The folding factor

In the October issue of ISMR, we unveil a selection of the latest new global CNC folding innovations, technologies and software.

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Sheet metal folders excel in precise, complex bends with fewer set-up and tooling changes. They are particularly suitable for the manufacture of components such as roofs, pans, trays and lids. New models, with greater capabilities and features, are continuously being launched into the market. 

Folders create a scratch-free outcome. A metal folder ‘air-bends’, meaning that the machine system doesn’t bottom or coin the material. Because of this, there is little to no wear in tooling for most folding applications. They can produce an aesthetically pleasing product without tearing, stretching or cutting. Users can curve and fold fascinating and elegant shapes from a single sheet of material. They are designed to make precise and consistent folds, saving time and effort, as well as processing a variety of sheet metal materials of varying thicknesses.

Folders feature an integrated support back gauge that holds up the weight of the items for the operator. There is no need for operators to push large sheets through from the front. The bending technique also makes it easier for operators to bend multiple-setup parts that would typically call for additional manual interference. 

For those manufacturing items using thin materials that are long and wide with short flanges, folders are a good fit. This is because they allow the material to rest on the folder bed for easier handling. Folders are easily identified by their large support tables and swinging ‘folding beam’, which bends the flange while the workpiece remains flat on the support table. These machines are suitable for many scenarios, especially for large blanks that would otherwise be difficult to handle.

Folding machines can bend all angles with a single set of tools. The machine automatically adjusts to the material thickness. Higher automated folding machines come with an automatic tool-changer.

A flexible approach

On a folding machine, the entire part is inside the machine. Only a short flange stands out of the upper and lower beam tool. Folding reduces the sliding area of tools on the material surfaces to a minimum, or completely eliminates it, on some machines. As there are only very slight relative movements between the tool and the material surface, the tooling shows no abrasion wear even after years of use.

On folding machines, a radius can be easily created of short bending segments. By using small steps, the outside of the radius will be smooth and the individual steps will not be visible. Folding does not require special tools for hemming.

The folding process is suitable for flexible applications because the tooling is not specific to the material thickness or angle required. “Universal” tool geometries allow for unlimited angle possibilities and are rated up to the maximum machine capacity and height. 

There are several types of folders. On systems equipped with segmented clamping tools, a new part can be set up by rearranging the tool segments on the tool rail. Machines without automatic tool changers still simplify the set-up process by advising the operator where to put tool stations. Common tooling allows for rapid changeover between parts and makes it easy for a single employee to program, operate and set up the machine for any compatible part. While not ‘a one-size-fits-all’ solution, folders offer strong flexibility for a wide variety of needs.

Another benefit is part handling. Larger parts can be manipulated on the gauging, eliminating the need for multiple operators and increasing part accuracy. Folding machines clamp and bend the part when it is laying flat on the gauging table and the flange is being bent, which helps accuracy so that the operator does not need to ‘manage’ the part during the forming process. Larger parts that require two operators typically can be manipulated by one operator on a folder because the bulk of the part is resting on the table and the operator can rotate it by themselves. 

Folders and press brakes complement each other in sheet metal bending operations; they each have individual advantages and benefits in the press shop. 

Folding innovations

In this article, we highlight some of the latest innovations in global CNC folding and software innovations, technologies and software. 

To read the rest of this article in the October issue of ISMR, see https://joom.ag/JO2d/p90