1. Definition of bending force of bending machine
The bending force of the bending machine refers to the force exerted on the metal plate during the working process of the bending machine. It is one of the key factors to ensure the quality of bending molding. This force’s size directly affects the plate’s deformation and the accuracy of processing and forming. In the bending operation, the bending machine bends the metal sheet along the required curve or angle by applying a certain amount of force to achieve the processing requirements of a specific shape.
2. Why do you need to calculate the bending force of the bending machine?
Accurate calculation of the bending force of a press brake is critical to every aspect of the metalworking process. Here are some important reasons why you need to calculate the bending force of your press brake:
2.1 Ensure bending quality
Accurate calculation of the bending force of the bending machine can help ensure bending quality. If the bending force is insufficient, it may cause problems such as breakage, springback, and wrinkling of the sheet, thus affecting the quality and accuracy of the processed parts. By reasonably calculating and controlling the bending force, it is possible to ensure that the metal sheet reaches the required shape during the bending process and avoid unnecessary damage and waste.
2.2 Improve production efficiency
Accurate calculation of the bending force of the press brake can also help improve production efficiency. Reasonable selection of the tonnage and process parameters of the bending machine can shorten the processing time and improve production efficiency. By accurately controlling bending forces, debugging time and scrap rates can be reduced, thereby reducing production costs and improving production line operating efficiency.
2.3 Reduce security risks
Accurately calculating the bending force of a press brake can also reduce safety risks. If the bending force is too large, it may cause the press brake equipment to be overloaded, resulting in equipment damage or the risk of personal injury or death. By reasonably calculating and controlling the bending force, the bending machine can be ensured to operate within a safe range and the safety and stability of the production site can be guaranteed.
3. What factors affect the bending force of the bending machine?
The bending force of the bending machine is affected by many factors, including the following aspects:
3.1 Material, thickness, width and length of the board
Material and thickness: The material and thickness of the plate are important factors affecting the bending force. Generally speaking, plates with higher strength and thickness require greater force to achieve the same deformation when bending. The force required to bend softer and thinner plates is relatively small.
Width and Length: The width and length of the sheet also affect bending forces. The greater the width and length, the longer the bending arm, and the same force will produce a greater bending moment on the longer bending arm, requiring greater force to complete the bending operation.
3.2 Mold shape and size
Mold opening width: The mold opening width determines the degree of local restraint the metal sheet receives during the bending process, thereby affecting the bending force. The smaller the opening width, the greater the constraints on the sheet and the greater the force required to complete the bend.
Shape of the mold: The shape of the mold also affects the bending force. Molds of different shapes exert different restraints on the sheet at different locations, thus resulting in different amounts of bending forces.
3.3 Tonnage and working speed of bending machine
Tonnage: The tonnage of the bending machine determines the maximum bending force it can provide. Bending machines with larger tonnage can provide greater bending force and are suitable for processing plates with thicker thickness or higher hardness.
Working speed: The working speed of the bending machine also affects the bending force. Faster working speeds may cause greater deformation of the plate, so greater force needs to be applied to ensure bending quality.
3.4 Lubrication conditions
Lubrication conditions: Good lubrication conditions can reduce friction and reduce the friction resistance between the plate and the mold, thereby reducing the bending force. Proper lubrication can effectively reduce energy loss and improve bending efficiency and quality.
4. How to theoretically calculate the bending force of a bending machine
The theoretical calculation of the bending force of a bending machine is a calculation method based on mechanical principles and mechanical properties of materials. By calculating the stress and deformation experienced by the metal sheet during the bending process, the required bending force is determined. The following are the basic steps for theoretical calculation of the bending force of a bending machine:
4.1 Determine the yield strength and fracture strength of materials
Before performing the theoretical calculation of the bending force of the bending machine, it is first necessary to determine the material properties of the metal sheet, including its yield strength and fracture strength. These parameters can be obtained by consulting material manuals, experimental tests, or technical information provided by the manufacturer.
4.2 Calculate the bending moment and torque resistance of the plate
According to the geometric dimensions and material properties of the metal plate, the material mechanics formula can be used to calculate the bending moment and torque resistance of the plate. Bending moment resistance refers to the ability of a plate to resist bending deformation when bent, while torque resistance refers to the ability of a plate to resist torsional deformation when twisted. These parameters are the basis for calculating the bending force of the bending machine.
