In the field of metal processing and manufacturing, sheet metal bending is a very important process, which can accurately transform the shape of the sheet, from flat sheet to three-dimensional structure of the transformation. sheet metal bending process level will directly affect the accuracy, strength and appearance of the product quality, and it is widely used in aerospace, automotive manufacturing, It is widely used in aerospace, automotive, home appliance, construction and many other industries, so it is very important to have a comprehensive understanding of sheet metal bending!
The article will analyze the knowledge of sheet metal bending in detail, first from its basic definition, then introduce the common types of technology, and finally list its main advantages and common applications to help you quickly and comprehensively understand sheet metal bending!
What is sheet metal bending?
Sheet metal bending is a cold working process in which a sheet metal is plastically deformed at a specific location by applying an external force to obtain a predetermined angle and geometry. Only the geometry is changed, the volume of the metal part remains unchanged. sheet metal bending is very important for the manufacture of components with precise angles and curves, and is an indispensable process for the manufacture of important functional components in the aerospace, automotive, and medical device industries.
The operation of sheet metal bending consists of three basic steps:
- Positioning: the sheet metal to be bent is placed between the upper die (punch) and the lower die (in the case of a V-shaped die) and positioned precisely where it needs to be bent.
- Applying pressure: the upper die moves downwards under hydraulic or electric drive, pressing the sheet metal into the V-shaped opening of the lower die.
- Forming and springback: the sheet metal undergoes permanent plastic deformation when the pressure exceeds the yield strength of the material. Due to the springback characteristics of sheet metal, the expected springback must be compensated for by over-bending the material during the manufacturing process. If the metal is intentionally bent slightly too far, a small amount of natural springback will result in the correct angle.
Common types of sheet metal bending techniques
There is not just one method of sheet metal bending. In actual production, we need to choose the most suitable bending technique according to the requirements of the workpiece, batch size and material properties. The following are five commonly used sheet metal bending methods
Air bending
This is the most widely used sheet metal bending method, the upper die (punch) will be pressed into the lower die V-shaped openings, but does not make the sheet contact the bottom of the mold cavity, bending angle is achieved by controlling the depth of the upper die downward pressure.
This sheet metal bending method of versatility, a set of molds can be controlled by the depth of the lower pressure to bend a variety of angles, high flexibility; and it does not require the material to be completely pressed into the mold cavity, the required pressure is smaller; production process, the material and the mold contact and friction is smaller, less wear and tear on the mold, which can be effective in extending the life of the mold.
However, Air bending is very sensitive to rebound, and the accuracy of the bending angle depends on the precise control of the machine’s downward pressure depth and the material’s characteristics.
Bottom bend
Bottom bend is an extension of Air bending, which provides higher precision. In this sheet metal bending method, the sheet metal is pressed completely into the bottom of the V-cavity of the lower mold, so that the material is in complete contact with the sides and bottom of the mold, and the sheet metal is pressed to the same angle as the mold.
Bottom bend, through the bottom contact and extrusion, can greatly overcome the impact of the rebound of the metal sheet, to obtain a very accurate bending angle, high precision, good stability; and its molding effect is good, can produce a clear bending line.
However, Bottom bend requires large tonnage, compared to Air bending requires greater pressure, and more specialized, each set of lower die is usually only applicable to a specific bending angle and material thickness, less flexible.
Imprinting
This is the most accurate sheet metal bending method and requires the highest pressure. The upper die violently presses the sheet metal into the lower die with extremely high pressure (about 3-5 times that of a Bottom bend), which causes the material to deform plastically in the die cavity and fit perfectly into the shape of the mold.
Imprinting is extremely accurate and virtually eliminates springback. It is also possible to mold complex tips or features, and can imprint fine textures or shapes on bends.
However, the tonnage required for Imprinting is very high and the power requirements of the bending machine are very high; and the extremely high pressure accelerates the wear of the tooling. Due to its high cost, it is usually used for precision sheet metal bending.
