FOCUS ON FOLDING
A FLEXIBLE CHOICE
Sheet metal folders excel in precise , complex bends with fewer set-up and tooling changes . They are particularly suitable for the manufacture of components such as roofs , pans , trays and lids .
Image : RAS .
A folded panel .
“ Folders offer strong flexibility for a wide variety of requirements . We outline their various benefits , capabilities and applications for sheet metal bending .”
Sheet metal folders are indispensable tools in the metalworking industry . Operators can curve and fold fascinating and elegant shapes from a single plane sheet of material without stretching , tearing or cutting . Folders are designed to make precise and consistent folds , saving time and effort , as well as processing a variety of sheet metal materials of varying thicknesses .
Folders feature an integrated support back gauge that holds up the weight of the items for the operator . There is no need for operators to push large sheets through from the front . The bending technique also makes it easier for operators to bend multiple set-up parts that would typically call for additional manual interference .
Folders are also very effective at bending polished , coated or other sensitive materials , as the part remains clamped securely while the folding beam creates the bend ( resulting in little or no marking of the material ). A folder employs motion that minimises stress on materials , making it suitable for processing delicate or pre-finished materials .
Folding machines also offer pre-aligned upper beam and lower beam tools ; this significantly minimises tool set-up time . This also allows fabricators to quickly switch from one part to another , which is crucial in today ’ s environment of small batch sizes and large volume requirements .
A flexible focus
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 .
Folders will bend all angles and thicknesses ( within the capacity of the machine ) without any tooling changes . This is a significant time-saver , especially when doing small batch work or interrupting production with an urgent off-cycle part .
There are several sheet metal bending applications that are well suited to folders . For example , one application at which folders excel
The Schröder Group ’ s MAK 4 Evolution UD folder with robot module in the control system . is when there is a requirement to bend small flanges on large sheets . On the folder only the flange to be bent will be out of the front ( with the rest of the material resting on the back gauge table ), avoiding distortion from the weight of the sheet .
For those manufacturing items using thin materials that are long and wide with short flanges , folders are a good fit . This is because they allow the material to rest on the folder bed for easier handling . 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 . These machines are suitable for many scenarios , especially for large blanks that would otherwise be difficult to handle .
Folding machines can bend all angles with a single set of tools . The machine automatically adjusts to the material thickness . Higher-end automated folding machines come with an automatic tool-changer or robot modules .
The folding process
Folding machines use upper and lower beams to clamp the workpiece to ensure its stability . The upper and lower beams are located above and below the workpiece , respectively , and are clamped by a hydraulic system . In this way , the workpiece maintains a firm position on the table of the folding machine .
During operation of the folding machine , a third beam is also introduced ( the folding beam ). This beam is mounted on the side of the machine and can swing . Swinging of the folding beam is carried out along the required folding line to fold the metal . The angle and position of the folding beam can be adjusted according to the requirements of the workpiece to obtain the required folding shape .
By using a folder , the operator can precisely
30 | ismr . net | ISMR February 2025