Precision Bending Processing: Key Technologies

Precision bending is a high-accuracy metal forming process widely used in electronics, automotive, aerospace, and other industries. It requires advanced technologies to ensure tight tolerances and consistent quality. Below are the core technologies involved:

1. High-Precision Tooling Technology

• Die Design & Manufacturing: CAD/CAM software is used to design dies that match the product’s curvature. High-hardness materials (e.g., SKD11, tungsten carbide) minimize wear.

• Micro-Clearance Control: Die clearance is typically 5%~10% of material thickness (e.g., 0.005~0.01mm for 0.1mm sheet metal) to prevent deformation or burrs.

2. CNC Press Brake Technology

• Multi-Axis Control: Servo motors and hydraulic systems control ram stroke (±0.01mm), back gauge positioning (±0.02mm), and angle compensation.

• Real-Time Feedback: Sensors (e.g., linear encoders or lasers) monitor bend angles and dynamically adjust pressure (±0.1° accuracy).

3. Material Property Management

• Springback Compensation: Finite element analysis (FEA) predicts springback (e.g., 2°~5° for aluminum), requiring overbending in die design.

• Stress Relief: Annealing hard materials (e.g., stainless steel) reduces cracking risks during bending.

4. Automation & Robotics Integration

• Robotic Loading/Unloading: 6-axis robots (e.g., Fanuc or KUKA) enable continuous bending, reducing cycle time to 3~5 seconds per part.

• Vision Positioning: CCD cameras align workpieces (±0.05mm accuracy) for complex bends.

5. Process Optimization

• Bending Sequence Planning: Avoiding interference (e.g., "Z"-shaped parts require inner bends first) using simulation software (e.g., AutoForm).

• Lubrication & Cooling: Extreme-pressure lubricants (e.g., molybdenum disulfide) improve surface finish (Ra ≤1.6μm).

6. Quality Inspection Technologies

• In-Line Measurement: Laser scanners (e.g., Keyence IM series) detect deviations in real time, triggering automatic corrections.

• 3D Profilometry: Systems like GOM ATOS verify full-dimensional accuracy, checking springback and distortion.

Typical Applications

• EMI Shielding Cases: 0.3mm stainless steel, ±0.05mm tolerance, requiring scratch-resistant die coatings.

• Automotive Brackets: High-strength steel (HSS) bends may need 200+ tons of force, with heated bending (200°C~300°C) to prevent cracks.

Future Trends

• AI-Driven Optimization: Machine learning adjusts parameters dynamically, reducing trial runs.

• Laser Cutting + Bending Integration: Combines processes to minimize repositioning errors.

Precision bending relies on equipment accuracy, material control, and process expertise, with adjustments based on material thickness, hardness, and other factors.