May. 13, 2024
Sheet metal bending is the manufacturing process by which most enclosures, electrical boxes, brackets, and components are formed using a machine known as a CNC pressbrake (or sometimes referred to as a brake press).
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This technical article explains how fabrication companies bend sheet metal using these types of machines. We hope that after reading this technical article, you will have a better understanding of how sheet metal bending works.
Sheet metal bending involves the forming of metal into different geometries by applying force to deform the metal. It is referred to as sheet metal bending because a thin sheet of metal is bent once or multiple times to form the final geometry. The thickness of sheet metal used can vary, generally ranging up to 6 mm thick for sheet steel. The bend radius should be equal to or greater than the thickness of the material.
Sheet metal bending is also known as forming, edging, folding, flanging, press braking, or die bending. The term "press braking" refers to cases in which a press brake machine is used to bend the sheet metal.
The purpose of sheet metal bending is to form various features onto a sheet of metal, such as body panels, reinforcement struts, floor panels, brackets, or doors. Bending is a much faster, cheaper, and more efficient way of producing thin-walled parts, as opposed to machining.
Sheet metal bending is utilized in multiple industries, including construction, automotive, transport, aerospace, and infrastructure. It can create features such as lips, joggles, flanges, and indents, and sometimes used to increase the stiffness of sheet metal parts.
Sheet metal bending with a press brake involves aligning and holding the metal to be bent in the press brake tool. Once aligned, the press moves down and applies force to the metal, forming it into a new shape by creating angles. Press brakes can exert forces well over 100 tons to bend steel up to 3 mm thick.
Different machines can bend sheet metal, but the most common is a press brake machine, which can be either mechanical/manual or CNC-controlled. The following steps outline the operation of a CNC press brake machine:
Before using the press brake, calculate the design parameters, including the force required, bend line, and the order of bends. Decide on the die to be used for creating the bends.
Input the design parameters into the CNC machine. This ensures the right amount of force is applied to create the correct bends in the specified order. Attach the appropriate tool and die to the press brake.
Align the metal between the tool and die. When the machine operates, it bends the sheet of metal along the bend line.
Engage the press brake to apply the force parameters inputted into the CNC machine. Once the metal is bent, remove the part and prepare it for the next stage of production.
Laser cutting enhances the efficiency of sheet metal bending by minimizing the time needed to prep the sheet metal. It provides edges with tight tolerances that assist in precision bending. Learn more about improving your sheet metal bending process with our guide on metal furniture panel bender.
Various metals are suitable for sheet metal bending, including:
Versatile and economical, steel includes mild and stainless steel varieties, which are widely used in automotive applications.
Lightweight and cost-effective, aluminum is commonly used in aerospace, electronics, and automotive industries.
Learn more about the benefits and applications of an aluminum sheet bending machine.
Copper is soft and highly conductive, making it perfect for electrical applications.
Brass is highly machinable and used in decorative applications due to its aesthetic appeal.
Hard and corrosion-resistant, stainless steel is used in medical and food processing equipment.
With a zinc coating, galvanized steel offers excellent corrosion resistance and is cost-effective for its durability.
For more information, explore our resources on sheet metal bending and related machines.
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