Sheet Metal Bending Research Articles

Error compensation and path planning for sheet metal bending process based on improved modeling algorithms

Error compensation and path planning for sheet metal bending process based on improved modeling algorithms

Experimental Study on Springback Properties of 6061 Aluminum in V-Bending

Sheet metal bending is one of the most commonly applied methods among sheet metal forming operations. In this study, the springback behavior of aluminum alloys of different thicknesses was examined by performing v-bending processes at different die angles and widths. The experiments were carried out on 1 and 1.5 mm thick plates at die angles of 140°, 150° and 160° and three different die widths: 10 mm, 16 mm and 20 mm. In this experimental study, it was observed that springback decreased as the die width increased. As the die angle increased, springback values also increased. It has been observed that sheet thickness has little effect on springback. As the sheet thickness increased, the amount of springback decreased. The lowest springback value of 0.1° was obtained in the 1.5 mm thick specimen with a die width of 10 mm and a die angle of 140°. The highest spring-go value of -2.7° was obtained in the 1 mm thick specimen with a die width of 20 mm and a die angle of 140°. As a result of the variance (ANOVA) analysis, it was seen that the die width had a more significant effect (78.42%) on springback than the die angle. The effect of die angle on springback is 10.73%. As a result of the experiments and statistical analysis, it was seen that the parameter that most affects springback is die width.

Technology Updates on Plate Bending Machines with Hydraulic Systems

The swift progression of industrial technology has profoundly influenced the manufacturing sector, especially in the domain of sheet metal manipulation. Hydraulic plate bending machines hold a pivotal role in contemporary production due to their precision in shaping sheet metal components. This study aims to elevate the versatility and efficiency of hydraulic plate bending machines through innovative modifications. Key components underwent substantial alterations, including punch substitution, installation of dual punch locking plates, and integration of a pressure gauge. An evaluation ensued to determine the optimal parameters duration and force requisite for bending sheet metals ranging from 1 mm to 4 mm in thickness, aimed at assessing machinery efficacy. Test outcomes unveiled the modified machine's adeptness in accurately bending sheets of varying thicknesses, affirming its intended functionality. Moreover, the machine's enhanced adaptability allowed for seamless interchangeability of punches with diverse sizes and shapes. These empirical findings provide invaluable insights for enterprises striving to streamline manufacturing processes and boost overall productivity. Notably, this study highlights the pivotal role of technological advances in hydraulic plate bending machines, offering firms an efficient avenue to cater to diverse sheet metal shaping demands, thereby amplifying productivity and adaptability in industrial operations.

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Finite element method–based multi-objective optimization of press-brake bending of sheet metal

Finite element method–based multi-objective optimization of press-brake bending of sheet metal

Digital Twin-based Predictive Maintenance for Sheet Metal Bending

This paper focuses on the implementation of predictive maintenance processes using both physics-based and data-driven methods, specifically applied to a Salvagnini panel bender. The primary objective is to enhance production data analysis through digital twin predictions, enabling the calculation of process parameters that cannot be directly measured. Two key aspects are addressed in this study: Firstly, two global measures of the effective cumulative load on a machine during its lifetime are formulated. These measures can be used as criteria for estimating the health condition of a machine and for comparing different machines. To achieve this, dimensionless parameters are derived from actual production data. Secondly, a remaining useful life (RUL) model is developed for two machine components relying on production data analysis and digital twin predictions. The first component under consideration is a hybrid hydraulic actuator. Internal leakage prediction for this component is performed based on its data history, resulting in a corresponding trend curve. Additionally, wear of critical bearings is calculated using an analytical model that depends on the production history log. Through the proposed hybrid approach, this paper aims to enhance the predictive maintenance process by leveraging both physics-based and data-driven methodologies. The findings from this study can offer valuable insights for optimizing maintenance strategies and improving the overall efficiency of similar manufacturing systems.

Improving Press Bending Production Quality through Finite Element Simulation: Integration CAD and CAE Approach

Efficient operations and output of outstanding quality distinguish superior manufacturing sectors. The manufacturing process production of bending sheet metal is a form of fabrication in the industry of manufacture in which the plate is bent using punches and dies to the angle of the work design. Product quality is influenced by plate material selection, which includes thickness, type, dimensions, and material. Because no prior research has concentrated on this methodology, this research aims to determine V-bending capacity limits utilizing the press bending method. The inquiry employed finite element analysis (FEA), along with Solidworks was the tool of choice to develop drawings of design and simulations. The ASTM E290 standard guides this study. The software in this package may combine CAD (Computer-Aided Design) and CAE (Computer-Aided Engineering) without requiring extra design applications. This study tested SPCC and SPHC plate materials with five thickness variations. The findings embrace the number of failure risks associated with press bending exhibited on the von Mises stress diagram, which is directly proportional to showing the thickness limit of each material type throughout the bending process. The study's findings lay the groundwork for improving manufacturing quality by lowering the number of faulty goods produced by trial and error. Because the maximum allowable die width is 12 mm, the thickness limit of the press bending process is 2 mm. However, due to the greater intensity of the SPCC material, it has a reduced defect rate compared to SPHC material.

