Post on 31-Jan-2016
description
Glossary
ACUTE ANGLE: An included angle tighter (less than) than 90 degrees. (The
material has been bent past 90 degrees) (see page 5)
AIR BEND: A bend determined by one line of force against two lines of
resistance. The BEND RADIUS is determined by die width and
material thickness. The bend angle is determined by punch
penetration.
APEX: The imaginary point where the two sides of an angle, if extended,
would meet. (see page 5)
BED: The load bearing surface of the lower beam.
BEND ALLOWANCE: The length of the neutral line through the bend from tangent line
to tangent line.
BEND DEDUCTION: Amount deducted from overall size to determine shear
dimensions. Abbreviated as B/D. Also known as “K” factor.
Equal to two times “set back”.
BEND LINE: Line on work piece where punch contacts material.
BEND RADIUS Curvature of material at the bend, expressed as distance from the
material to the center point of that bend. Also see Inside Radius.
BOTTOM BENDING: When material is pressed between the punch and die, the punch
tip penetrates the material. The inside radius is determined by the
punch tip. Bend angle is determined by tooling.
COINING: Process of bending by applying large amounts of force to cause
material to flow. Springback is eliminated, because the material
in the bend zone undergoes plastic deformation. The inside radius
of the bend is determined by the radius of the punch tip.
DIE: The concave, or female tool. Normally mounted on the bed, or on
spacers mounted on the bed.
DISTANCE PIECE: Punch holders on Amada style machine. Used to adjust for
varying amounts of ram and/or beam deflection.
FLANGE: The portion of sheetmetal that has been formed up or down to
obtain rigidity or desired shape.
Amada School Bending Workbook Version 1.4d, April 2002
Page 2 Glossary
HEM: A bend where the sheetmetal is folded over on top of itself. This
may be done to provide a smooth edge, to provide stiffness, or to
join two pieces together.
INCLUDED ANGLE Angle formed around the punch.
INSIDE RADIUS Distance from the inside surface of the material at a bend to the
center point of that bend. Abbreviated as IR. (see page 5)
HYDRAULIC Machine driven by fluid power provided by hydraulic pump.
NEUTRAL LINE: Line through the material that remains at constant length when
the material is bent. (see page 26) Used for flat pattern
development.
OBTUSE ANGLE: An included angle of greater than 90 degrees. (The sheet metal
has not been bent far enough to reach 90 degrees)
OPEN HEIGHT: Distance between the ram and bed of machine when the ram is
fully retracted.
PRESS BRAKE: Machine designed to form metal parts using punch and die.
PUNCH: The convex (male) tool. Normally mounted to the upper beam.
RAM: Beam that moves to supply bending force, can be upper or lower.
SET BACK: Amount of material deducted from flange length to place bend
line. Same as ½ of the bend deduction or ½ “K” factor.
SHEAR SIZE Dimension of blank piece before bending.
SHUT HEIGHT: Distance between upper and lower beams when the ram is fully
extended.
SPRINGBACK: Tendency of material to return to flat condition after forming.
(see page 26)
TANGENT: The point where a line meets a radius.
TENSILE STRENGTH: Measurement of resistance (in pounds/square inch or similar
units) that metal can be stretched before fracture.
UPPER BEAM: Upper part of machine that holds tooling and supplies bending
force or resistance depending on machine style.
YIELD STRENGTH: Measurement of resistance (in pounds/square inch or similar
units) that metal can be stressed before forming.
Version 1.4d, April 2002 Bending Workbook Amada School
Glossary Page 3
The Basics of Brake BendingIn brake bending, the material is supported by a die and a punch is forced intothe material. The punch is centered between the two edges of the die, causingthe material to bend evenly on each side of the punch.
The first illustration below showsa punch and die with materialpartially bent. The secondillustration shows some of theforces involved and the materialmotion during the bend.
Amada School Bending Workbook Version 1.4d, April 2002
Page 4 The Basics of Brake Bending
Simple bend
Punch
materialmotion
materialmotion
Die
Forces in simple bend
Bend Angle
When sheet metal is bent in a press brake, it (usually) begins “in the flat”. Asit is bent, the angle can be described by either of two numerical values:
The “included angle” is the angle formed around the punch.
The “complementary angle” is the amount the metal has been bent from flat.
The two angles always sum to 180 degrees.
Version 1.4d, April 2002 Bending Workbook Amada School
The Basics of Brake Bending Page 5
f H
30°
IR
IR
IR
Angle A
Angle A
Apex
90°90°
1.815"
135°
45°0.234"
45 complementary angle,
135 included angle
°
°
T
Materials
Materials
Purpose of chapter
This chapter contains general information about various materials, such asCarbon Steel, Aluminum and various alloys. Also presented are Inch-Metricconversions, Fraction to decimal equivalents, and sheet weights for variousmaterial thicknesses and sheet sizes.
