clamping bar which will come down and hold the material
firmly during the bend. This clamping action may be manual, automatic
or operated using a foot pedal. The front, gate-like, plate of the machine
is hinged and may be lifted, forcing the material extended over a straight
degrees, somewhat more in the case of a bar folder. If the area to be bent
inserting the bend under the clamping bar and lowering it.
Cornice Brake
A cornice brake has a solid clamping bar, the full width of the
machine; thus, it can only make straight bends, the entire width of the
workpiece.
Box-and-Pan Brake
30
bending of restricted areas of a piece of sheet metal or of already
Bar Folder
workpiece and makes the bend, in a single motion, but the depth is
usually much less than what a cornice or box-and-pan brake can handle.
Press brake
Sizes of brakes
Brakes come in sizes suitable for light aluminum or brass for small
31
CHAPTER 2
Construction
mechanical or hydraulic)
The type of tool shop and its capacity (e.g., store revolving type,
capacity 34 tool)
32
Speed of movement without shock (speed-load displacement)
Safety features
Power consumption
To reduce manpower
Less Maintenance
33
CHAPTER 3
BENDING MECHANISM
34
3.1 BENDING DIAGRAM
Bend line - The straight line on the surface of the sheet, on either
side of the bend, that defines the end of the level flange and the
Outside mold line - The straight line where the outside surfaces of
the two flanges would meet, were they to continue. This line
defines the edge of a mold that would bound the bent sheet metal.
Mold line distance - The distance from either end of the sheet to
Setback - The distance from either bend line to the outside mold
line. Also equal to the difference between the mold line distance
Bend axis - The straight line that defines the center around which
Bend length - The length of the bend, measured along the bend
axis.
35
Bend radius - The distance from the bend axis to the inside surface
inside bend radius. The outside bend radius is equal to the inside
Bend angle - The angle of the bend, measured between the bent
sheet metal. The outside portion of the sheet will undergo tension and
compression and shortens. The neutral axis is the boundary line inside
present. As a result, the length of this axis remains constant. The changes
in length to the outside and inside surfaces can be related to the original
flat length by two parameters, the bend allowance and bend deduction,
36
Fig. 3.2 Neutral Axis
Neutral axis - The location in the sheet that is neither stretched nor
operation, bend angle, etc.) and is typically greater than 0.25, but
37
Bend allowance - The length of the neutral axis between the bend
lines, or in other words, the arc length of the bend. The bend
length.
the difference between the mold line lengths and the total flat
length.
material will cause the sheet to spring back slightly after the bending
sheet a precise amount to achieve the desired bend radius and bend angle.
The final bend radius will be greater than initially formed and the final
bend angle will be smaller. The ratio of the final bend angle to the initial
38
Fig. 3.4 Springback
to best suit the given application. A press brake contains an upper tool
called the punch and a lower tool called the die, between which the sheet
metal is located. The sheet is carefully positioned over the die and held in
place by the back gauge while the punch lowers and forces the sheet to
bend. In an automatic machine, the punch is forced into the sheet under
39
the depth to which the punch forces the sheet into the die. This depth is
used for the punch and die, allowing a low initial cost and suitability for
bending operations but will add to the cost. The tooling material is
chosen based upon the production quantity, sheet metal material, and
40
Press Brake (Open)
41
While using a press brake and standard die sets, there are still a
variety of techniques that can be used to bend the sheet. The most
common method is known as V-bending, in which the punch and die are
"V" shaped. The punch pushes the sheet into the "V" shaped groove in
the V-die, causing it to bend. If the punch does not force the sheet to the
bottom of the die cavity, leaving space or air underneath, it is called "air
bending". As a result, the V-groove must have a sharper angle than the
angle being formed in the sheet. If the punch forces the sheet to the
for more control over the angle because there is less springback.
the sheet thickness. This value is referred to as the die ratio and is equal
42
V Bending
sheet to be held against the wipe die by a pressure pad. The punch then
presses against the edge of the sheet that extends beyond the die and pad.
The sheet will bend against the radius of the edge of the wipe die.
43
Wipe Bending
Design rules
material is present, and preferably with straight edges, for the sheet to be
Bend radius
tooling or setups
44
Bend direction - Bending hard metals parallel to the rolling
bend may be distorted. The distance of such features from the bend
should be equal to at least 3 times the sheet thickness plus the bending
radius.
can be cut along the bend line to reduce the manual force required.