Product Design and Development According to the Project of Equipping the Summer Kitchen and Bar using Sheet metal Bending Tools

Product Design and Development According to the Project of Equipping the Summer Kitchen and Bar using Sheet metal Bending Tools

Modeling of Stainless Steel Bending Force on CNC Press Brake

Bending processing is one of the most common plastic deformation processing procedures. It is widely represented in the metal processing industry. In this paper, sheet metal bending on a CNC press with a tool that has two basic parts is analysed: the lower-die and the upper-punch. The sheet metal material is stainless steel, which is one of the most commonly used materials. During the bending process on presses, one of the main challenges is the experimental determination of the bending force. The methodology used in this work is based on the experimental stochastic method, that is, design of experiment. A rotatable plan for three input parameters: material thickness, bending angle and bending line length, are varied at five levels. The output parameter is precisely the bending force. No special devices are needed to measure the bending force as an output parameter, because the bending force is measured and registered on the CNC press via the control panel. After the experiment, using the experimental design matrix, the coefficients of an adequate nonlinear mathematical model were determined. Such a mathematical model is suitable for analysis and optimization of the bending force.

A data-driven simulation and Gaussian process regression model for hydraulic press condition diagnosis

Improving overall performance and increasing operational reliability are currently among the leading research topics in the field of hydraulic systems. In recent years, the use of artificial intelligence-based modeling and design techniques has developed rapidly to account for the nonlinear properties of Gaussian systems and to predict fault reasoning in hydraulic systems. In this study, feature acquisition and selection are proposed to prepare input data for a simulation-based learning approach. In addition, a cause-and-effect analysis is performed by considering various what-if scenarios as external disturbances that affect the response of the hydraulic press. While the objective of the sheet metal bending cycle and a pulley system is to initiate a load on the hydraulic press, an intelligent sensing system is used to observe the behavior of the hydraulic press during the phases of sheet metal bending cycle, i.e., the forming, leveling, and movement. In addition, the Gaussian process regression method is used to build data-driven prediction models with different predictors that contribute significantly to improving predictive accuracy. The condition diagnosis indicates the accurate performance of predictive models observing the coefficient of determination R2 at 0.998 for the bending phase, 0.962 for the leveling phase, and 0.999 for the movement phase. Although the approximation of the simulation model is efficient, it is found that certain features are reasonably well approximated with regard to the forming phases.

Dynamic analysis and sliding mode control method of 5-DOF manipulator

Background The five degree of freedom (5-DOF) manipulator greatly improves the machining efficiency and accuracy because of its high flexibility. They see wide application in various automation fields. The dynamic analysis and modeling of manipulators is of great significance to improve the working accuracy of a manipulator. Methods For the robot task of sheet metal bending, a 5-DOF manipulator based on sliding mode control strategy is designed in this paper. Firstly, the dynamics of the 5-DOF manipulator is analyzed and the dynamic equation is established. Secondly, based on the principle of sliding mode control, a proportional integral (PI) sliding mode control method for 5-DOF manipulator based on nominal model is proposed. PI sliding mode control method has the advantages of solving system deviation problem, eliminating steady-state error, strong adaptability, good robustness, sliding mode design and easy implementation. Finally, the sliding mode control simulation experiment of 5-DOF manipulator is carried out to verify its stability. Results The 5-DOF manipulator with PI sliding mode control has a good control effect by overcoming the influence of modeling error due to its strong robustness, and effectively realizes good control stability. Conclusions The experimental results show that the 5-DOF manipulator has good response speed and stability. The results also suggest that the manipulator can be widely used in complex scenarios such as medical surgery or industrial production line with high safety requirements.

Analysis of Printing Parameters for Sheet Metal Bending with FDM Printed Tools

The objective of this work is to use PLA plastic matrices printed using the FDM additive manufacturing technique as an alternative to conventional sheet metal bending. In this way, the demand of the industry to obtain highly customized short series bent parts at a reduced price is covered. To demonstrate this hypothesis, first, the maximum compressive strength of FDM printed specimens with different manufacturing parameters was characterized by performing a parametric analysis using a factorial design of experiments (DOE) model and based on the ISO 604 standard. Once the results were analysed, an articulated bending tool was designed and printed with the best configuration obtained previously. Then, 50 S280GD galvanized steel sheets of 1 mm thickness were bent. Finally, the bending angles of the sheets were examined, checking that the bending was performed correctly, obtaining the desired shape in the sheet. As for the analysis of the economic impact, a 97.75% reduction in the manufacturing price of the tooling with respect to conventional tooling was observed, demonstrating the viability of these dies in an industrial environment.

