EMI uses a CNC brake press for Metal Bending. This process consists of bending and forming the metal into the desired shape. In concept, metal bending and forming are simple. However, the actual process requires precision positioning of the tooling and workpiece material, combined with the proper programming of the CNC Press Brake, to achieve the precision bending and forming.
CNC Press Brake Metal Bending Services
CNC press brake bending is one of the most common sheet metal fabrication operations. Also known as press braking, metalworkers use this method to bend a material into an angular shape.
Press brake metal forming services are used to form a piece of sheet metal along a straight axis into a V, U, or channel shape. The press brake uses specialized molded dies and a punch that helps form the shape of the sheet metal for specific design needs.
Press brake machines rely on high pressure to perform their work. As a result, they can shape most materials, including bronze, copper, aluminum, iron, steel, and composites.
The critical factors influencing the mechanics of bending and forming are the material, sheet thickness, width over which the bend or form occurs, machinery, tooling, and specific metal process.
We can take your custom prototype or design and bring it to life for your specific project and needs. With individual experience averaging over a decade, Elemet Manufacturing’s talented workforce takes pride in maintaining a level of quality second to none. Your products are bent and formed accurately, on time, with minimal distortion and maximum consistency.
The Metal Bending Machine Process
Hydraulic press brakes work by clamping the workpiece or sheet metal between a matching punch and die. Once the workpiece or sheet metal is positioned underneath the press brake machine punch, the tool setter activates the machine. The press brake machine, using hydraulic pressure, pushes the punch down against the surface of the workpiece into the die, which shapes the workpiece.
Three Types of Metal Bending Services
There are three types of bending on a press brake. The relationship of the end tool position to the thickness of the material defines each type. These three types are air bending, bottoming, and coining.
1. Air Bending
The flexibility and relatively low pressure required by air bending make it a popular choice. In the Air bending process, the metal workpiece does not touch the tooling parts entirely. The workpiece rests on 2 points, and a radiused tipped punch pushes the material into a die with a U or V-shaped channel to create the bend.
Air bending can produce different profiles and products using a single set of top and bottom tools and varying press-stroke depth. The bend’s angle is determined by how far the punch tip penetrates the “V” cavity. The greater the penetration of the punch tip, the greater the rise achieved. The stroke depth must be very accurate to achieve a quality bend.
Correcting the bend angle is simple. If the load is released and the material’s spring back results in a wrong angle, it is simple to adjust by applying some more pressure.
Advantages of air bending
- Requires less bend force
- Uses smaller tools than other methods
- No retooling
- Angle accuracy is approximately ±0.5 deg
In the bottoming process, the metal workpiece is forced against the punch and the groove width opening in the bottom tool. However, the two pieces do not make complete contact.
The optimum width of the opening (V) should be 6 to 12 times the sheet metal thickness (t) for sheets 3-12 mm thick. The bend radius should be at least 0.8-2t for sheet steel. Bottoming requires a different toolset for each bend angle, sheet thickness, and material.
Advantages of bottoming
- greater accuracy
- less spring back
In the coining process, the top tool forces the material into the bottom die with high force, causing permanent shaping through the workpiece.
Advantages of Coining
- Very little spring back
- Can produce an inside radius as low as 0.4t with a V as high as 5t
- High precision
Issues from Improper Metal Bending Services
Metal bending and forming require proper positioning of the workpiece, the die, and the punch while precisely determining the bending radius, pressure, and clearance. Errors in positioning or bend calculations can result in poorly formed parts that may not fit well with other parts in the assembly process. Types of problems that can occur include:
- Broken parts
- A bending edge that is not straight and an unstable size
- Cracks at the bending angles
- A bending surface that is too thin
- An uneven or bulging surface on the part
- Misaligned holes in the part
Work with EMI for your Metal Bending Services
Elemet Manufacturing (EMI) has various CNC Press Brake machines to handle any job, no matter the size. CNC technology allows us to provide press brake metal bending and forming faster, more accurately, and with reliable consistency. Our machines include:
- Accupress Mechanical 135-ton Press/Brake (10’)
- Hydraulic 25-ton press
- Hamilton 250-ton Press
EMI offers creative manufacturing solutions to our clients and eliminates having to work with several different partners, saving you time and money. In addition to our CNC Metal Bending Services, we provide:
- CNC milling, turning, threading, and machining
- 5-axis waterjet cutting
As part of the Elemet Group, we offer one-stop metal manufacturing, machining, fabricating, and coating solutions. Our other group company services include:
- Glenn Metalcraft offers high-quality, close-tolerance, heavy-gauge, metal spinning, and 6-axis CNC turning and milling, laser, plasma, and waterjet cutting, as well as manual and robotic welding.
- Minnesota Industrial Coatings offers both Powder Coating and E-coating.
The Benefits of Working with Elemet Manufacturing
- Competitive pricing
- Fast production times
- Reliable accuracy and consistency
- Can produce one prototype or large production runs
- All work performed under one roof
When you work with us, you are more than a client; you are a valuable partner. Our team at Elemet Manufacturing is happy to assist you with your project and will help you to determine the correct bending and forming method for your needs. Give us a call.