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BENDING
STEEL SHEET AND
STRIP PRODUCTS
die
5.1.1. AIR BENDING The press size to handle single bending
In air bending, the sheet surface is touched by operations can be calculated from Equation 2:
the tools at three points only (the punch Equation 2
surface and the corners of the open die) Required capacity
throughout the whole operation.
C1 Rm L t2
F = x 10-3
Figure 5 Air bending in a press brake
W
punch where F = bending force, kN
C1 = constant for die width/steel
thickness combination
(Figure 6)
Rm = yield strength of steel, MPa
L = bend length, mm
die limit of stroke
t = steel thickness
(steel base if coated sheet), mm
W = V-notch opening, mm
The shape and nose radius of the punch are
This value is only for air bending in which the
varied to suit the workpiece. The required
required shape is reached without the sheet
angle is produced on the workpiece by
reaching the bottom of the V-notch. The
adjusting the depth to which the punch enters
required angle is obtained by adjusting the
the die opening. This allows the sheet to be
depth to which the top tool enters the bottom
bent beyond the design angle to produce the
tool. Air bending is widely used as it can
correct profile after spring back.
allow for the degree of overbending necessary
When the metal is deformed plastically (that to compensate for spring back which is
is, the punch force exceeds the yield strength of inevitable in steel sheet. The degree of spring
the steel) the radius formed bears a definite back must be checked by trial and error on
relation to the opening in the die. A small die prototypes before production runs commence.
opening produces a small radius. The use of a
A further advantage of air bending is the
large die opening increases the radius but
ability to produce a great variety of bend
compensation must be made by overbending
angles with fewer tools as the angle on the
for increased spring back. Changing the size
workpiece, the top tool angle and the V-notch
of the die opening also changes the amount of
need not be matched.
force needed to make the bend. As the die
opening is increased, less force is required.
Conversely, as the die opening decreases, 5.1.2. BOTTOMING AND COINING
bending leverage is less and thus more force Two alternatives to air bending are bottoming
is required. and coining in which a top tool, workpiece
and V-notch are in solid contact when the
Figure 6 Variation of C1 factor for bend is completed.
V-Bends with W/t ratio.
Figure 7 Bottoming and Coining
1.63 t t
punch t 90 90
1.50
W
C1 FACTOR
V = 612 x t V = 56 x t
1.38 Bottoming Coining
1.33
Both methods are used for achieving greater
1.30 bend accuracy than is achievable with air
1.28
bending. Bottoming is more commonly used
1.24 as it requires less pressure than coining. The V
1.20 width for bottoming is 6 - 12t. Coining, which
uses high surface and bite by a sharp punch
6 7 8 10 12 14 16
to control springback, uses a V width of 5 - 6t.
WIDTH/THICKNESS COMBINATION
These methods produce more accurate bends Figure 8 Wiping dies for channels
with consistent spring back and neat transition
from bend to flat.
Inherent disadvantages with these techniques punch
restrict their use. These include:
a) The top and bottom angle must be
accurately matched so more tools are
required for the same work range
compared to air bending pad
F1
F2 =
5
2
2RP L t
F3 = x 10-3
3W
F4 = F1 + F2 + F3
punch punch
die die
t = Metal thickness
R = Inside radius
t
(a) Better formability - transverse bend neutral axis or
line in bend
t
R surface in
compression
n
dir ling
tio
ec
rol
surface in
tension
(b) Reduced formability - longitudinal bend
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