Amada School Bending Workbook Version 1.4d, April 2002
Page 10 Materials
Conversions
Version 1.4d, April 2002 Bending Workbook Amada School
Materials Page 11
InchFractions
InchDecimal
Milli-meters
1/64 0.015625 0.397
1/32 0.031250 0.794
3/64 0.046875 1.191
1/16 0.062500 1.588
5/64 0.078125 1.984
3/32 0.093750 2.381
7/64 0.109375 2.778
1/8 0.125000 3.175
9/64 0.140625 3.572
5/32 0.156250 3.969
11/64 0.171875 4.366
3/16 0.187500 4.763
13/64 0.203125 5.159
7/32 0.218750 5.556
15/64 0.234375 5.953
1/4 0.250000 6.350
17/64 0.265625 6.747
9/32 0.281250 7.144
19/64 0.296875 7.541
5/16 0.312500 7.938
21/64 0.328125 8.334
11/32 0.343750 8.731
23/64 0.359375 9.128
3/8 0.375000 9.525
25/64 0.390625 9.922
13/32 0.406250 10.319
27/64 0.421875 10.716
7/16 0.437500 11.113
29/64 0.453125 11.509
15/32 0.468750 11.906
31/64 0.484375 12.303
½ 0.5000000 12.700
33/64 0.515625 13.097
17/32 0.531250 13.494
35/64 0.546875 13.891
9/16 0.562500 14.288
InchFractions
InchDecimal
Milli-meters
37/64 0.578125 14.684
19/32 0.593750 15.081
39/64 0.609375 15.478
5/8 0.625000 15.875
41/64 0.640625 16.272
21/32 0.656250 16.669
43/64 0.671875 17.066
11/16 0.687500 17.463
45/64 0.703125 17.859
23/32 0.718750 18.256
47/64 0.734375 18.653
3/4 0.750000 19.050
49/64 0.765625 19.447
25/32 0.781250 19.844
51/64 0.796875 20.241
13/16 0.812500 20.638
53/64 0.828125 21.034
27/32 0.843750 21.431
55/64 0.859375 21.828
7/8 0.875000 22.225
57/64 0.890625 22.622
29/32 0.906250 23.019
59/64 0.921875 23.416
15/16 0.937500 23.813
61/64 0.953125 24.209
31/32 0.968750 24.606
63/64 0.984375 25.003
1 1.000000 25.400
1” = 25.4 mm = 2.54 cm
1 cm = 0.3937”
1 mm = 0.0394”
MM to Inch
Amada School Bending Workbook Version 1.4d, April 2002
Page 12 Materials
MM INCH
0.1 0.0039
0.2 0.0079
0.3 0.0118
0.4 0.0157
0.5 0.0197
0.6 0.0236
0.7 0.0276
0.8 0.0315
0.9 0.0354
1 0.0394
2 0.0787
3 0.1181
4 0.1575
5 0.1969
6 0.2362
7 0.2756
8 0.3150
9 0.3543
10 0.3937
11 0.4331
12 0.4724
13 0.5118
14 0.5512
15 0.5906
16 0.6299
17 0.6693
18 0.7087
19 0.7480
20 0.7874
21 0.8268
22 0.8661
23 0.9055
24 0.9449
25 0.9843
26 1.0236
27 1.0630
28 1.1024
29 1.1417
MM INCH
30 1.1811
31 1.2205
32 1.2598
33 1.2992
34 1.3386
35 1.3780
36 1.4173
37 1.4567
38 1.4961
39 1.5354
40 1.5748
41 1.6142
42 1.6535
43 1.6929
44 1.7323
45 1.7717
46 1.8110
47 1.8504
48 1.8898
49 1.9291
50 1.9685
51 2.0079
52 2.0472
53 2.0866
54 2.1260
55 2.1654
56 2.2047
57 2.2441
58 2.2835
59 2.3228
60 2.3622
61 2.4016
62 2.4409
63 2.4803
64 2.5197
65 2.5591
66 2.5984
67 2.6378
MM INCH
68 2.6772
69 2.7165
70 2.7559
71 2.7953
72 2.8346
73 2.8740
74 2.9134
75 2.9528
76 2.9921
77 3.0315
78 3.0709
79 3.1102
80 3.1496
81 3.1890
82 3.2283
83 3.2677
84 3.3071
85 3.3465
86 3.3858
87 3.4252
88 3.4646
89 3.5039
90 3.5433
91 3.5827
92 3.6220
93 3.6614
94 3.7008
95 3.7402
96 3.7795
97 3.8189
98 3.8583
99 3.8976
100 3.9370
0.001” = 0.0254 mm
Standard gauges of sheet metal
Version 1.4d, April 2002 Bending Workbook Amada School
Materials Page 15
Specifications of selected Materials
Amada School Bending Workbook Version 1.4d, April 2002
Page 16 Materials
Other Alloys
Version 1.4d, April 2002 Bending Workbook Amada School
Materials Page 17
Type Element StockYield
StrengthTensile Strength Rockwell
Hastelloy-X Co 1.5 Fe 18.5 Cr 22.0Mo 9.0 W0.6 C0.15
C0.17 Ni bal.
Wrought Sheetmill annealed
Investment Cast
26000-
23300
5600033500
-
20.818.4
-
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Hastelloy-C Cr 16.0 Fe 6. W 4. C.15 Mo 17. Ni bal.
Sand cast (anneal.)Investment castRolled (anneal.)
250002500035500
390004000065000
21.32322
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Inconel-C Cr 13. Cb 2.Mo 4.5 C .15
Ti .6 Al 6.Ni (+Co) bal.
Investment cast(anneal.)
5100060000
Application: high strength, high temp engine parts, resistant to oxidation at high temps
Inconel-X Ni (+Co) 72.85Mn .65 S .007Cu .05 Al .75
Cb (+Ta) .85 .04 Fe6.8 Si .3
Cr 15. Ti 2.5
(Anneal.)Age Hardened
2500052500
5250087500
1632.2
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Waspoloy C .08 Cr 19.5 Mo 4.3Ti 3. Co 13.5
Cold Rolled 13500 137500 51
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Udimet 700 C .08 Cr 15. Mo 5. Ti3. Al 4.3 Co 18.5
Cold Rolled 140000 142500 53
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Zinc-40 Cu 1. Zn bal. Hot RolledCold Rolled
--
1200015500
5.66.4
Application: Weatherstripping, spun pieces.
Zinc ASTMB69
Cd .35 Pb .08 Zn bal. Hot Rolled 9.75 4.1
Zilloy-15 Cu 1.0 Mg .01Zn bal.
Hot RolledCold Rolled
14.5 6.5
Amada School Bending Workbook Version 1.4d, April 2002
Page 18 Materials
Aluminum
Version 1.4d, April 2002 Bending Workbook Amada School
Materials Page 19
Amada School Bending Workbook Version 1.4d, April 2002
Page 20 Materials
Notes on Aluminum
Three common grades of aluminum are:
5052-H32 Easy to work with, warps easily.
5051-H32
6061-T6 Usually quite flat but doesn’t form well. (cracks)
Hardness may be designated by “T” and a number, 0~80 = dead soft2 = ¼ hard4 = ½ hard6 = ¾ hard8 = full hard
Version 1.4d, April 2002 Bending Workbook Amada School
Materials Page 21
Bending Theory
Bending TheoryThis chapter describes how material responds to bending stress, the three typesof bends, and what happens to the work piece as it is being formed.
Stresses and springback
While a blank is still flat, both sides and the middle are all the same length. Aswe form the material in the die space the material towards the inside of theneutral line is compressed, and the material towards the outside of the neutralline is stretched. Material that is compressed or stretched enough will staypermanently deformed. That material has been “plastically deformed”.
