In recent years, there has been an increasing demand for skilled technicians proficient in the preparation of complex bending machine operations in sheet metal processing plants. Many factories rely on the operators themselves to prepare and operate the bending machines. The sheet metal processing industry has seen numerous technological advancements in machine tools and molds. Today, machine tools can stamp, cut, and bend at speeds and accuracies that exceed expectations.
Following standard operating procedures (SOP) helps ensure consistency, reduces the need for repeated part setups, and minimizes material waste. These SOPs not only contribute to minimizing processing preparation time but also enhance the consistency of bending sequence operations, while reducing deviations caused by individual operators.
Preparation Sheets: For routine processing tasks, one method available to bending machine operators is the use of "preparation sheets." These sheets document, in a file format, the tooling used for each purpose and provide specific processing task prompts, which must be used each time the same processing task arises.
Photographs: Factories should consider using snapshots to record tool positioning and specialized stops. These photographs can also serve as references for future applications.
Loading in the Open Position: Another important method is to load tooling, or feed material, only when the machine is fully open, providing operators with easier access to the workspace and creating a safer working environment.
Specialized Tools
Factories should also consider implementing appropriate procedures and tool systems, such as loading and unloading devices, to enable workers to perform routine processing tasks more quickly and efficiently.
Auxiliary Tool Features: Many progressive forming die systems include punch seats, button-operated safety clamps, quick-change 2V dies, and electric clamping mechanisms, allowing an operator to change dies very quickly. These systems also help operators work more independently and effectively without compromising safety.
Segmented Dies: Precision-ground segmented die components can be manufactured according to the required bending lengths without the need to spend time cutting the dies to a specific length. Precision-ground dies also reduce or eliminate the need for shim adjustments. Segmented dies are lightweight and easy to handle, reducing physical labor, fatigue, and the likelihood of accidents. To extend their lifespan, precision-ground dies undergo hardening and surface enhancement treatments.
Die Identification: Almost all dies now have laser-etched information for quick identification, planning, and reordering by workers. This information typically includes part numbers, cutting edge angles, radii, V-grooves, lengths, and rated tonnage.
Die Storage: Organized cabinet storage of dies provides a dual benefit of improved safety and enhanced material/tool management. With an orderly storage system, there's no need to search through tool racks for a custom length die. Additionally, organized storage enables management to more vigilantly monitor the condition of the dies, ensuring high-quality inventory, promptly identifying wear and damage, and determining the method and timing for die replacement.
Utilizing Machine Tooling Capabilities
New press brakes offer advanced functionalities and many features that can help operators run the machines more efficiently. Operators who are proficient in utilizing these new machine control features can enhance productivity.
Workpiece Tooling Specifications Storage: Most new CNC press brakes share a common feature—a capability to store workpiece specifications and all relevant processing information, such as die model, position, and bending sequence. Additionally, the CNC functionality enables operators to store and access tooling libraries, providing convenient management of tooling inventory.
Material Thickness Detection: When using precision-ground tooling, the press brake can detect variations 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 part bending process on the controller screen as the workpiece takes shape, helping to avoid incorrect part forming and material wastage.
Offline Programming: Offline programming for press brakes can save setup time, as operators do not have to create part processing programs; these can be prepared by technical personnel and transferred to the press brake.
Universal Die Height Setting: Universal die height tooling simplifies complex staged tooling adjustments using a "plug and play" feature. Universal die height tooling was developed alongside the introduction of CNC vertical backgauge. To accurately utilize the principle of "universal die height," vertical CNC control is necessary, as universal die height ensures that the bottom opening of the lower die remains at the same height (from the lower die seat). When the lower die opening expands, the total height of the lower die must correspondingly increase. This is why universal die height tooling no longer requires the use of special blocks or dedicated shims to synchronize the closing of the tooling.
Small and complex parts often require offset bending, 90° bending, and flattening, tasks that typically need to be performed on multiple machine tools or equipment. Staged or universal die height tooling enables these operations to be completed on a single press brake during one loading. With universal die height tooling, operators can mount a 30° die, offset die, flattening die, and gooseneck die on the same die seat and complete all part processing.
Maximizing Bending Technology
Metal fabrication shops employing press brakes currently face complex challenges; high raw material costs dictate that every blank must become a quality part. Being responsive and willing to change bending forming operations to adapt to the current needs of the sheet metal processing plant can reduce setup time, leading to increased production capacity and reduced scrap rates. Effectively utilizing storage and inventory systems, harnessing machine tooling capabilities, and fully tapping into human resources are effective methods to help bending forming workshops improve efficiency and productivity.
