FOCUS ON FOLDING material surfaces to a minimum or completely eliminates it on some machines . As there are only very slight relative movements between the tool and the material surface , the tooling shows no abrasion wear even after years of use .
On folding machines , a radius can be easily created of short bending segments . By using small steps , the outside of the radius will be very smooth and the individual steps will not be visible . Folding does not require special tools for hemming .
The folding process is suitable for flexible applications because the tooling is not specific to the material thickness or angle required . “ Universal ” tool geometries allow for unlimited angle possibilities and are rated up to the maximum machine capacity and height .
There are several types of folding machines . On systems equipped with segmented clamping tools , a new part can be set up by rearranging the tool segments on the tool rail . Machines without automatic tool-changers still simplify the set-up process by advising the operator where to put tool stations . This common tooling allows for rapid changeover between parts and makes it easy for a single employee to program , operate and set up the machine for any compatible part . While not ‘ a onesize-fits-all ’ solution , folders offer strong flexibility for a wide variety of needs .
Another advantage is part handling . Larger parts can be manipulated on the gauging , eliminating the need for multiple operators and increasing part accuracy . Folding machines clamp and bend the part when it is laying flat on the gauging table and the flange is being bent , which helps accuracy so that the operator does not need to ‘ manage ’ the part during the forming process . Larger parts that require two operators typically can be manipulated by one operator on a folder because the bulk of the part is resting on the table and the operator can rotate it by himself / herself .
Folders and press brakes complement each other in sheet metal bending operations ; they each have individual advantages and benefits in the press shop .
Folding innovations
In this article , we highlight some of the latest innovations in global CNC folding and software technologies .
German folding specialist , Biegemaster , designed the Biegemaster BendTron to be its first generation to be driven completely by electric motors . The BendTron enables users to bend all common profiles with a bending length ranging from 4-15 metres with material thicknesses of up to 1.5mm ( steel ). It is particularly suitable for demanding roof , wall and façade profiles . Precise positioning
Above and below : Electro-kinetic bending on the Biegemaster BendTron .
Folders are easily identified by their large support tables and swinging ‘ folding beam ’, which bends the flange while the workpiece remains flat on the support table
is possible with an electronic back gauge and flexible sheet metal grilles .
“ Shaft-controlled bending is assured through fully electro-kinetically driven bending joints for quiet and powerful operation . Inclined bending beams and optimised clamping beam geometry offer a high degree of flexibility and short counter-folds ,” explained Biegemaster .
The Biegemaster Dura offers a wide range of applications for simple and quick bending of demanding roof , wall and façade . Common profiles from 3-15 metre bending lengths with material thicknesses of up to 3mm can be folded . It is optionally equipped with a hydraulic adjustable clamping beam for material thickness adjustment . There is an archive of all previously used projects on the machines and an intuitive control system via multi-touch display with a wide range of functions .
“ For double bends , the Biegemaster XBend bends material thicknesses of up to 2mm steel sheet metal automatically ( lengths of 3-12 metres ). Users benefit from high productivity and easy handling . Fully automatic bending is possible in two directions without turning the sheet around and an electronic back gauge ensures precise positioning . The clamping beam can be controlled with millimetre precision for perfect folds and automatic loading assistance is featured for the easy insertion of sheet metal ,” added the manufacturer .
Blech-Tec GmbH manufactures mini bending machines . The BT-500 is a folding machine and press brake in one . Combining both bending processes offers flexibility , as both processes have their geometric advantages . The BT-150 is designed as a table machine for even smaller parts .
“ Our patented folding process yields a result with hardly any bending traces because the tool lies flat against the workpiece at all times . In addition , users benefit from the precision of BT-500 , which is designed for small parts , and the comfortable two-finger guide unit . The unique design allows the different kinds of bending , even in one program . The comfortable twofinger guide supports these new possibilities . It is designed as a compact freestanding machine , which can be operated while sitting or standing ,” said the manufacturer .
Companies in The Bradbury Group have been manufacturing rollforming machinery since 1959 . The Group has also developed a hydraulic folder , which features the Intelli- Fold™ Controller made by its partners at Beck Automation . The Intelli-Fold™ Controller features resident programs and a graphic display that allows operators to save time by sketching a part profile and then entering its dimensions and angles . Screen prompts guide the process .
The combination BT-500 folder and press brake in one machine .
ISMR April 2024 | ismr . net | 61