Now picture a band of metal following the neutral line that has not beencompressed or stretched enough to reach a “plastic” condition. This band ofmaterial maintains an “elastic” condition. This elastic material will tend toreturn to its original unbent position, tending to straighten the material. Theforces of the “elastic” metal (trying to return to its original condition) and theforces of the “plastic” metal (trying to stay permanently deformed) come to anequilibrium, determining “spring back”.
☞ The amount of spring back is determined by the amount of materialstressed enough to reach a plastic condition.
Harder metals will have more spring back due to the higher elastic limit, whichresults in a larger elastic band at the bend.
As metal is bent farther (through more degrees) the plastic zone becomeslarger, reducing the amount of springback.
A sharper or smaller bend radius will reduce spring back by creating a largerplastic zone, due to the higher tensile stresses at the outside surface of thematerial at the bend radius. This may also cause tearing or fracturing.
Amada School Bending Workbook Version 1.4d, April 2002
Page 26 Bending Theory
NEUTRAL AXIS
TENSILE STRESSES
COMPRESSIVESTRESSES
OUTER ZONE PLASTICALLYDEFORMED BY TENSION
INNER ZONE PLASTICALLYDEFORMED BY COMPRESSION
ELASTIC ZONE
SPRINGBACKNEUTRAL AXIS
SPRINGBACKFORCES
Considering no change in the inside radius, thicker materials have less springback since there is more plastic deformation.
Overcoming Spring backMethods of overcoming spring back include over-bending, bottoming orsetting, and stretch bending.
OVER BENDING is bending the material past the target angle, so that it re-laxes to the correct position. This may be accomplished using common meth-ods: tooling with an angle smaller than the required bend, or cam dies.BOTTOMING consists of striking the metal severely at the radius. This com-presses the material beyond the yield strength and causes a larger plastic zone.Bottoming must be carefully controlled. When adjusting ram depth settings,forces will rise at a high rate, careless operation can cause die breakage andeven machine failure.STRETCH BENDING uses a special setup or special tooling to stretch theworkpiece to bring the entire bend zone into yield, so that it retains its shapewhen released.
When a work piece is flat the neutral line is in the center of the material. Asthe material is formed the neutral line shifts toward the inside radius of thebend.
As the radius of the bend is decreased the neutral axis of the material will shiftcloser to the inside surface.
The length of the neutral axis, which is the object of the blank sizecalculations, is dependent on the following factors:
type of forming employedmaterial type and hardnessinside bend radius (as related to material thickness)grain direction
Since the neutral line is affected by each of the variables listed, accurateblank size calculations can be difficult. There are several methods or formulascommonly used to calculate precise blank sizes. These formulas and charts arelisted in the Bend Allowance Chapter. (See page 46 )
Version 1.4d, April 2002 Bending Workbook Amada School
Bending Theory Page 27
Bending Methods
There are basically three types or methods of bending sheetmetal with a pressbrake: Air Bending, Bottoming, and Coining
Air BendingThe angle is determined by the penetration of the punch tip into the dieopening. The inside radius of the bend is determined by the width of the dieopening, except soft materials such as some aluminums which may conform tothe punch radius. An inside radius of 15% of the vee die width can be expectedwhen forming mild steels. Smaller vee die widths decrease inside radius whileincreasing tonnage requirements.
If the die width is too small, excessive tensile stresses will occur, which cancause fracturing. Larger die widths increase inside radius and reduce tonnage.Excessive die width will draw too much material into the vee and may cause abulge in the outside radius of the bend.
Air bending requires minimum tonnage,extending the brake’s capacity and reducingwear. Tooling becomes more versatile and less“per job” tooling is required.
Air forming is practical for precision work. Theability to determine the inside radius by veewidth rather than punch radius can increase theshop versatility, allowing the brake operator to“fudge” on bend deduction figures by changinginside radiuses. This allows the operator the ability to adjust for blanks thatmay not meet tolerances. Within reasonable vee sizes, material imperfectionswill not greatly affect the given angle.
Amada School Bending Workbook Version 1.4d, April 2002
Page 28 Bending Theory
Bottom Bending
Bottoming is accomplished by striking thematerial severely at the bend radius. Toolingconfiguration determines bend angle, partshape, and inside radius. Material greater than16 gauge is seldom bottomed due to the largetonnage requirements.
Bottoming puts a tremendous amount of forceon the brake and tooling. Great care must betaken during set up to avoid damage tomachine tooling and the operator. Pressmaintenance becomes crucial to press life. Bending accuracy can be veryconsistent but extensive set up by experienced operators must take place first
CoiningA coining operation is one in which the amount of force applied to the workpiece is enough to cause the material to “flow”. If you look at the cross sectionof a coin you will notice that the material has been struck so hard that thematerial between the thinner areas of the die set have been forced to “flow”into the thicker areas. Forces of 100 tons per square inch are not uncommon.Coining is seldom performed on a press brake due to the tonnage requirementsalthough “bottom bending” is often referred to as “coining” in many shops.
Version 1.4d, April 2002 Bending Workbook Amada School
Bending Theory Page 29
Blueprint reading
Blueprint readingThis section presents some commonly used symbols, followed by samples andexercises in basic blueprint reading.
Amada School Bending Workbook Version 1.4d, April 2002
Page 34 Blueprint reading
Figure 1
First-angle or Third-angle projection describes how the part is rotated fromview to view.
Version 1.4d, April 2002 Bending Workbook Amada School
Blueprint reading Page 35
Perpendicularity
Angularity
Parallelism
Position
.XXX M B C
A ReferencedatumsModifier
Tolerance
Type ofcontrol
Datumsymbol
Third-angle First-angle
U.S. customary projection ISO projection
Amada School Bending Workbook Version 1.4d, April 2002
Page 36 Blueprint reading
1.50"
12.00"
1.00"9.00
"
4.50
"
9.00
"2.
00" 2.00"
0.75"
0.206 RO(4 plcs)
Figure 2
Version 1.4d, April 2002 Bending Workbook Amada School
Blueprint reading Page 37
0.50"
1.25"
0.63"
0.38"
0.50"
0.688”
1.25"
0.88"
0.375"0.437"
0.875"
Figure 3
Amada School Bending Workbook Version 1.4d, April 2002
Page 38 Blueprint reading
0.250"
0.187"
0.500"
1.000”
0.250”
1.000"
0.375"
0.767"
0.126 DIA
(2 PLCS)
0.125"
1.250"
1.250"
Figure 4
The drawing on this page shows an assembly of three individual parts.