4.3 Determine the bending arm according to the shape and size of the bending mold
The bending arm refers to the lever effect produced by the force exerted by the bending machine on the metal sheet. Its size depends on the shape and size of the bending mold. For molds of different shapes, the bending arm calculation methods are different. Generally speaking, the bending arm can be determined by measuring the geometric dimensions of the mold and the plate.
4.4 Calculate bending force by applying material mechanics formula
Finally, based on the bending resistance of the plate and the bending moment arm, the material mechanics formula can be applied to calculate the required bending force. Commonly used calculation formulas include bending moment formula and moment balance formula. Choose the appropriate formula for calculation according to the specific situation.
5. How to calculate the bending force of the bending machine using numerical simulation method
The numerical simulation method is a calculation method based on numerical simulation technology such as finite element analysis (FEA). By establishing a model of the metal plate and conducting simulations on a computer, more accurate bending force calculation results can be obtained. The following are the basic steps of how the numerical simulation method calculates the bending force of the bending machine:
5.1 Establish finite element model
First, a finite element model of the metal plate needs to be established, which includes defining the geometry, material properties, boundary conditions and loading methods of the model. During the modeling process, the actual geometry of the sheet metal as well as the constraints and support structures of the press brake need to be considered.
5.2 Set material properties
When establishing a finite element model, it is necessary to set the material properties of the metal plate, including elastic modulus, Poisson’s ratio, yield strength, etc. These parameters directly affect the mechanical behavior of the metal sheet during the bending process and are crucial to the accuracy of the simulation results.
5.3 Set boundary conditions
Setting boundary conditions refers to constraining the movement of the metal plate to simulate the constraint situation in the actual bending process. Common boundary conditions include fixed boundaries (such as fixing one side of a plate), displacement boundaries (such as applying displacement or pressure), etc.
5.4 Set loading method
In the numerical simulation, it is necessary to set the same load mode as the actual processing, that is, the force exerted on the metal sheet. This can be achieved by imposing corresponding loading conditions in the model, such as applying forces or bending moments normal to the plate surface.
5.5 Simulate the bending process
Using the established finite element model and the set loading conditions, numerical simulation is performed in the finite element analysis software to simulate the deformation and stress distribution of the metal plate during the bending process. During the simulation process, complex factors such as nonlinear deformation and contact deformation of the plate need to be considered to obtain more accurate simulation results.
5.6 Analyze the results and extract the bending force
Finally, the bending force data are extracted from the simulation results, analyzed and evaluated. According to the simulation results, the magnitude and distribution of the force exerted on the metal sheet during the bending process can be obtained, thereby obtaining the bending force of the bending machine.
6. How to optimize bending process parameters based on calculation results
According to the bending force calculation results of the bending machine, the bending process parameters can be optimized to improve bending quality, efficiency and safety. Here are some common optimization methods:
6.1 Select the appropriate press brake tonnage
Based on the calculated bending force, it is very important to select the appropriate press brake tonnage. The tonnage of the bending machine should be greater than or equal to the calculated bending force to ensure that the bending machine has enough power to complete the bending operation. Choosing the appropriate tonnage can avoid problems caused by too large or too small force and ensure the bending quality and equipment safety.
6.2 Adjust the shape and size of the mold
According to the calculation results, the shape and size of the bending mold can be adjusted to improve bending efficiency and quality. By adjusting the opening width and shape of the mold, the restraint of the metal sheet can be optimized, reducing local stress concentration and sheet deformation, thereby achieving more precise bending operations.
6.3 Determine reasonable bending speed and feeding speed
Bending speed and feed speed are also very important for bending quality and efficiency. Based on the calculation results of the bending force, determine a reasonable bending speed and feeding speed to match the bending force to avoid problems caused by too fast or too slow speeds. Reasonable speed setting can reduce the stress and deformation of the plate, improve the bending quality, and reduce the production cycle.
6.4 Adjust lubrication conditions
Good lubrication conditions are also crucial for bending operations. According to the calculation results of the bending force, the type and coating method of the lubricant can be adjusted to ensure that the friction coefficient between the plate and the mold is appropriate, reduce friction resistance, reduce the bending force, and improve the bending quality and efficiency.
