In the past few years, the sheet metal industry has developed a number of technological advances in machine tools and molds. Now the machine tools can be punched, cut and bent and the speed and precision are beyond the expectation of people.
However, no matter how advanced the new technology is, the bending shop or section of the sheet metal processing plant will encounter some bottleneck problems, and even the most advanced factories can't avoid. Although these problems cannot be attributed to one reason, metal processing plants can make many improvements. These improvements can help reduce lengthy preparation time, increase efficiency, and increase overall production capacity.
Perform SOP on repetitive tasks
Sheet metal processing plants are now faced with a problem: most of the processing tasks have small batch sizes and tight tolerances. It is common for each shift to perform 15 tooling adjustments, and many factories far exceed this number. Technicians who specialize in the preparation of complex bending machines are becoming more and more hard-to-get, so factories mostly rely on operators to complete the preparation and operation of the bending machines themselves.
Performing standard operating procedures is easy to ensure consistency, reducing the number of parts to be set up and the resulting material waste. These SOP not only help to shorten the processing time, but also improve the consistency of the bending sequence operation, and reduce the deviation of parts caused by individual operators.
Preparation Worksheet: One of the means available to bending machine operators for repetitive machining tasks is to use a “preparation worksheet”. The preparation worksheet documents the tooling used for each application and the instructions for the specific processing task in the form of a document. It must be used each time the processing task occurs.
professional tools
Factories should also consider the use of appropriate procedures and tooling systems, such as upper and lower feeders, to enable workers to complete frequent processing tasks more quickly and efficiently.
Auxiliary Tool Features: Many step-forming mold systems include punch holders, push-button safety clips, quick-change 2V compression molds, and motorized compression mechanisms, so the operator alone can change the mold very quickly.
These systems also help operators to complete tasks more efficiently without compromising safety.
Segmented mold: According to the required bending length, the precision grinding segment mold assembly is manufactured without having to spend time cutting the mold into a certain length. Grinding molds can also reduce or eliminate the need for shimming. The segmented molds are lightweight and easy to handle, thus reducing manual labor and fatigue and the possibility of accidents. In order to extend the service life, the precision grinding mold is also hardened and surface-strengthened.
Die Marking: Almost all of the information on laser etching is now available in the mold, allowing workers to quickly identify, plan, and reorder molds. This information typically includes category number, tooltip angle, radius, V shape slot, length and rated tonnage.
Mold storage: Grouping molds with cabinets can achieve the dual benefits of improved safety and improved material and tool management. With an orderly storage system, you don't have to look for tool shelves for a custom length mold. In addition, orderly storage allows managers to monitor the status of the molds more alertly, thus ensuring high-quality inventory, recognizing mold wear and damage in time, and determining the way and time for the replacement of the mold.
Using machine tool processing features
The new bending machine provides advanced functionality and many features that can help workers run the machine more effectively. Operators who master the control characteristics of new machine tools can use these functions to improve their performance.
Workpiece mold specification memory: Most of the new CNC bending machines have a common feature: they can store the workpiece size and all relevant processing information such as the mold type, position, and bending sequence. Moreover, the CNC function allows operators to store and access the tool library, providing convenience for managing tool inventory.
Material Thickness Detection: When using a precision grinding mold, the bending machine can detect changes in material thickness and perform real-time bending calculations, thereby reducing the number of parts with excessive or insufficient bending angles.
3-D graphical display and bending simulation: With the bending of the workpiece, these functions can display the bending process of the parts on the controller screen to avoid material scrap caused by improper molding of the parts.
Offline programming: bending machine programming can save time because workers do not have to work out parts processing program; the part program can be compiled by technicians and passed down to the bending machine.
Universal Die Height: Universal Die Height Tooling Series can be used to simplify complex hierarchical die adjustments using “plug-and-play” functionality. The universal mold height mold was successfully developed because of the appearance of CNC vertical movement of the rear stopper. In order to accurately use the principle of “universal mold height”, vertical CNC control is necessary because the universal mold height is achieved by keeping the bottom of the lower opening of the mold at the same height (from the lower mold base). When the opening of the lower die is large, the total height of the lower die must be increased accordingly. This is why it is no longer necessary to use a special pad or special gasket to drive the mold to be closed simultaneously.
Small and complex parts often require offset bending, 90° bending, and leveling, and their preparation usually requires multiple machine tools or equipment. The grading or universal mold height mold enables this operation to be performed by one bender with one feed. Using the universal mold height mold, the operator can install the 30° mold, offset head mold, leveling mold, and gooseneck mold on the same mold base and complete the entire machining of the part.
Make full use of bending technology
Metal processing plants using bending machines currently face some complex problems. The high cost of raw materials makes each blank must become a good product. The rapid response and willingness to change the operation mode of the bending and forming section to meet the current needs can reduce the preparation time, thereby obtaining greater production capacity and reducing the scrap rate.
The development and implementation of well-designed SOPs, better use of storage and inventory systems, comprehensive utilization of machine tool functionality, and full exploration of human resources are several ways to help bend-forming shops improve efficiency and productivity.