Rotating bend
Rotating bends are used for bending parts that require an angle greater than 90 degrees. This method of sheet metal bending does not scratch the surface of the sheet, and it pays special attention to protecting the surface of the workpiece, resulting in a more uniform and aesthetically pleasing part. rotating bend uses a roller with a freely rotating lower die. When the upper die is pressed down, the roller rolls along with it, thus molding the sheet.
Rotating bend is a rolling friction rather than a sliding friction, which minimizes scratches or indentations on the surface of the workpiece, making it ideal for bending sheet metal that carries a coated, painted, or polished surface; it is also suitable for manufacturing products with long arcs.
However, this sheet metal bending method is usually more expensive in terms of equipment and tooling costs, slower in processing speed, and is not suitable for all types of bending.
Wiping bending
Wiping bending is the process of bending the edge of a sheet metal by fixing one side of the sheet metal and then moving the upper mold up and down from the other side of the sheet metal.
Wiping bending can bend closed corners that are difficult to achieve with other sheet metal bending methods, and has the mechanical advantage of bending the sheet metal with less force. However, it also leaves machining marks on the surface of the workpiece, is not suitable for making obtuse bends, and requires the use of specialized tooling and more complex programming setups.
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Advantages of sheet metal bending
- Enhancement of structural strength: sheet metal bending bends flat sheets into three-dimensional shapes (such as V-shape, U-shape, or box-shape) at a certain angle, which enhances their structural rigidity and load-bearing capacity, making the finished parts more durable and able to withstand greater loads.
- High precision and flexibility: sheet metal bending can easily create a variety of angles, multiple bends, and complex box structures; and advanced CNC equipment provides high precision and repeatability to ensure that each metal part meets specifications.
- Cost Effectiveness: sheet metal bending is often combined with laser cutting, stamping, and other processes to minimize material waste; and modern CNC bending machines allow for quick clamping and automated bending, with high productivity, effectively reducing overall project costs.
- Rapid Production and Delivery Cycle: Whether it is sheet metal prototyping or mass production, sheet metal bending’s high production efficiency shortens the cycle from design to completion of production, which allows it to respond quickly to the needs of the market and the industry.
- Simple connection and beautiful appearance: Compared with individual parts spliced or welded together, sheet metal bending molds parts with fewer and neater seams and a more integrated appearance, providing better sealing and aesthetics.
Common applications of sheet metal bending
Chassis cabinet and shell: This is the most extensive and classic application field. Whether it is a computer mainframe, server cabinet, network switch, or a variety of industrial control cabinets, instrumentation enclosures, almost all through sheet metal bending manufacturing.
Automobile manufacturing: chassis and frame components of automobiles, including various load-bearing and connecting brackets; door frames, seat skeletons, compartment panels and structural beams of trucks and trailers, and so on.
Construction: roof and wall panels, ventilation ducts, door and window frames, curtain wall keels, stairs, handrails, etc.
Home appliances and electronic products: internal skeleton and shells of refrigerators and washing machines, shells of ovens, ventilation ducts and shells of range hoods, bases of laptop computers, shells of radiator fans, etc.
Aerospace and medical equipment: support structures for aircraft wing ribs, electronic equipment compartments and brackets inside aircraft, shells and internal structures of medical equipment (such as operating tables and analyzing instruments), etc.
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Summary
If you are in need of metal cutting and bending services, contact us today! Supro is a professional custom metal manufacturer, with the advantage of advanced equipment, rich manufacturing experience and professional engineering team, providing more than 3000 companies around the world with perfect custom metal fabrication solutions for more than 3000 companies worldwide with genuine manufacturer’s quotations.
At Supro, our sheet metal bending services can meet your every need, whether you need a simple design or a complex one. As a state-of-the-art custom metal manufacturer, we have the expertise, technology, and state-of-the-art equipment to understand the needs and standards of sheet metal bending parts for a variety of industries, including agriculture, medical, automotive manufacturing, aerospace, and more.Supro has 12 different sheet metal bending machines. With 12 different sheet metal bending machines, Supro is able to provide one-stop sheet metal bending services for any industry, while offering high quality products, professional customer service and on-time delivery.
If you have any questions or concerns about our customized sheet metal bending services, please contact us today and we will actively work to meet any requirements you may have for your project!