Applicability of a laser pre-treatment for a robust subsequent bending of thin sheet metal

In conventional bending, locally varying residual stress states are one of the main causes for dispersion of bending angle. In this paper, a novel approach is investigated to reduce the dispersion of bending angle by modifying the residual stress state of thin sheets prior to the forming process. For this purpose, steel sheets were pre-treated with a nanosecond-pulsed fiber laser in confined ablation. The deflections were compared to sheets processed with thermal laser bending. It is revealed that the thermal mechanism dominates with respect to the deflection of the sheet because the deflection is in the same direction as that of laser-bent sheets. However, the induced deflection is smaller compared to the laser-bent ones. Moreover, it can be demonstrated that the robustness of subsequent bending operations is increased by the laser pre-treatment. The increase in robustness allows to achieve narrower tolerance windows for thin sheet metal without using cost-intensive tools and high punch forces.

Step Bending of Sheet Metal in the Manufacture of Thin-Walled Body Parts

Step Bending of Sheet Metal in the Manufacture of Thin-Walled Body Parts

Study on the Influencing Factors and Forming Process Selection of Sheet Metal Bending Spring Back Defects

In recent years, with navigation, aviation, chemical manufacturing, and automobile bodies increasing requirements for lightweight, high efficiency, and energy saving, quality requirements in the selection of materials and manufacturing process are also improved. However, there is an unavoidable elastic deformation in the process of plastic bending deformation of the panel veneer, and the accuracy of the workpiece is impacted by the spring back phenomenon, which causes dimensional and shape inaccuracies in the panel veneer. The purpose of this paper is to summarize and analyze the phenomenon of flexural spring back caused by material selection and processing techniques and to discuss the solution of the flexion bounce problem from the material selection, processing method, and machining mold, which can be applied to avoid material wastage.

Sheet Metal Cutting and Bending by Pneumatic Actuator

Sheet Metal Cutting and Bending by Pneumatic Actuator

On the influence of tool contact stress on tensile instabilities in plane strain stretching and bending of sheet metals

It is well known that the widely used forming limit curve (FLC) based upon in-plane stretching fails to account for the delay in plastic instability in the presence of appreciable bending and tool contact pressure. The recently proposed General Incremental Stability Criterion (GISC) – a generalization of the Modified Maximum Force Criterion (MMFC) to triaxial loading – revealed the dependence of the boundary conditions on the formation of tensile instabilities. Nevertheless, it remains unclear how the combined effect of radial bending stresses and tool contact pressure affects the formation of an acute neck. It is shown in this study that a compressive normal stress causes a shift of the strain state from initial plane strain tension to positive minor strains for material layers within the cross-section. The convex (outer) layer remains in a state of plane strain-plane stress. Accounting for the shift in the strain state is key to capture the dependence of the contact pressure on necking. A simplified modelling approach, which enforces plane strain tension of the cross-section, was able to capture the formability gain due to bending but failed to account for the delay in plastic instability due to the contact pressure. An incremental multi-layer model was required to account for non-monotonic loading due to bending over the punch and the biaxial shift in the strain path caused by the contact pressure. The models were then applied to the experimental forming limits of a 3rd Gen 1180 advanced high strength steel to demonstrate the formability gains under triaxial loading due to the contact pressure.

Prediction of bending parameters and automated operation planning for sheet-metal bending orientated to graphical programming

Prediction of bending parameters and automated operation planning for sheet-metal bending orientated to graphical programming

Fabrication of Pneumatic Punching and Bending Machine Powered by Solar Panel

The sheet metal is majorly used in automobile and medical platforms. These are used in several places mainly, in small scale industries because the cost of hydraulic machine is not affordable in small scale industries. It gives major advantage in cost reduction. Therefore, many small scale and medium scale industries involving in sheet metal operations, punching, and bending works. This process is done by using compressor so the pressurized air is used in the process. This concept is used in construction and mechanical industries. Small scale mechanical industries and others which change sheet metal into various shapes by many operations such as cutting, punching, bending, blanking, trimming etc. Using different machining as per our search there is no machine which has bending and punching machine. The main drawback of this process is which is not having continuous power supply so we have concluded to make a supporting machine which can do both bending & punching operations in a same machine by using solar energy in this method we can overcome the lack of continuous power supply.

METHODOLOGY FOR CALCULATING THE COST PRICE OF THE BENDING PROCESS FOR THE NEEDS OF MANUFACTURING LOGISTICS

The research of this paper aims to characterize and describe the methodological sequence of operations necessary for the correct calculation of the cost price when performing a bid calculation in the bending process step on a bending machine. The research focuses on determining the methodology and its application exclusively to sheet metal parts in the engineering industry in the processing of steel and stainless-steel sheets. To research this issue, we used empirical and quantitative research in a real work environment. The methodology for calculating the cost price of bending sheet metal parts yields the relationships between component inputs, the result of which is a time parameter that is expressed by the actual production costs. The results can be used in the real working environment of manufacturing companies for comparison with already established practices and a verification of their outputs. At the same time, it is possible to use the determined methodological procedure as a basis for implementation in the Aurendi web application.