FOCUS ON FOLDING
JORNS folder at EuroBLECH 2024 in Hanover , Germany . Folded sheet metal panel ( CIDAN ).
Programming the MEGAbend folder on RAS ’ s stand at EuroBLECH 2024 in Hanover , Germany . control the metal folding process . A control system on the machine tool allows the operator to set the motion parameters of the folding beam ( such as swing angle , speed and position ). Adjustment of these parameters can be optimised according to specific folding needs to ensure the best folding results .
On a folding machine , the entire part is inside the machine . Only a short flange stands out of the upper and lower beam tool . Folding reduces the sliding area of tools on the material surfaces to a minimum or 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 .
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 .
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 one-size-fits-all ’ solution , folders offer strong flexibility for a wide variety of needs .
The TD Double Folder on the CIDAN Machinery stand at EuroBLECH 2024 in Hanover , Germany .
Versatile part handling
Another advantage , when using folders , is part handling . Larger or heavier parts can be manipulated on the gauging , eliminating the need for multiple operators and increasing part precision .
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
Sheet metal bending on RAS folders . 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 themselves .
When handling metal sheets that are five feet in width or over , folders keep the material flat on the back gauge table and avoid directing metal sheets towards the operator , which enhances safety and handling ease .
Operator fatigue can also be reduced , as the material to be formed is laid flat on the machine bed . This method also results in springback being controlled more easily .
Skilled labour is not necessarily required to operate the folder as the bending cycle is automated and managed by the CNC system . A standard interface is provided on various folders to allow a wide range of automated robots and handling devices to be fitted .
In conclusion
Folding machines 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 . New models , with greater capabilities and user-friendly , connectivity and automation features , are continuously being launched into the market .
Folders create a scratch-free outcome . A metal folder ‘ air-bends ’, meaning that the machine system doesn ’ t bottom or coin the material . Because of this , there is little to no wear in tooling for most folding applications . They can produce an aesthetically pleasing product without tearing , stretching or cutting .
Folders and press brakes complement each other in sheet metal bending operations ; they each have individual advantages and benefits in the press shop . Although their purpose is to shape metals , there are significant differences in operating principles , scope of application and processing methods .
There are jobs that can only be produced on a press brake and vice versa ; however , for a significant number of applications , users always have a choice . n
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