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OEM Custom Sheet Metal Fabrication Service Aluminum Stainless Steel Bending Laser Cutting Folding Sheet Metal Processing Parts

Step Bending
Step bending is a continuous V-bending process designed to produce large-radius products. This method allows for the cost-effective manufacture of large products using standard tooling, making it one of the most innovative metal bending techniques. However, a disadvantage of step bending is that it requires a complete bend to avoid misalignment of the part.

Roll Bending
Roll bending is used to produce various shapes such as pipes or cones, and is particularly well-suited for large-radius bends. This technique can produce one or more bends, depending on the machine capacity and the number of rolls. The process typically uses two driven rollers and one adjustable roller, which rely on friction for movement. If the part requires bending at both ends or in the middle, additional operations are required, typically performed on a hydraulic press or press brake, otherwise the edges of the details may be flattened.

Wipe Bending
Wipe bending (or edge bending) is another method used to bend the edge of sheet metal. Ensuring that the sheet metal is properly pushed into the wipe die is crucial, as the wipe die determines the inside radius of the bend. The clearance between the wipe die and the punch plays a significant role in achieving good results.

Advantages of using wipe bending include high repeatability and a low skill level. However, this method often results in springback. To control springback, a return flange is often added to the forming punch and the die is pressed to initiate metal flow, creating the desired curved top. However, this method can weaken the metal and part quality, so it should be used with caution.

Rotary Bending
Rotary bending is a method for bending metal edges that offers significant advantages over wipe bending or V-bending. Rotary bending does not scratch the material surface, and the use of specialized polymer tools eliminates any tool marks or scratches.

This technique can achieve bends sharper than 90 degrees, making it ideal for common angles, where springback is less of a concern. Another advantage of rotary bending is the ease of angle adjustment, and height adjustments for grinding assembly are less time-consuming.

However, a disadvantage of rotary bending is the higher price of the equipment. Nevertheless, the long-term cost savings of a rotary bending machine may outweigh the initial investment. Two passes are common, but a single pass is also an option. This method is particularly suitable for producing U-shaped channels close to flanges, as it offers greater flexibility than other bending methods.

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