45
CHAPTER 4
various diameter
depending on the type of clutch or braking system with which they are
require a full revolution of the crankshaft for them to come to a stop. This
"dogs" to fall into matching slots to stop the ram. A full revolution clutch
can only bring the ram to a stop at the same location- top dead center.
Newer presses are often "part revolution" presses equipped with braking
When the stopping mechanism is applied the air is bled, causing the
46
clutch to open and the braking system to close, stopping the ram in any
cylinder rather than a flywheel, and are either valve controlled or valve
allows greater control over the stroke of the ram, and increases
stroke up and down but can operate within a very short window of stroke.
the table along the X and the Y axis to a desired position. Once in
position, the control initiates the Bending sequence and pushes the ram
from top dead center (TDC) to bottom dead center (BDC) through the
material plane. (The terms BDC and TDC go back to older presses with
47
pneumatic or hydraulic clutches. On today's machines BDC/TDC do not
actually exist but are still used for the bottom and top of a stroke).
On its stroke from TDC to BDC, the punch enters the material,
pushing it through the die, obtaining the shape determined by the design
of the punch and die set. The piece of material (slug) cut from the
workpiece is ejected through the die and bolster plate and collected in a
scrap container.[1] The return to TDC signals to the control to begin the
next cycle.
48
CHAPTER 5
BENDING TOOLS
"V" Bending
"L" Bending
"U" Bending
V Bending Dies
V Bending dies have the simplest bending die design. The bending
die have the shape of V with an included angle of 90 in most cases. The
bending punch is also in the shape of V, but with a lesser angle than the
die. And in some cases the bending punches may have a relief after a
straight land to a certain length.
49
L Bending Dies
is due to the presence of spring loaded clamping pads which will hold
sheet metal closer to the bending line and then the bending punch pushes
the sheet metal into the bending die along the bending line. L bending
dies can also be used for bending angles smaller than 90 by providing
Die components
Die block - This is the main part that all the other parts are
attached to.
Punch plate - This part holds and supports the different punches in
place.
Blank punch - This part along with the Bending Die produces the
curved part.
50
Stripper plate - This is used to hold the material down on the
Blank/ Pierce Die and strip the material off the punches.
position.
Guide / Back gage / Finger stop - These parts are all use to make
sure that the material being worked on always goes in the same
Setting Block - This part is used to control the depth that the punch
Die operations are often named after the specific type of die that
a bending die. Operations are not limited to one specific die as some dies
Bending
51
forming operation and a bending operation is the bending operation
operation may create a curved bend (such as the bottom of a drink can).
Blanking
Generally a blanking die may only cut the outside contour of a part, often
amount of clearance between the punch and die, will produce a part that
process, the end result is a flat part that may retain a specific level of
52
Broaching
cutting teeth, with each tooth cutting behind the other. A broaching die is
often used to remove material from parts that are too thick for shaving.
Bulging
A bulging die expands the closed end of tube through the use of
two types of bulging dies. Similar to the way a chefs hat bulges out at the
the part.
Coining
coining die may form completely different features on either face of the
blank, these features being transferred from the face of the punch or die
respectively. The coining die and punch flow the metal by squeezing the
blank within a confined area, instead of bending the blank. For example:
an Olympic medal that was formed from a coining die may have a flat
53
surface on the back and a raised feature on the front. If the medal was
formed (or embossed), the surface on the back would be the reverse
Compound operations:
Compound die:
A type of die that has the die block (matrix) mounted on a punch
plate with perforators in the upper die with the inner punch mounted in
the lower die set. An inverted type of blanking die that punches upwards,
leaving the part sitting on the lower punch (after being shed from the
upper matrix on the press return stroke) instead of blanking the part
through. A compound die allows the cutting of internal and external part
Curling: The curling operation is used to roll the material into a curved
54
Cut off: Cut off dies are used to cut off excess material from a finished
additional operations.
dies use extremely high pressure from the punch to squeeze the metal out
into the desired form. The difference between cold forming and extrusion
that it squeezes the blank material but cold forming uses the punch and
55
Roll forming: a continuous bending operation in which
sheet or strip metal is gradually formed in tandem sets of rollers until the
only perform one simple procedure with the finished product being
removed by hand.
stampings.
