Pressing

Resource Material

Guidelines for bent parts

See below considerations when designing bent parts. In the event of deviations from our bending guidelines, we cannot guarantee professional production. Due to the additional technical clarification required, the delivery date and the component price can no longer be guaranteed.

Bent part quality:

Edge marks can always appear on bent parts, regardless of the unfoiled material, foiled material or visible side configuration.
The larger the bending area or leg length, the smaller the strength of the impressions (since larger tools and lower pressingforce can be used = greater leverage).

Limitations

Material: No hardened Material (QT, Bisalloy, etc.)
Maximum length: 3000mm*
Maximum sheet thickness: 12 mm
Maximum weight: manual handling max 50kg flip -75kg one side/direction
Box depth maximum: 144mm high standard or 235 mm with extensions**

*Long & wide parts may hit the frame internally if the leg length is greater than 400mm, if so, maximum part length = 2600mm.
** If channel width is less than height tool collision is likely

Requirements for your CAD files as per cutting plus
File format: Step preferred
Mirror parts must always be uploaded as separate items.
Pdf/drawing to

Tolerances

Pressing accuracy
typically +/-1mm and 1 deg -Varies with length, thickness and amount of folds.

Minimum leg length

In order to ensure parts can be manufactured, there are tool-related limit dimensions that must be considered during construction.If the bending leg is too short for the required lower tool, the desired bend cannot be created.The values may deviate depending on the geometry of the component and the length of the bend.

The minimum distance between the inner contour and the bend.

If the minimum hole spacing cannot be maintained due to the design, relief cuts can be made. These prevent bores or recesses from being distorted near the bending zone. The following points must be observed when designing relief cuts:

There must still be enough material in the bending zone to ensure the stability of the component.
Sharp-edged cut-outs, such as rectangles, are often a source of cracks because the material in the corners is weakened.
The ideal shape for cutting free the bending zone is a rectangular cut-out with rounded corners.

Relief cuts

There must still be enough material in the bending zone to ensure the stability of the component.
Sharp-edged cut-outs, such as rectangles, are often a source of cracks because the material in the corners is weakened.
The ideal shape for cutting free the bending zone is a rectangular cut-out with rounded corners.

Folding a part with a tapered point

If the component has pointed bends or other outer contours near the bending edge, the same rules apply here as for the minimum leg length.
From a certain point, the contour falls below the minimum leg length and the material no longer rests completely on the lowertool (die).As a result, this area can warp during the bending process or is not completely bent over.

To prevent this you have 3 options:
Remove the bend in the critical area (SLIT CUT)

Increase the bend in the critical area to the minimum leg length
Cut the bend free so that the critical area does not have to be bent as well

Minimum Z-bend height (Joggle)

In the case of two consecutive bends (Z-bend), the following minimum dimensions arise due to the tool.

Maximum leg length

Collision with the tool for U-profiles

If the bending legs are too long or the designed U-profile too narrow, a collision with the upper tool (punch) or the press beam above it can occur.From a material thickness of 6 mm, depending on the geometry and component size, no gooseneck punch (below) can be used, but only a straight punch. Possible solutions to this problem include slit cutting an edge for manual bending (requires post-welding), pre-bending, ‘W’ bend, leg removal or redesign.

Horn tools

Tools with lateral extensions (horn) make it possible to create hidden bending edges in closed-frame constructions.

Minimum bend radius

The values listed can vary greatly depending on the tool used.
The internal bending radii mainly result from the selection of the bending die, the selection of the bending punch has only a minimal influence.
The inner bending radii can vary depending on the material batch, tool condition and component geometry
Constructed radii are not taken into account during production unless you ask them specifically and are automatically changed to radii in the displayed range.

Bending undercut

Since laser cuts also have a minimum width, it is necessary for them to be displayed correctly in your CAD file.We would like to ask you to ensure that the laser lines are executed as bending undercuts.You can provide a small cut-out in your drawing for this. Without some space between the bending zones, the material can tear further along the cut.With some spacing between the bend zones, there is no notch effect and your part can be bent correctly.We recommend a slot width of at least 1mm with rounded corners.

Step Bending Large Radii

As we don’t roll in-house, an alternative we offer is step pressing.
Step Bending or Bump Bending is a method for forming a Large Bend Radius in a sheet metal part, without the need for special tooling, by creating a series of highly open bends in close proximity. This method will have advantages over using a roller because the length of the rolled section can be controlled more precisely with high repeatability. The drawbacks are that it takes some time to properly execute and is technically difficult. Each bend must be set up perfectly to prevent misalignment from propagating through the part.