On the following pages, the individual parts are drawn.
Version 1.4d, April 2002 Bending Workbook Amada School
Blueprint reading Page 39
1.343"
0.563"PART 1
PART 3
PART 2
Figure 5
Amada School Bending Workbook Version 1.4d, April 2002
Page 40 Blueprint reading
0.672"
1.657"
0.578"
0.313"
0.501"
0.28
1"
0.40
5"0.
188"
0.25
0"
0.68
8"
1.68
8"
1.844"
Part 1Material thickness: 0.094”
Figure 6
Version 1.4d, April 2002 Bending Workbook Amada School
Blueprint reading Page 41
1.657"
0.656"0.313"
2.281"
0.313"
0.078"
0.500"
0.656"
1.125"
0.469"
0.156"
0.156"0.125"
0.125"
1.345"
Part 2
material thickness: 0.094”
Figure 7
Amada School Bending Workbook Version 1.4d, April 2002
Page 42 Blueprint reading
0.344" 0.297"
1.657"
0.500"
0.156"
0.156"
1.000"
0.688"
0.313"0.375"
1.033"
0.312"
0.359"
0.280"
1.406”
1.657"
0.125"
Material thickness: 0.094”
Part 3
Figure 8
Bend AllowanceBend Deduction
Bend Allowance, Bend Deduction
Introduction
When bending material, several factors must be considered to create accurateresults. The neutral line, (herein referred to as N/L), is an imaginary line thatsplits the material thickness. The N/L is used in blank developmentcalculations.
The N/L is easily measured when the stock is flat. (See Figure 9) Now let usconsider this same piece of stock after it has been formed to 90 degrees.
Note the location of the N/L in reference to the measure points. On the left endof figure 10 the N/L is unchanged. On the right side the N/L is within thematerial and can’t be measured directly. In the shop we can only measurefrom the outside or the inside of the flange at point B. Measuring to theoutside edge of the flange is usually easy and accurate, and has become themost common and preferred way to develop flat patterns. In either case(outside or inside measurement)we must compensate for thematerial that is between themeasurement point and the N/L.
Amada School Bending Workbook Version 1.4d, April 2002
Page 46 Bend Allowance, Bend Deduction
AA
NEUTRAL LINE
Neutral line touchescalipers at points A
Figure 9: N/L of flat material
BA
NEUTRAL LINE
Neutral line touches calipers atpoint A, but not at point B
Distance between theedge of the part andthe Neutral Line
Figure 10: N/L of material with bend
Bend Deduction
This material that lies between the N/L when measuring between points “A”also exists if we measure between points “A”, “B”. This would seem to makethe part “grow” when bent. The material does stretch some and, as wediscussed in the chapter on “theory”, we know that the N/L shifts a littleduring bending.
The “Bend Deduction” (hereinafter referred to as B/D) found in the charts orformulas in this book is adequate for most jobs. This assumes that precisionequipment is used and the tooling setup is known and correct for the job.
This also assumes that the material thickness and strength correspond to thoseused in developing the charts.
In some cases, it may be necessary to make a test bend using actual toolingand material.
Bend Radius
All the computations for bend allowance and bend deduction assume that thebending radius is known. The bend radius may be predicted as follows:
Bottoming or Coining:Punch tip radius = bend inside radius.
Air Bending:Determined by material thickness and Vee-Die opening. See the “Air BendingForce Chart” in the Amada Press Brake Tooling catalog.
Usage of Bend Deduction
The bend deduction method is most useful when a part (or bend within a part)is at 90 degrees or is dimensioned to the apex of the bend. When a bend is not90 degrees and is dimensioned to the material instead of the apex, the bendallowance method may be easier. (see page for the bend allowance method)
To use B/D: add the outside (apex) dimensions together, then subtract one B/Dfor each of the bends in the part.
Note: for a 90 degree bend, the “outside” dimension is the same as thedimension to the apex of the bend.
On the following pages we have provided a “Bend Deduction” chart for 90degree bends. This chart is generated from formula 3 on page 50.
The chart is provided for classroom use, and not shop use.
Version 1.4d, April 2002 Bending Workbook Amada School
Bend Allowance, Bend Deduction Page 47
Amada School Bending Workbook Version 1.4d, April 2002
Page 48 Bend Allowance, Bend Deduction
Insi
deR
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0.00
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70.
131
0.13
70.
143
0.15
1
0.05
90.
083
0.08
50.
088
0.09
40.
101
0.10
80.
113
0.12
10.
135
0.14
20.
147
0.15
5
0.06
00.
084
0.08
70.
089
0.09
60.
103
0.10
90.
115
0.12
30.
136
0.14
30.
149
0.15
6
0.06
30.
089
0.09
10.
093
0.10
00.
107
0.11
30.
119
0.12
70.
140
0.14
70.
153
0.16
0
0.07
40.
104
0.10
60.
108
0.11
50.
122
0.12
80.
134
0.14
20.
155
0.16
20.
168
0.17
5
0.08
00.
112
0.11
40.
117
0.12
30.
130
0.13
60.
142
0.15
00.
164
0.17
00.
176
0.18
4
0.09
00.
126
0.12
80.
130
0.13
70.
144
0.15
00.
156
0.16
40.
177
0.18
40.
190
0.19
7
0.10
50.
146
0.14
80.
151
0.15
70.
164
0.17
10.
176
0.18
40.
198
0.20
50.
210
0.21
8
0.12
00.
167
0.16
90.
172
0.17
80.
185
0.19
10.
197
0.20
50.
218
0.22
50.
231
0.23
9
0.12
50.
174
0.17
60.
178
0.18
50.
192
0.19
80.
204
0.21
20.
225
0.23
20.
238
0.24
5
0.13
50.
187
0.19
00.
192
0.19
90.
205
0.21
20.
217
0.22
60.
239
0.24
60.
251
0.25
9
0.18
80.
260
0.26
20.
265
0.27
10.
278
0.28
50.
290
0.29
80.
312
0.31
90.
324
0.33
2
0.25
00.
345
0.34
70.
350
0.35
60.
363
0.37
00.
375
0.38
30.
397
0.40
40.