56
Shaving: The shaving operation removes a small amount of
material from the edges of the part to improve the edges finish or part
Side cam die: Side cams transform vertical motion from the
reduces the size of the part. The end of a shell casing that captures the
irregular features from a part, they are usually the last operation
performed.
Steel-rule die
cut sheet metal and softer webs, such as plastics, wood, cork, felt, fabrics,
and cardboard. The cutting surface of the die is the edge of hardened
steel strips, known as steel rule. These steel rules are usually located
57
using saw-cut grooves in plywood. The mating die can be a flat pieces of
can have a matching groove that allows the rule to nest into. Rubber
strips are wedged in with the steel rule to act as the stripper plate; the
workpiece out of the die. The main advantage of steel-rule dies is the low
cost to make them, as compared to solid dies; however, they are not as
robust as solid dies, so they usually only used for short production runs.
Rotary die
In the broadest sense, a rotary die is a circular shaped die that may
circular shaped dies used to process soft webs, such as paper and
cardboard. Two dies are used, one has cutting and creasing rules, while
the other acts as the anvil. Rotary dies are faster than flat dies, but not as
accurate.
Wire pulling
or rod of steel, copper, other metals, or alloy enters into one side and is
lubricated and reduced in size. The leading tip of the wire is usually
58
pointed in the process. The tip of the wire is then guided into the die and
rolled onto a block on the opposite side. The block provides the power to
entrance angle that guides the wire into the die. Next is the approach
angle, which brings the wire to the nib, which facilitates the reduction.
Next is the bearing and the back relief. Lubrication is added at the
entrance angle. The lube can be in powdered soap form. If the lubricant is
soap, the friction of the drawing of wire heats the soap to liquid form and
coats the wire. The wire should never actually come in contact with the
die. A thin coat of lubricant should prevent the metal to metal contact.
which the wire had been pulled. Thus, a higher-numbered wire gauge
meant a thinner wire. Typical telephone wires were 22-gauge, while main
59
CHAPTER 6
BLOCK DIAGRAM
Power
Work piece in
Ac mptor Rack and Extension opposite
pinion rod with direction to bend
bend tool
Bending
Finished job
60
CHAPTER 6
CONSTRUCTIONAL DETAILS
61
CHAPTER - 7
62
CHAPTER 8
WORKING PRINCIPLE
is provided. At one end of the lead screw handle of the Bending tool is
attached. Another tools is fixed on the based plate. The Bending machine
consists of a base plate in which the work piece is placed. When the
handle is rotated the lead screw moves down and the bending tool press
the sheet and the sheet metal is bended. Different size & shape of the
consists of an electric motor and a frame with lead screw. The sheet is
fitted in the vice. When the motor switched gets on the rotary motion of
lead screw arrangement. A bending tool is attached at the end of the lead
63
CHAPTER 9
bending defects.
Verify the clearance between bending punch and die. There should
64
Provide adequate bending radius and polish it to high surface
important to have very good surface finish at this area for smooth
flowing of material.
the bending line to overcome spring back. Please note that corner
setting may not be possible on very think sheet materials and sheet
Bend radius
Material factor
Material Factor
Material thickness
Shear factor
65
The face of the punch tip
Die Clearance
CHAPTER 10
DESIGN CALCULATION
a process in which a V-shaped punch presses the sheet into a V-die. The
bending force can be calculated from the sheet thickness, die opening,
bend length, and the ultimate tensile strength of the material. The die
66
ratio may be entered to calculate the die opening, which is typically 6 to
18times the sheet thickness. The calculated tonnage can be used for the
operation.
F = BA x t x l x
Where
l = Bend length
t = Thickness of sheet
F = BA x t x l x
67
CHAPTER 11
Advantages
Low cost .
Less maintenance.
Simple in construction
On/Off switch.
Higher accuracy
Disadvantages
2. Noisy operation
68
CHAPTER- 12
CONCLUSION
This project is very much useful for Bending the sheet metal.
Thus by means of the Bending machine, we can bend the sheet metal.
This is one of the most reliable and simple machine in the machine
69
REFERENCES
Reference Guide
Machines, McGraw-Hill,
Industry,
70