6.5 Real-time monitoring and adjustment
In the actual bending operation, the bending force and plate deformation can also be monitored in real time, and the process parameters can be adjusted in time to adapt to the characteristics and bending requirements of different plates. By continuously optimizing process parameters, a more efficient and stable bending production process can be achieved.
7. Common problems and solutions encountered when calculating the bending force of the bending machine
When calculating the bending force of a press brake, you may encounter some common problems. Here are these problems and their solutions:
7.1 Inaccurate material parameters
Problem description: The accuracy of material parameters (such as tensile strength, yield strength) directly affects the accuracy of calculation results.
Solution:
Experimental tests: Experimental tests are conducted to obtain accurate values of material parameters.
References: Consult reliable materials manuals, databases, or literature for standard material parameter values.
7.2 The calculation process is complicated
Problem description: The calculation process of bending force on a press brake can be very complex, especially when complex plate geometries and loading conditions are involved.
Solution:
Finite element simulation: Use numerical simulation techniques such as finite element analysis (FEA) to perform simulation calculations on a computer by establishing a model.
Professional software support: Using professional numerical simulation software, such as ANSYS, ABAQUS, etc., can simplify the calculation process.
7.3 The calculation results are inconsistent with the actual situation
roblem description: In practical applications, the calculated bending force may deviate from the actual situation, resulting in poor processing quality or low production efficiency.
Solution:
Consider actual factors: Modify the calculation model by considering various factors in the actual processing process, such as friction, plastic deformation of the plate, etc.
Real-time monitoring and adjustment: In actual production, the bending force and plate deformation are monitored in real time, and the process parameters are adjusted in a timely manner.
7.4 Other issues
Problem description: Other problems that may be encountered include calculation errors, deviations caused by model simplification, etc.
Solution:
Calculation verification: Verify and compare calculation results to ensure the accuracy of calculations.
Comprehensive consideration: Comprehensively consider the impact of various factors on the calculation results to minimize the error.
8. Summary and conclusion: How to effectively calculate the bending force of the bending machine to improve processing quality and production efficiency?
Calculating the bending force of a press brake is one of the key steps to improve sheet metal processing quality and production efficiency. By rationally selecting calculation methods, considering actual processing conditions and continuously optimizing process parameters, the accuracy and efficiency of bending processing can be effectively improved. Here are some key points:
8.1 Master the calculation method of bending force of bending machine
First of all, you need to master the common calculation methods of bending force of bending machines, including empirical formulas, theoretical calculation formulas and numerical simulation methods. Understand the advantages and disadvantages of different calculation methods and choose the appropriate method for calculation according to the specific situation.
8.2 Choose an appropriate calculation method
When selecting a calculation method, factors such as the properties of the material, the geometry of the plate, and processing requirements need to be comprehensively considered. For simple bending operations, empirical formulas can be used for quick estimation; for complex processing situations, theoretical calculations or numerical simulation methods can be used for accurate calculations.
8.3 Consider various factors in actual processing
When making calculations, it is necessary to consider various factors that may be encountered in actual processing, such as friction, plastic deformation of the plate, mold shape, etc. By comprehensively considering these factors, the calculation model can be corrected and the accuracy of the calculation results can be improved.
8.4 Continuously optimize calculation methods and process parameters
With the continuous development of technology and the accumulation of production practice, calculation methods and process parameters need to be continuously optimized to adapt to changes in different materials and processing requirements. Through real-time monitoring and adjustment, timely optimization of process parameters can improve the quality and efficiency of bending processing.
KRRASS Company Profile
KRRASS Company is a company specializing in the production of bending machines, with many years of industry experience and technology accumulation. The company is committed to providing customers with high-quality, high-efficiency bending machine products and services to help customers improve production efficiency and product quality.
KRRASS bending machines have high precision, high efficiency, high stability and high safety, and are widely used in automobile manufacturing, aerospace, home appliance manufacturing and sheet metal processing industries. The company provides complete pre-sales consultation, technical training, and after-sales services, committed to providing customers with high-quality bending machine products and services. If you want to know more about KRRASS bending machines, please visit the company website or contact the company sales staff.