409
0.41
7
Version 1.4d, April 2002 Bending Workbook Amada School
Bend Allowance, Bend Deduction Page 49
Insi
deR
adiu
s>
0.19
00.
203
0.21
90.
234
0.25
00.
312
0.34
40.
375
0.43
00.
500
Mat
eria
lth
ickn
ess
bend
dedu
ctio
n
0.01
60.
104
0.10
90.
116
0.12
30.
129
0.15
60.
170
0.18
30.
207
0.23
7
0.01
80.
106
0.11
20.
119
0.12
50.
132
0.15
90.
173
0.18
60.
210
0.24
0
0.02
00.
109
0.11
50.
122
0.12
80.
135
0.16
20.
175
0.18
90.
212
0.24
2
0.03
00.
123
0.12
80.
135
0.14
20.
149
0.17
50.
189
0.20
20.
226
0.25
6
0.03
20.
126
0.13
10.
138
0.14
50.
151
0.17
80.
192
0.20
50.
229
0.25
9
0.03
60.
131
0.13
70.
144
0.15
00.
157
0.18
40.
197
0.21
10.
234
0.26
4
0.04
00.
137
0.14
20.
149
0.15
60.
162
0.18
90.
203
0.21
60.
240
0.27
0
0.04
80.
148
0.15
30.
160
0.16
60.
173
0.20
00.
214
0.22
70.
251
0.28
1
0.05
00.
150
0.15
60.
163
0.16
90.
176
0.20
30.
217
0.23
00.
254
0.28
4
0.05
60.
159
0.16
40.
171
0.17
70.
184
0.21
10.
225
0.23
80.
262
0.29
2
0.05
90.
163
0.16
80.
175
0.18
20.
188
0.21
50.
229
0.24
20.
266
0.29
6
0.06
00.
164
0.17
00.
176
0.18
30.
190
0.21
60.
230
0.24
40.
267
0.29
7
0.06
30.
168
0.17
40.
181
0.18
70.
194
0.22
10.
234
0.24
80.
271
0.30
1
0.07
40.
183
0.18
90.
196
0.20
20.
209
0.23
60.
249
0.26
30.
286
0.31
7
0.08
00.
191
0.19
70.
204
0.21
00.
217
0.24
40.
258
0.27
10.
295
0.32
5
0.09
00.
205
0.21
10.
218
0.22
40.
231
0.25
80.
271
0.28
50.
308
0.33
8
0.10
50.
226
0.23
10.
238
0.24
50.
252
0.27
80.
292
0.30
50.
329
0.35
9
0.12
00.
246
0.25
20.
259
0.26
50.
272
0.29
90.
313
0.32
60.
350
0.38
0.12
50.
253
0.25
90.
266
0.27
20.
279
0.30
60.
319
0.33
30.
356
0.38
7
0.13
50.
267
0.27
30.
279
0.28
60.
293
0.31
90.
333
0.34
60.
370
0.40
0
0.18
80.
340
0.34
50.
352
0.35
90.
365
0.39
20.
406
0.41
90.
443
0.47
3
0.25
00.
425
0.43
00.
437
0.44
40.
451
0.47
70.
491
0.50
40.
528
0.55
8
Bend Allowance
There are several ways that formedparts are dimensioned. In certaincases it is easier to add the flatsegments of a piece (measured totangent points rather than apex)together, then add a “bend allowance”.
Bend Allowance is the length of theN/L between tangent lines.(see figure 11)
☞ Note:The “bend angle” used in Formulas 1, 4 (below) is the
complementary angle, not the included angle.(For angle definitions, conversions, and illustrations, see thefollowing pages)
B/A, B/D Formulas
Formula 1 is used to compute the B/A. This may be needed when computingblank layout or finding the B/D for an angle much bigger or smaller than 90degrees.
Formula 1:[(.0078 x Mat. Thickness )+ (.017453 x IR)] x bend angle = B/A
Bend Deduction Formulas
Formulas 2, 3 provide the B/D for a 90 degree bend. When used for non-90degree bends, they will be less accurate. For high accuracy of non-90 bends,see formula 4 on page 51.
Formula 2:
(3 x (Mat. Thickness + IR)) x = B/D for 90°
Formula 3:(.43 x IR) + (1.372 x Mat. Thickness) = B/D for 90°
Amada School Bending Workbook Version 1.4d, April 2002
Page 50 Bend Allowance, Bend Deduction
Tangent line
BA = Length ofNeutral Axis
Tangent line
I.R.
T = 0.048”
R = 0.030
Figure 11
0.454 for air bend
0.434 for bottom bend
Bend Deduction (cont.)
To determine B/D for angles other than 90 degrees, use formulas 1 and 4.Formula 1 provides the B/A , which is used in formula 4 to develop the B/D.
Formula 4:
( )22
×
× +
−
Tan
Bend AngleMtrlThickness IR B A/ *
=B D/
* See formula 1 (page 50) for B/A*Note: Any B/D divided in half equals “set back” for that bend.
Arc LengthArc Length: The length of a segment of a circle. This formula is used in stepbending.
6 28180
360.
*× ×
−
=radius
AArc length
*A = Included angle as shown infigures - on page 52.
AnglesThe “Included Angle” is the anglemeasured on the inside of thematerial. It is the angle used whenprogramming an Amadabackgauge.
The examples on the followingpage illustrate “included” and“complementary” angles, as well asother details of a bend. Also seepage 5.
Version 1.4d, April 2002 Bending Workbook Amada School
Bend Allowance, Bend Deduction Page 51
Tangent line
Outside arc length Tang
ent l
ine
T = 0.048”
R = 0.030
Figure 12
Angles (continued)The complementary angle andincluded angle always add up to180° .Acomp. Aincluded+ =180deg
Amada School Bending Workbook Version 1.4d, April 2002
Page 52 Bend Allowance, Bend Deduction
IR
135°
45°
45 complementary angle
135 included angle
°
°
Figure 13: Obtuse angle
IR
Angle A90°90°
90 complementary angle,
90 included angle
°
°
Figure 14: Right angle
IR
Angle A
Apex
150 complementary
angle, 30 included angle
°
°
T
30
150°
Figure 15: Acute angle
When to Use B/A
Figure16 depicts a piece bent at an acute angle.
