FOCUS ON FOLDERS
A flexible approach
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 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 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 folders. 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-sizefits-all’ solution, folders offer strong flexibility for a wide variety of needs.
Another benefit 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 themselves.
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 innovations, technologies and software.
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 is possible with an electronic back gauge and flexible sheet metal grilles.
Above: Electro-kinetic bending on the Biegemaster BendTron.
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.
“ 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 roof, wall and façade. Common profiles from 3-15 metre bending lengths with material thicknesses of up to 3mm can be folded( bending angles up to 150 °). 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.
“ The freely positionable foot switch enable both hands to remain free when fixing the sheet metal,” said the manufacturer.
“ 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.
The BMS multi-touch control system enables intuitive operation by touching the screen. New profiles can be created quickly or created using touchscreen painting. The control system can draw on stored profiles. Automatic bend sequence calculations with graphic simulation and illustration are also offered.
Blech-Tec GmbH manufactures mini bending machines for small parts production. The BT-500 is a combination folding, pressbrake and pressing machine for small parts. Combining the bending processes offers flexibility, as the processes have their geometric advantages. It is a compact freestanding machine, which can be operated while sitting or standing.
“ Our patented folding process yields a result with hardly any bending traces because the tool always lies flat against the workpiece. In addition, users benefit from the precision of the BT-500, which is designed for small parts, and the comfortable two-finger guide unit. The unique design enables different kinds of bending, even in one program. The comfortable two-finger guide supports these new possibilities,” said the manufacturer.
The BT-150 is designed as a table machine for even smaller parts.
Companies in The Bradbury Group have been manufacturing roll forming 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
The combination BT-500 folder and press brake.
ISMR October 2025 | ismr. net | 91