FEATURE ON BENDING & FORMING

Electric sheet lifters for press brakes

Gasparini has introduced its new press-brake electric sheet lifters, which are completely controlled by the CNC. The lifters are available in single- or dual-axis versions, with optional interpolation for better sheet tracking and support.

In dual interpolated axis configuration, the device continuously follows the part during bending, reducing the risk of scratches and counterbends. A counterbend can occur during the bending of very large, heavy or thin plate. The overhang generates a torque that makes the sheet bend around the die edge under its own weight. To overcome this issue, the sheet lifter supports the plate during the entire bending cycle.
An optional optimisation of the bending process consists of raising the ram before lowering the sheet lifter. This operation avoids, in case of a U-shaped bend, the return flange getting caught on the punch. When the ram goes up, the plate is lifted and then falls down, with potential damage to the part, tools and operators.
Sheet lifters are available in two sizes, providing a torque of 600 or 1200 Nm for the largest and heaviest sheets. Parts that needed two operators, can now be bent by just one person, in complete safety and without physical strain. In many cases, the use of forklfts and overhead travelling cranes may also be reduced.
Extended stroke allows bending angles as closed as 70° to be achieved. Height can be adjusted from -30 to +170 mm, to match dies with openings as wide as 100 to 160 mm. The resting surface is equipped with ball transfers and allows the installation of several options such as brushes, anti-scratch cladding, rulers, adjustable stops and telescopic extensions.
For further information www.gasparini.it

Why invest in custom press brake tooling?

According to Wilson Tool, deciding whether or not to invest in special tooling for a particular job is likely to give any fabricator food for thought.

While it’s true that custom press-brake tooling can be more expensive and may require a bit more lead-time than standard tooling, there are also significant benefits over standard tool sets. For instance, custom press-brake tooling makes it possible to solve challenging bending and forming applications while reducing material handling, minimising set-up time and improving the quality of parts.
Working with a tooling manufacturer to determine the best way to form a part can result in a positive ROI in terms of increased productivity and fewer reject parts. Whether faced with a unique part design, the need to simplify a complex bend or improve press brake performance, tooling manufacturers have the experience and knowledge to help shops determine the best way to make a part.
Tooling manufacturers also understand there is more to improving press brake performance than simply reducing the amount of time or number of strokes it takes to form a part. For example, consider the process of forming a channel. With a standard punch and die set, forming a channel requires two strokes of the machine. In contrast, using a custom channel tool, it is possible to produce two bends in one stroke. While certainly reducing the amount of time it takes to produce a part, the added benefit of choosing a channel tool set is the consistency gained in the finished component. As the part is now produced in a single stroke, it only needs to be gauged or located once rather than twice. After all, every time a component needs to be repositioned, re-gauged or relocated is an opportunity for something to go wrong, increasing the likelihood of producing a reject part.
For further information www.wilsontool.com

Latest bending innovations from Prima

A number of new technologies and solutions by Prima Power had their world premiere at the Blechexpo in Germany last November, including the company’s LPBB (Laser cutting – Punching – Buffering – Bending) manufacturing line. The LPBB features fibre-laser cutting, punching and automatic bending enhanced with LSR loading and stacking robot technology.

Prima Power’s EBe5-3 included in the LPBB system is an automatic servo-electric bending machine with a maximum bending length of 2750 mm. The machine is equipped with PCD picking and centring device, BTD bend-turning device, a single wagon for standard pallet with new part-stacking function, and a new lifting door designed to reduce the machine footprint. Among main innovations, Tulus HMI software presents optimised tool change, a monitoring view function to follow the process flow step by step, as well as a new interpolation function that generates new angle correction parameters to bend parts with thicknesses and bending lengths that do not correspond to the values saved in the database.
Also on show was the eP-1030 servo-electric press brake, which is now available with the new version of the bending follower option, allowing simpler and faster positioning of big and heavy parts that cannot be handled by a single operator. The eP-press can also be equipped with a flattening table to increase productivity and facilitate the operation. Wila-style upper and lower hydraulic tool clamping by Prima Power and an Iris Plus device for the real-time correction of angles complete the machine.
For further information www.primapower.com

CAD enhanced for smart manufacturing

LVD has released a new version of its CADMAN programming and shop management software. The v8.5 release includes enhancements for every CADMAN module, such as an improved dashboard for more intuitive use, and extends the software’s integration capabilities to include the next generation of LVD’s Touch-P punch-press control, as well as non-LVD cutting and punching equipment.

Beyond its new look and feel, there are major updates such as improved bend solution identification in CADMAN-B bend CAM software, including tool pre-selection based on active catalogue(s). Furthermore, CADMAN-B is now available for use with LVD’s Synchro-Form press brakes. Synchro-Form is the next generation of adaptive bending system designed specifically for the forming of XXL profiles.
The company’s Touch-B control software, which can be used in combination with CADMAN-B, is also improved. Here, the time between
bending parts is now said to be optimised, resulting in a significantly higher press
brake speed.
CADMAN-L and CADMAN-P CAD/CAM software modules have been upgraded with advanced nesting capabilities for laser cutting and punching. New functions such as ‘minimal heat impact’ when finishing parts one by one, as well as material thickness defined parameters, ensure more smooth and automatic preparation for laser cutting. For punching, smart functionality such as ‘avoid hits with form tools’ and ‘punch with form tools last’ ensure reliable punching preparation. In the common module, parts can be detected automatically or manually in a multiple-part drawing.
Finally, CADMAN-SDI (Smart Drawing Importer), makes generating accurate cost estimates from imported CAD files easier and more accurate with a greater number of built-in cost drivers that help fabricators identify their indirect manufacturing costs.
For further information www.lvdgroup.com

Compact, ergonomic, productive press brake

Amada has unveiled its new compact press brake. The HFE-5012M2 is designed with user ergonomics and high productivity in mind when bending small parts of medium complexity. The machine provides 50 tonnes of bending force and a working width of 1270 mm.

HFE M2 5012, presse plieuse, prise de vues le 15 novembre 2017, usine de Chateau du Loir.
(photo by Patrick Berger)

Due to the performance of the upper beam, combined with the velocity and flexibility of the new back gauge, efficiency is said to be a primary attribute of the HFE-5012M2. The open height of the frame has been increased, resulting in an optimised solution for all tooling types, and allowing for deeper box bending. Furthermore, the new, narrower lower beam increases process flexibility and combines ergonomics with crowning precision, while the back gauge with active security provides both better productivity and safety with its high-speed motion yet low-impact force.
Amada’s HFE-5012M2 has been equipped with several features designed specifically to support the comfort of the operator, including: a reclining and adjustable table; an ergonomic chair with adjustable height and back-rest inclination; a retractable foot rest; six drawers (located at a convenient height) equipped with tooling and inserts; and a workplace lighting kit.
The HFE-5012M2 is the first in a series of bending machines developed to more carefully consider actual working environments, aiding the operator’s daily activity with the benefits of comfort and enhanced productivity.
For further information www.amada.co.uk