Length B can be directly measured, as can the thickness. When a drawing isdimensioned to B or C as shown, use the B/A method (formula 1, page 50)
If the bend is dimensioned to the apex, use the B/D method instead.(beginning page 47)
Version 1.4d, April 2002 Bending Workbook Amada School
Bend Allowance, Bend Deduction Page 53
IR
Apex
B
B
IR+thkthk
C
Figure 16: Measuring acute angle
Hems
HEM: Where the material is folded on top of itself.
It is generally safe to use 43% of the material thickness for a hem deduction(up to about 0.080 thick).
For tolerances closer than about ± .005 in both directions, it is better topretest a piece of the material
Open Material Hem: Hem deduction is usually 0.Material is folded over with a gap of 1 material thickness left between thehem.
Note: Depending on how hard a hem is hit with a set of flattening dies the hemdeduction can vary.
Amada School Bending Workbook Version 1.4d, April 2002
Page 54 Bend Allowance, Bend Deduction
x 0.430.025 (hem deduction)
0.059 (material thickness)
± .005
± .005
Figure 17: Closed Hem
.750 .750-.025 (hem deduction)
2.25
.725+2.250
2.975 = developed length
Material thk.
Material thk.Distortion from flattening
Coining squeezes material out
Joggles
Generally, a joggle is formed by making a single hit with a special punch anddie set. A test bend can be made with the material to be used, if the adjustmentis not already known for the particular tool and material combination.
Version 1.4d, April 2002 Bending Workbook Amada School
Bend Allowance, Bend Deduction Page 55
IF THIS DIMENSION IS EQUAL TO A MATERIALTHICKNESS THEN IT IS CALLED AN OFFSET
MATERIAL IS PULLED INWHEN FORMING A JOGGLE
“JOGGLE ADJUSTMENT”
PART MEASUREMENT + JOGGLE ADJUSTMENT = BLANK LENGTH
2.952"
Figure 18
Flat Pattern Development
Flat Pattern DevelopmentFlat pattern development consists of several steps. These include calculation ofshear size, location of holes in the flat, determining other features such asnotches, and drawing or sketching the actual flat pattern.
Dimension Points
For bends other than 90° , the dimensions may be to the apex, or the tangentlines, or the physical inside or outside of the bend. For a 90° bend, the apexand outside measurements are the same.
Determining Shear Size
This procedure uses the B/D method.Step 1: Closely check the way your blueprint is dimensioned. Note which
dimensions are to the outside and or inside of the material.
Step 2: Determine Material thickness.
Step 3: Add together all of the OUTSIDE dimensions. (At each dimension calledout to the inside, add one material thickness to get the outside dimension.)
Step 4: Determine IR. (Refer to tooling catalog if needed)
Step 5: Use the B/D charts (pages 48, 49) or one of the formulas (page 50) todetermine the B/D. If more than one bend angle is used, then compute theB/D for bends of each angle.
Step 6: Add up number of bends for each bend angle.
Step 7: Take number of bends times the B/D.(if different angles, then number of bends of each angle times the B/D forthat angle, add it all up)
Step 8: Shear Size.= (outside dimension in Step 3 ) - (total from step seven)
Amada School Bending Workbook Version 1.4d, April 2002
Page 60 Flat Pattern Development
Example 1Step 1: Dimensions check- this drawing
only has a 90 bend, so the apexand outside dimensions are thesame.
Step 2: Thickness is 0.125
Step 3: Total outside dimensions are1.000 + 2.000 = 3.000
Step 4: Inside radius = 0.500
Step 5: Computed B/D = 0.387
Step 6: Number of bends = 1
Step 7: Total B/D ⇒1 x 0.387 = 0.387
Shear Size ⇒3.00 - .387 = 2.613
Version 1.4d, April 2002 Bending Workbook Amada School
Flat Pattern Development Page 61
Acute Angle / ApexIn this example, the dimensions are called out to the Apex of the angle (point“A”). The B/D method is used.
If your print is dimensioned to the edge of the part (dimensions “B”) you caneither:
a. Calculate (using Trigonometry) the position of the Apex, and use the B/Dmethod of Example 1b. Subtract a material thickness and an inside radius to find the tangent dimen-sion (A), then use bend allowance formula to solve (as in example 3).
When a bend is dimensioned to the tangent points (dimensions “A”):Use the bend allowance formula to solve, as in example 3, page 63. For partmeasurement, add a material thickness and an inside radius to find the outsidedimension.
Example 2
Step 1: Dimensions check: angle isdimensioned to apex.Angle is 180 - 70 = 110 degrees.1
Step 2: Thickness is .07"
Step 3: Total outside (apex) dimensionsare 2.5 + 3.5 = 6.000
Step 4: IR = 1.000
Step 5: B/D = 1.076(Formula 4, page 51)
Step 6: Number of bends = 1
Step 7: Total B/D ⇒1 x 1.076 = 1.076
Shear Size ⇒6.000 - 1.076 = 4.924
Amada School Bending Workbook Version 1.4d, April 2002
Page 62 Flat Pattern Development
2.50"
3.50"
A
A
B
B
1.00 R
0.070"
70
1 Note the use of complementary angle here.
Acute Angle / TangentStep 1: This part (Example 3) is dimensioned differently than Example 2. Here, the
dimensions are to the tangent lines, not the apex.
Step 2: Add together the lengths of the flat segments. (from the edges of the part tothe tangent lines.)
Step 3: Determine material thickness.
Step 4: Refer to the B/D, B/A chapter, page 50. Using formula 1, calculate the B/Afor the given conditions.
Step 5: Add the results of Step 2 to the B/A (from step 4) = Shear Size.
Example 3Step 1: Dimensions check : dim to tangent.
Find complementary angle:180 - 70 = 110 degrees
Step 2: flat length ⇒1.500 + .750 = 2.25
Step 3: material thickness = 0.060
Step 4: B/A ⇒1.491
Step 5: Shear Size ⇒2.25 + 1.491 = 3.741
Version 1.4d, April 2002 Bending Workbook Amada School
Flat Pattern Development Page 63
Features in the Flat
To locate a hole or other feature “in the flat”, follow these steps:Step 1: Determine shear size
Step 2: Add OUTSIDE dimensions from edge of part to hole center.(Where dimensions are called out to the inside, be sure to add materialthickness to arrive at outside dimension.)
Step 3: Using the B/D that you used when developing the shear size, add thenumber of bends between the edge of the part and the hole center. TakeB/D times the number of bends.This assumes all bends of same angle and radius. If angle and radius vary,use the B/D computed for each bend.
