In the past few years, the sheet metal processing industry has witnessed several technological advancements in machine tools and dies. Today, machine tools are capable of stamping, cutting, and bending at speeds and precision beyond expectations.
However, regardless of how advanced the new technologies are, bending workshops or sections in sheet metal processing factories still encounter various bottleneck issues, even in the most advanced facilities. While these problems cannot be attributed to a single cause, metal processing factories can make improvements in multiple areas to reduce lengthy setup times, improve efficiency, and enhance overall production capacity.
Sheet metal processing factories are now facing a challenge: most of the processing tasks have small batch sizes and tight tolerances, with 15 tooling adjustments per shift being a common occurrence, and in many factories, the number is even higher. Skilled technicians proficient in complex bending machine setups are becoming scarce, leading many factories to rely on operators to handle the setup and operation of the bending machines themselves.
Implementing Standard Operating Procedures (SOPs) helps ensure consistency, reduces multiple part setups, and minimizes material waste. These SOPs not only contribute to reducing processing setup times but also improve the consistency of bending sequence operations and reduce part deviations caused by individual operators.
Setup Sheets: One of the means that bending machine operators can employ for frequent processing tasks is the use of "setup sheets." Setup sheets document the specific tooling used for each purpose and provide prompts for the specific processing tasks, which must be followed each time the task is repeated.
Photographs: Factories should consider using snapshots to record the positioning of dies and specialized blocks. These photographs can also serve as references for future applications.
Loading in the Open Position: Another important measure is to load the tools in the fully open position, providing operators with easier access to the workspace and creating a safer working environment.
Specialized Tools: Factories should also consider adopting appropriate procedures and tooling systems, such as loading and unloading devices, to enable workers to complete routine processing tasks more quickly and efficiently.
Auxiliary Tooling Features: Many progressive tooling systems include punch holders, button-operated safety clamps, quick-change 2V dies, and electric clamping mechanisms, allowing the operator to change dies rapidly on their own. These systems also help operators work independently and efficiently without compromising safety.
Segmented Dies: Manufacture precisely ground segmented die components according to the required bending lengths, eliminating the need to cut the dies to specific lengths. Precision-ground dies also reduce or eliminate the need for shim adjustments. Segmented dies are lightweight and easy to handle, reducing physical labor and fatigue while minimizing the risk of accidents. To extend their lifespan, precision-ground dies undergo hardening and surface strengthening treatments.
Die Identification: Laser engraving of relevant information is now present on almost all dies, enabling workers to quickly identify, plan, and rearrange the dies. This information typically includes classification numbers, cutting edge angles, radii, V-shaped grooves, lengths, and rated tonnage.
Die Storage: Storing dies in grouped cabinets offers the dual benefits of improved safety and enhanced material/tool management. With an organized storage system, there is no need to search through tool racks for a custom-length die. Additionally, organized storage allows management to monitor the status of the dies more effectively, ensuring high-quality inventory, promptly identifying wear and damage, and determining the method and timing of die replacement.
Utilizing Machine Tool Features
New bending machines offer advanced functionality and numerous features that can help workers operate the machines more efficiently. Operators who are familiar with the new machine control features can leverage these capabilities to improve productivity.
Workpiece and Die Specification Memory: Most modern CNC bending machines have a common feature - the ability to store workpiece specifications and all related processing information, such as die models, positions, and bending sequences. Additionally, CNC functionality enables operators to store and access tool libraries, facilitating tool inventory management.
Material Thickness Detection: When using precision-ground dies, the bending machine can detect changes in material thickness and perform real-time bending calculations, reducing the number of parts with excessive or insufficient bending angles.
3D Graphic Display and Bending Simulation: These features display the process of bending the part on the controller screen as the workpiece takes shape, helping to avoid material wastage caused by incorrect part forming.
Offline Programming: Offline programming for bending machines saves setup time as workers no longer need to create part processing programs. Part programs can be created by technicians and downloaded to the bending machine.
Universal Tooling Height: Universal tooling height die series simplifies complex staged die adjustments with its "plug and play" functionality. The development of universal tooling height dies coincided with the introduction of CNC vertical movement of the backgauge. Vertical CNC control is necessary to accurately utilize the principle of universal tooling height, as it ensures that the bottom of the die opening remains at the same height (relative to the lower die seat). When the lower die opening expands, the overall height of the lower die must increase accordingly. This eliminates the need for specialized blocks or dedicated shims to synchronize the closing of the universal tooling height dies.
Small and complex parts often require offset bending, 90° bending, and flattening, which typically involve multiple machine tools or equipment for setup. Staged or universal tooling height dies allow these operations to be completed on a single bending machine with one loading. With universal tooling height dies, operators can install 30° dies, offset dies, flattening dies, and goose neck dies on the same die seat and complete all processing for the part.
Maximizing Bending Technology
Metal processing factories that utilize bending machines face complex challenges, as the high cost of raw materials necessitates that every blank becomes a quality product. Sheet metal processing factories that are responsive and willing to change the operation of the bending section to adapt to current needs can reduce setup time, increase production capacity, and lower scrap rates.
Developing and implementing carefully designed SOPs, optimizing storage and inventory systems, harnessing the functionality of machine tools, and fully leveraging human resources are several methods to help improve efficiency and productivity in bending workshops.
