FOCUS ON FOLDING
Folding innovations
The operator does not need to ‘ manage ’ the part during the forming process
tools should last for many years because of the unique process of swing-beam folding . Flanges are bent to the correct angle with flat tooling that eliminates scratching or sliding on the workpiece . Not only does this equate to better quality parts , but it also means that there is almost zero tool wear .
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 .
The clamping tool of a folder enables the folding beam to form an acute angle bend for hemming applications . That acute angle is then positioned under the clamping tool foot to close the hem to a specific height . This height can be selected for parallel hems , teardrop hems or even open hems used in assembly .
When the part needs a large radius to be formed , the same tooling can be used on a folding beam to smoothly make incremental bends until the necessary radius is achieved . While not a one-size-fits-all solution , folders offer strong flexibility for a wide variety of needs .
“ CNC folding machines have pre-aligned upper beam and lower beam tools , minimising tool set-up time and allowing the fabricator to change from part to part very quickly . In today ’ s pressures on small batch sizes and large volume , this is one of the main advantages of folding ,” RAS told ISMR .
Another advantage is part handling . Larger parts can be manipulated on the gauging , eliminating the need for multiple operators and increasing part accuracies . Folding machines
The TETRON 40 electric swing folder has a bending capacity of 4mm steel ( 6mm aluminium ) of up to 3m in length .
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 themselves . The CNC control will prompt the operator on how to position the part . Precision tooling and CNC control technology will check for bending collisions and select bend sequences , shrinking the actual set-up time and providing more run time .
“ Unlike a press brake that gauges the flange and rotates the part up , sheet-metal folding machines gauge the whole section and turn the flange up . Folding machines have an integrated support back gauge that holds up the weight of the items for the operator . The folding machine ’ s design promotes ergonomic operation , and you don ’ t need to push massive sheets through from the front . Additionally , their bending technique makes it easier for operators to bend multiple-setup parts that would typically call for additional manual interference ,” explained Southern Fabricating Machinery .
Folders and press brakes complement each other in sheetmetal bending operations ; they each have individual advantages and benefits in the press shop .
In this article , we highlight a selection 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 to 15 metres with material thicknesses of up to 1.5mm ( steel ). It is particularly suitable for demanding roof , wall and façade profiles . Precise positioning 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 ,” added Biegemaster .
The Biegemaster Dura offers a wide range of applications for simple and quick bending of demanding roof , wall and façade profiles . 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 . 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 .
The TETRON is its new electric swingbending range .
Blech-Tec GmbH produces mini bending machines . Its combination BT-500 is a folder
The BT-500 combi folder from Blech-Tec .