Step 4: Distance of hole from edge = outside dimension (total from step 2 ) - totalB/D from step 3
Example 4Step 1: (t = 0.056, ir = 0.062, B/D = 0.103)
Shear size ⇒1.647
Step 2: total outside dimension ⇒1.00 + .375 = 1.375
Step 3: B/D x # bends ⇒1 x 0.103 = 0 .103
Step 4: step2 - step3 ⇒1.375 - .103 = 1.272
Amada School Bending Workbook Version 1.4d, April 2002
Page 64 Flat Pattern Development
Thickness = 0.056
Sketching the Layout
An easy way to draw a flat layout is to use mold lines. See the followingdrawing and explanation
Using MOLD LINES
The Mold Lines represent the outside lines of the flanges after they are bent.The distance between each pair of Mold Lines equals one B/D. In the aboveexample flange “A” is represented by dimension “A” on the M/L drawing.Flange “B” and “C” are shown the same way.
Once the M/L are in place, features located anywhere on the blueprint areeasily placed on the M/L drawing.
Each bend line is located midway between the corresponding pair of MoldLines. See “D” above.
A =
B =
C =
Shear Size =
Version 1.4d, April 2002 Bending Workbook Amada School
Flat Pattern Development Page 65
1.008"
0.750"
0.375"
0.254"
1.440"
AB
C
1.000"
Example print
A
B
C
D D
B/D B/D
t = 0.056ir = 0.062B/D = 0.103
Mold Line Drawing
Corner To Corner Notches
When manufacturing a box where a corner-to-corner type construction iscalled for, use this formula for calculating the depth of the notch.
Notch Depth = OUTSIDE flange dimension + material thickness - B/DRelief Hole Diameter = material thickness x 3.Center relief holes on bend lines.
The part shown on page 78 has relief holes and mold lines.
Amada School Bending Workbook Version 1.4d, April 2002
Page 66 Flat Pattern Development
corner-to-corner notch 50% weld notch
Closed notch Relieved notch
Notch Types
Basic Layout Exercises
Use Bend Deduction Charts on pages 48, 49
Exercise 1Solve for the shear size using Drawing 1
Thickness = .056
I.R. = .062
Shear size = __________
Exercise 2Solve shear size for drawing 1using new conditions.
Thickness. = .09
I.R. = .125
Shear size = __________
Exercise 3Solve shear size for Drawing 2.
Thickness. = .059
I.R. = .094
Shear size = __________
Exercise 4Solve shear size for Drawing 2using new conditions.
Thickness = .048
I.R. = .047
Shear size = ___________
Version 1.4d, April 2002 Bending Workbook Amada School
Flat Pattern Development Page 67
4.000”
0.750”
DRAWING 1
1.500”
0.625”
1.250”
DRAWING 2
Exercise 5Use Drawing 3 and solve shear size.
Thickness = .036
I. R. = .031
Shear Size = __________
Exercise 6Solve shear size for drawing 3 usingnew conditions.
Thickness = .074
I. R. = .075
Shear Size =__________
Exercise 7Use Drawing 4 and solve for shear size
Thickness = .056
I. R. = .075
Shear Size =__________
Exercise 8Solve shear size for drawing 4using new conditions.
Thickness = .105
I. R. = .203
Shear Size = _________
Amada School Bending Workbook Version 1.4d, April 2002
Page 68 Flat Pattern Development
1.750”
0.750”
0.875”Typ.
DRAWING 3
2.000”0.500”
typ
0.750”Typ.
DRAWING 4
Class Exercises
Class ExercisesExercise 9:
For Drawing 5, determine “Bend Allowance” then solve for shear size.
Mat. = .125
I.R. = .500
Bend Allowance = ________
Shear Size = ________
Amada School Bending Workbook Version 1.4d, April 2002
Page 72 Class Exercises
DRAWING 5
Exercise 10:Use Bend Deduction formula to solve for shear size in Drawing 6.
Mat. = .125
I.R. = .5
Bend Allowance = ________
Bend Deduction = ________
Shear Size = ________
Version 1.4d, April 2002 Bending Workbook Amada School
Class Exercises Page 73
DRAWING 6
Exercise 11:Solve for shear size and hole locationusing Drawing 7.
All dimension called from side “A”.
Mat. = .04
I.R. = .031
Shear Size = ________
Hole 1 = ________
Hole 2 = ________
Amada School Bending Workbook Version 1.4d, April 2002
Page 74 Class Exercises
1.000"
0.031” radius
0.375"
0.750"
0.750"
0.500"
0.250” dia.
0.187” dia.
A
DRAWING 7
Exercise 12:Solve for shear size and hole location for Drawing 8
All Dimension called out from edge A.
Mat. = .059
I.R. = .062
Shear Size = ________
Hole 1 = ________
Hole 2 = ________
Hole 3 = ________
Hole 4 = ________
Version 1.4d, April 2002 Bending Workbook Amada School
Class Exercises Page 75
2.750"
0.250"
1.000"
0.500"
1.500"
0.750"2.000"2 pl.typ.
2 pl.
0.500"
A
1
2 3
4
DRAWING 8
Amada School Bending Workbook Version 1.4d, April 2002
Page 76 Class Exercises
DRAWING 9
An important part of bending is determining a workable bend sequence.Find a workable sequence for Drawing 10.
The letters “A” - “F” on the drawing identify the respective bends.
Version 1.4d, April 2002 Bending Workbook Amada School
Class Exercises Page 77
A BC D
E
F
DRAWING 10
Drawings 11 and 12 show a simple box in the folded and flat conditions. Deter-mine the blank dimensions.
Amada School Bending Workbook Version 1.4d, April 2002
Page 78 Class Exercises
DRAWING 11
Version 1.4d, April 2002 Bending Workbook Amada School
Class Exercises Page 79
dim to center ofrelief hole
dim to center ofrelief hole
DRAWING 12
Bending Sequence
Version 1.4d, April 2002 Bending Workbook Amada School
Page 81
Bending SequenceThis chapter illustratesseveral bend profiles andshows a possible sequenceto use in bending eachprofile.
Legend
In the upper illustration,the circled numbers “①”indicate the bend number.The flanges are labelledH1, H2 and so forth.