However, regardless of how advanced the new technologies are, bending workshops or sections in sheet metal processing factories still encounter various bottleneck issues, even in the most advanced facilities. While these problems cannot be attributed to a single cause, metal processing factories can make improvements in multiple areas to reduce lengthy setup times, improve efficiency, and enhance overall production capacity.
Sheet metal processing factories are now facing a challenge: most of the processing tasks have small batch sizes and tight tolerances, with 15 tooling adjustments per shift being a common occurrence, and in many factories, the number is even higher. Skilled technicians proficient in complex bending machine setups are becoming scarce, leading many factories to rely on operators to handle the setup and operation of the bending machines themselves.
Implementing Standard Operating Procedures (SOPs) helps ensure consistency, reduces multiple part setups, and minimizes material waste. These SOPs not only contribute to reducing processing setup times but also improve the consistency of bending sequence operations and reduce part deviations caused by individual operators.
Setup Sheets: One of the means that bending machine operators can employ for frequent processing tasks is the use of "setup sheets." Setup sheets document the specific tooling used for each purpose and provide prompts for the specific processing tasks, which must be followed each time the task is repeated.
Photographs: Factories should consider using snapshots to record the positioning of dies and specialized blocks. These photographs can also serve as references for future applications.
Loading in the Open Position: Another important measure is to load the tools in the fully open position, providing operators with easier access to the workspace and creating a safer working environment.
Specialized Tools: Factories should also consider adopting appropriate procedures and tooling systems, such as loading and unloading devices, to enable workers to complete routine processing tasks more quickly and efficiently.
Auxiliary Tooling Features: Many progressive tooling systems include punch holders, button-operated safety clamps, quick-change 2V dies, and electric clamping mechanisms, allowing the operator to change dies rapidly on their own. These systems also help operators work independently and efficiently without compromising safety.
Segmented Dies: Manufacture precisely ground segmented die components according to the required bending lengths, eliminating the need to cut the dies to specific lengths. Precision-ground dies also reduce or eliminate the need for shim adjustments. Segmented dies are lightweight and easy to handle, reducing physical labor and fatigue while minimizing the risk of accidents. To extend their lifespan, precision-ground dies undergo hardening and surface strengthening treatments.
Die Identification: Laser engraving of relevant information is now present on almost all dies, enabling workers to quickly identify, plan, and rearrange the dies. This information typically includes classification numbers, cutting edge angles, radii, V-shaped grooves, lengths, and rated tonnage.
Die Storage: Storing dies in grouped cabinets offers the dual benefits of improved safety and enhanced material/tool management. With an organized storage system, there is no need to search through tool racks for a custom-length die. Additionally, organized storage allows management to monitor the status of the dies more effectively, ensuring high-quality inventory, promptly identifying wear and damage, and determining the method and timing of die replacement.
Utilizing Machine Tool Features
New bending machines offer advanced functionality and numerous features that can help workers operate the machines more efficiently. Operators who are familiar with the new machine control features can leverage these capabilities to improve productivity.
Workpiece and Die Specification Memory: Most modern CNC bending machines have a common feature - the ability to store workpiece specifications and all related processing information, such as die models, positions, and bending sequences. Additionally, CNC functionality enables operators to store and access tool libraries, facilitating tool inventory management.
Material Thickness Detection: When using precision-ground dies, the bending machine can detect changes in material thickness and perform real-time bending calculations, reducing the number of parts with excessive or insufficient bending angles.
3D Graphic Display and Bending Simulation: These features display the process of bending the part on the controller screen as the workpiece takes shape, helping to avoid material wastage caused by incorrect part forming.
Offline Programming: Offline programming for bending machines saves setup time as workers no longer need to create part processing programs. Part programs can be created by technicians and downloaded to the bending machine.
Universal Tooling Height: Universal tooling height die series simplifies complex staged die adjustments with its "plug and play" functionality. The development of universal tooling height dies coincided with the introduction of CNC vertical movement of the backgauge. Vertical CNC control is necessary to accurately utilize the principle of universal tooling height, as it ensures that the bottom of the die opening remains at the same height (relative to the lower die seat). When the lower die opening expands, the overall height of the lower die must increase accordingly. This eliminates the need for specialized blocks or dedicated shims to synchronize the closing of the universal tooling height dies.
Small and complex parts often require offset bending, 90° bending, and flattening, which typically involve multiple machine tools or equipment for setup. Staged or universal tooling height dies allow these operations to be completed on a single bending machine with one loading. With universal tooling height dies, operators can install 30° dies, offset dies, flattening dies, and goose neck dies on the same die seat and complete all processing for the part.
Maximizing Bending Technology
Metal processing factories that utilize bending machines face complex challenges, as the high cost of raw materials necessitates that every blank becomes a quality product. Sheet metal processing factories that are responsive and willing to change the operation of the bending section to adapt to current needs can reduce setup time, increase production capacity, and lower scrap rates.
Developing and implementing carefully designed SOPs, optimizing storage and inventory systems, harnessing the functionality of machine tools, and fully leveraging human resources are several methods to help improve efficiency and productivity in bending workshops.
