Straight bends are essential for perfectly folded parts. A sturdy and solid machine design powerfully resists the bending forces. An intelligent crowning system and 120 tons of clamping pressure ensure perfect folded parts on 6 mm mild steel or 4 mm stainless.
The upper beam moves down and up with a spindle drive. For clamping the parts PowerBoosters are activated. They create 120 metric tons of clamping pressure, hold thick workpieces in position and have sufficient reserves for hemming.
The folding beam is the heart of each folding machine. The intelligent crowning system of GIGAbend automatically compensates elastic beam deformation caused by the bending forces. Sensors measure the beam deflection. The results are straight bends and precision parts.
Straight bends without test bends and without programming for:
On a program change, the machine automatically adjusts in 5 seconds to the new sheet thickness and bending radius. A digital display provides additional comfort during the folding beam initialization.
The gauging system positions the part for each bend. It supports the weight of the large and heavy components. The stop fingers can be lowered in any program line so that the workpiece does not collide during rotation.
The tools of the upper beam, folding beam and lower beam are segmented. The front-free or rear-free geometries provides plenty of space for long C-flanges or narrow components. Different tool heights and shapes cover the variety of bending challenges. In case of a focussed part analysis a single tool set is often sufficient for the entire range of parts.
For some materials, material manufacturers recommend the use of radius tools. The larger bending radius avoids cracks on the material surface. Especially when bending thick aluminum, the radius tools lead to excellent bending results.
In contrast to press brake bending, which usually leaves clearly visible pressure and scratch marks next to the bending line, metal folding can also be described as gentle forming. This makes a considerable difference in quality for parts with a demand on the optical finish. However, if upper beam tools with a radius are used instead of sharp tools, the sliding section of the folding beam tool on the material surface will be also longer. In such applications folding beam tools with a plastic insert avoid pressure marks on high-quality material surfaces.
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