In the lower illustration, thenumbers following the bendnumber indicate the flangescomprising the distance betweenthe gauge surface and the bendbeing made.
The graphics can be displayed onAmada press brakes equippedwith graphics displays.
Amada School Bending Workbook Version 1.4d, April 2002
Page 84 Bending Sequence
18
18
H1
H2
H3
H4
H5
14.514.5
75°75°
Bending Profile 1
*3
1
* 4
5
Bending Sequence
Version 1.4d, April 2002 Bending Workbook Amada School
Bending Sequence Page 85
100
H9
H8
H7H6 18
H5
H4H3
H2
H1
16
43 13.5
25
(165)
Bending Profile 2
1+2+3
4+5
6
*5
*9
*8
2
1
Bending Sequence
Amada School Bending Workbook Version 1.4d, April 2002
Page 86 Bending Sequence
Bending Profile 3
Bending Sequence
Version 1.4d, April 2002 Bending Workbook Amada School
Bending Sequence Page 87
17.5
12.5
43.5
11.5
21.5
H1
H2
H3H4
H5
H6
12
Bending Profile 4
*6
1
2
*5
3
Bending Sequence
☞ NOTE: Using this bendsequence, the second bendcreates a pinch point.
Amada School Bending Workbook Version 1.4d, April 2002
Page 88 Bending Sequence
25 mm
50 mm
20 mm
8 mm
Bending Profile 5
1
1+2
*4
Bending Sequence
Version 1.4d, April 2002 Bending Workbook Amada School
Bending Sequence Page 89
Bending Profile 6
Bending Sequence
Exercise Answers1. Shear size = 4.647
2. Shear size = 4.573
3. Shear size = 3.192
4. Shear size = 3.251
5. Shear size = 3.347
6. Shear size = 3.172
7. Shear size = 3.176
8. Shear size = 2.786
9. Bend Allowance = 1.067Shear size = 3.192
10. Bend Allowance = 1.067Bend Deduction = .718Shear size = 4.657
11. Shear size = 1.682Hole 1 = .5Hole 2 = 1.307
12. Shear size = 4.686Hole 1 = .25Hole 2 = .892Hole 3 = 3.794Hole 4 = 4.436
Box SizesBox L = 7.806Box W = 5.806Notch Depth = 0.959Hole Location = 0.951
Amada School Bending Workbook Version 1.4d, April 2002
Page 90 Exercise Answers
SAFETY MEASURES Chapter 2 1/30 OPERATOR’S MANUAL HFE M2 – X41176A Issue 05/2010
2. SAFETY MEASURES
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On all machines
Risks of pinching or crushing between tools Risks of plucking or destruction between worksheet and tools during bending. Risks of injuries by sudden movements of the worksheet during bending. Electric danger Refer to the operator’s manual
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2.3. SAFETY PRECAUTIONS 2.3.1. GENERAL POINTS During machine installation, operation, and maintenance, apply all necessary safety measures, and the following in particular: • Do not adjust or service the machine until you have read the manual. • All electrical work must be performed by a qualified and authorized electrician to avoid all
equipment damage or physical injury. • Never place your hands between tools for any reason. • Do not modify the control circuits or any component of the machine. • Never use the machine with any of its safety devices removed or disabled. • Do not enter the safety zone or hazardous area protected by safety device. • Inspect the machine daily before starting work, ensuring that:
- All protective devices are in place. - The free space between the tools is not obstructed. - The access area for the various devices is clear. - The floor around the machine is free of grease, oil, and water.
• Never wear a tie, scarf, or loose clothing when adjusting or operating a press brake.
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2.6. PERSONAL PROTECTIVE EQUIPMENTS (PPE) The so-called “Personal Protective Equipments” (PPE) are not included in Amada supplies. You will find below as informative examples the type of Personal Protective Equipments possibly required on our machines:
• gloves, • helmets, • ear guards, • goggles, • safety shoes, • etc.
the user of these so-called PPE should check that they fully comply with the European directive. The employer is obliged to:
supply the appropriate PPE, ensure that the appropriate PPE are selected with regards to the risks involved, ensure that the employee is using them efficiently, ensure their compliance with the regulation, inform people who are responsible for the implementation (work shop manager,
foremen, etc.), ensure the PPE are in perfect working condition and periodic maintenance is
carried out, inform users which potential risks are protected by the use of PPE, train and lead users in the regular use of PPE.
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Figure 2.12
Figure 2.13
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2.7. RULES FOR SAFE OPERATION Release the part to be bent as soon as it is gripped between tools (Fig. 2.12).
Install or remove the tools in full compliance with the procedure described in the
Operator’s Manual (§ 7.5) and/or the recommendations specific to your tooling. (Fig. 2.13).
To avoid damage to your tooling or any accident, Amada urge you to follow strictly the procedure below :
• Every time you change a program, select adjustment mode and mute stop.
• Carryout a dry cycle • Check visually that all parameters correspond to the tooling
mounted on the machine, the mute point is 6 mm above sheet pinch point and the end of bend is correct.
• Switch to normal cycle.
CAUTION: Handling devices for heavy parts are not included in the Amada supplies. They must be installed for risk-free use in accordance with ergonomic principles.
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Figure 2.14
Figure 2.15
Figure 2.16
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Never attempt to support the end of the worksheet by holding it on either side of the tools. Only install the tool length required for the current job on the machine (Fig. 2.14).
Never place your hand between the worksheet and the backgauge during operation (Fig. 2.15).
Never place your part against/over the backgauge finger before backgauge is positioned on programmed position.
No part of your body must enter the hazardous area during bending operations (Fig. 2.16).
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Figure 2.17
Figure 2.18
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Beware of sudden movements of the worksheet during bending (Fig.
2.17).
Observe the allowable tool load (Fig. 2.18 and § 7.5). Par example : - 1,2 T/cm for standard punches, except: - 1,5 T/cm for heavy punches - 0,5 T/cm for punches with extra thin blades
(1 T = 10 kN) The specific value for each tool type is shown in the special Tooling catalogue (AMADA or equivalent).
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Figure 2.19
Figure 2.20
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The dutch bending or hemming tool should be firmly secured to the lower beam (Fig. 2.19). This type of tooling shouldn’t be used on “High Speed” press brakes i.e. where working speed can reach 20 mm/s.
Never hold the sheet by its folded edge; hold it from the sides (Fig. 2.20).