November 11, 2015 | By Steve Benson
In this installment of the Grand Unifying Theory of bending, press brake guru Steve Benson describes bending calculations for aircraft tooling. He also covers the basics of bottoming
October 28, 2015 | By Steve Benson
Radius bends—defined here as any bend with an inside radius greater than 125 percent of the material thickness—require careful calculation, not only because of their significant springback, but also because of the tooling these bends require. This includes the use of relieved dies.
September 8, 2015 | By Steve Benson
Press brake guru Steve Benson proposes a new theory of bending, altering some long-held labels and definitions and introducing new formulas. Those long-held definitions worked well, but these new definitions and formulas may help a press brake technician become even more accurate in predicting how a part will form.
August 12, 2015 | By Steve Benson
You can use some common rules of thumb to predict the inside bend radius when air forming, and the results you get are usually close enough, but with the help of a few online calculators, you can get even closer.
July 21, 2015 | By Steve Benson
Using the 20 percent rule works well when calculating the floated radius in an air form, but what about the radius at different bend angles? To calculate this, we start with geometry to find the arc length and radius at different bend angles. We then manipulate these results by factoring in real-world bending conditions.
June 29, 2015 | By Steve Benson
Air bending soft aluminum has such a low tensile strength that it doesn't take much for a narrow punch tip to penetrate the surface and turn the bend sharp.
May 3, 2015 | By Steve Benson
To ensure you always work within the tonnage limits of your press brake and tooling, first calculate how much tonnage you need. Second, identify your tooling’s load limits. Third, calculate the sinking tonnage limit, which, if exceeded, can embed tooling into the ram or bed. Fourth, determine your press brakes’ centerline load limit.
April 30, 2015 | By Steve Benson
Why do air bends in cold-rolled steel turn sharp at an inside radius that’s about 63 percent the material thickness? It has to do with the relationship between forming forces and a material’s tensile and yield strength.
April 1, 2015 | By Steve Benson
A material’s minimum inside bend radius shows the smallest radius that’s physically possible in an air bend, though your machines and tooling may not be able to handle the tonnage. The recommended inside bend radius, such as those found on bend allowance charts for air bends, shows you what’s optimal in typical applications
February 17, 2015 | By Steve Benson
When bending with a hand brake, you can use the tooling that came with the machine, but investing in a tool with a radius on the punch nose has its benefits.
February 16, 2015 | By Steve Benson
Choosing the right die for an application hinges on the tooling and press brakes you have, and the tonnage limitations of both.
July 9, 2014 | By Steve Benson
Why exactly does springback occur, and how can a technician predict it? Press brake guru Steve Benson covers the basic factors.
May 12, 2014 | By Steve Benson
If you pick the right offset tool for the job, you'll find you will be able to produce many different offset geometries quickly and safely.
March 24, 2014 | By Steve Benson
Press brake setup is a critical part of doing any bending job correctly. By focusing on a few key areas—selection of tools and forming processes, easy-to-understand setup sheets, and ISO documentation—the press brake operator is in a much better position to succeed.
January 27, 2014 | By Steve Benson
Large or profound-radius bends are those in which the inside bend radius exceeds eight times the material thickness, but is still too small to move to the plate roll. At this point, a press brake operator has to change his mindset before proceeding. This is not a typical bending job.