How to accurately preview every bending deformation in sheet metal bending?
Publish Time: 2024-12-18
Sheet metal bending is a common machining process used to bend sheet metal into desired angles and shapes. Precisely rehearsing each bending deformation is crucial to improving production efficiency and product quality.1. Understand the basic principlesSheet metal bending is achieved by applying external force to plastically deform the metal sheet. During the bending process, the inner side of the metal sheet is compressed and the outer side is pulled, forming an arc. The angle and shape of the bend depend on the force applied, the geometry of the mold, the thickness of the sheet and the mechanical properties of the material.2. Selection of bending machineChoosing a suitable bending machine is the first step to accurately preview bending deformation. There are two main types of bending machines: CNC bending machines and hydraulic bending machines. CNC bending machines are suitable for bending complex shapes and precise angles, while hydraulic bending machines are suitable for mass production. In addition, the tonnage of the bending machine, the length of the workbench and the richness of the mold library must also be considered.3. Mold selection and optimizationThe mold is a key factor in the bending process. Choosing the right mold can significantly reduce bending deformation. The choice of mold includes upper mold and lower mold. The upper mold is usually a V-shaped groove, and the groove width is usually 8-12 times the thickness of the plate. The lower mold has various shapes, such as 90 degrees, 88 degrees, 30 degrees, etc., which need to be selected according to the bending angle. By optimizing the geometry and materials of the mold, bending accuracy can be improved.4. Plate pretreatmentBefore bending, proper pretreatment of the plate can reduce bending deformation. For example, annealing a sheet can improve its plasticity and make it easier to bend. In addition, ensuring that the surface of the plate is clean and free of oil and dirt can also reduce slippage during bending and improve bending accuracy.5. Bending parameter settingsBending parameters include bending force, bending speed, setback, etc. These parameters need to be set precisely according to the material of the sheet, its thickness and the required angle. For example, for harder materials, greater bending force is required; for thinner materials, slower bending speeds are required. By experimenting and adjusting these parameters, optimal bending conditions can be found.6. Prediction of bending deformationBending deformation can be estimated through mathematical models and empirical formulas. Commonly used methods include:R/T ratio: the ratio of bending radius to plate thickness. The larger this ratio is, the smaller the bending deformation is.K factor: A parameter describing the position of the neutral layer of the plate, affecting the calculation of the expansion length.Springback amount: The angle change caused by elastic recovery of the material after bending. The bending angle needs to be calculated and adjusted in advance.7. Use simulation softwareModern simulation software such as SolidWorks, ANSYS, etc. can simulate the sheet metal bending process and predict bending deformation. These software can take into account material properties, mold geometry, bending parameters and other factors to generate detailed deformation prediction maps. Through simulation, potential problems can be discovered and solved before actual production, thereby improving production efficiency.8. Actual testing and adjustmentDespite the help of theoretical calculations and simulation software, practical testing is still essential. Through small batch trial production, it is possible to verify whether the previewed bending deformation is accurate and make adjustments according to the actual situation. For example, if you find that the amount of springback is greater than expected, you can increase the bending angle appropriately or replace the mold with a harder one.9. Data recording and feedbackRecord the actual data of each bending, including bending angle, bending force, plate thickness, etc., and feed these data into the preview model to continuously optimize the preview accuracy. Through big data analysis, patterns can be discovered to improve the consistency and accuracy of bending.10. Continuous improvementThe bending process is a process of continuous improvement. With the emergence of new materials, new technologies and new equipment, bending preview models also need to be constantly updated. Maintaining an understanding of the latest bending technology through regular training and technical exchanges can improve the accuracy of rehearsals.By selecting the appropriate bending machine and mold, preprocessing the sheet, accurately setting the bending parameters, and using mathematical models, simulation software and actual testing, each sheet metal bending deformation can be accurately previewed. This not only improves production efficiency and product quality, but also provides strong support for responding to complex and changing production needs.
