Technical information
Bending Technology
Technical information
Bending Technology
Edition: 05/2007
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TRUMPF Werkzeugmaschinen GmbH + Co. KG
Technische Dokumentation
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This document was compiled by the Technical Documentation Dept. of
TRUMPF Werkzeugmaschinen GmbH + Co. KG
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consent of TRUMPF Werkzeugmaschinen GmbH + Co. KG Subject to errors
and technical changes.
© TRUMPF Werkzeugmaschinen GmbH + Co. KG
TRUMPF Werkzeugmaschinen GmbH + Co. KG cannot be held responsible
for possible mistakes in this documentation. Any warranty for direct and
indirect damages, arising in connection with the delivery or the use of this
documentation, is excluded, as far as this is in conformity with the law.
Before You proceed...
Contents
This Technical information brochure "Bending Technology"
provides a quick overview of the essentials of bending.
After a brief outline of the TruBend Series 5000, the individual subassemblies of the press brake are described in greater detail. This
is followed by explanations on the technology of bending (bending
methods and calculations) and of the TRUMPF tooling system;
attention is also paid to the ACB® angle sensor. Information
concerning materials and tips and tricks from daily practice round
off the topics discussed.
A list of key words provided at the end of this document makes it
easier to find specific information more quickly.
T488EN00.DOC
Before You proceed...
0-5
Table of Contents
Chapter 1
Machine technology TruBend Series 5000
1.
Machine concept............................................................ 1-3
2.
2.1
Technical data................................................................ 1-4
Axes of the TruBend Series 5000.................................... 1-6
3.
3.1
3.2
3.3
3.4
Sub-assemblies ............................................................. 1-7
Machine frame ................................................................. 1-8
Ram and downstroking drive ......................................... 1-10
Bed with crowning.......................................................... 1-11
Tool holder..................................................................... 1-13
Lower tool adjustment, I axis .................................... 1-14
Lower tool adjustment by example of
„Flattening“................................................................ 1-15
CNC-controlled lower tool adjustment (Option)........ 1-18
Bending aid (optional)............................................... 1-19
TASC 6000 control ........................................................ 1-22
Control panel ............................................................ 1-23
Operating station ...................................................... 1-24
Additional footswitch................................................. 1-25
3.5
Chapter 2
4.
4.1
4.2
4.3
Backgauge.................................................................... 1-26
Backgauge axis system ................................................. 1-29
Technical data: Backgauge ........................................... 1-31
Stop fingers and stop positions ..................................... 1-33
Micrometer stop fingers (Option) .............................. 1-35
5.
TRUMPF BendGuard ................................................... 1-36
Technology (Application technology)
1.
1.1
1.2
0-6
Table of Contents
Bending methods: Overview ........................................ 2-3
Air bending....................................................................... 2-3
Coining............................................................................. 2-5
T488EN00.DOC
1.3
1.4
1.5
Hemming.......................................................................... 2-7
Flattening ......................................................................... 2-8
Sensor bending................................................................ 2-9
Overview: Sensor bending ....................................... 2-13
Learned bend............................................................ 2-13
2.
2.1
2.2
2.3
2.4
2.5
2.6
Calculations ................................................................. 2-14
Press tonnage................................................................ 2-14
Box height ...................................................................... 2-17
Inside radius .................................................................. 2-19
Selecting the die width................................................... 2-21
Shortest flange length.................................................... 2-23
Flat length ...................................................................... 2-26
Calculating the flat length in case of large bend
radii ........................................................................... 2-27
Calculating the flat length in case of small bend
radii ........................................................................... 2-29
Use of the compensation value in the machine
controller ................................................................... 2-33
Minimum distances and lengths .................................... 2-34
Different bending flange shapes.................................... 2-35
2.7
2.8
Chapter 3
T488EN00.DOC
Tool system
1.
Terminology ................................................................... 3-2
2.
2.1
2.2
2.3
2.4
2.5
Tools from TRUMPF ...................................................... 3-3
Tool identification............................................................. 3-3
Upper tools ...................................................................... 3-4
Lower tools ...................................................................... 3-6
Die width ..................................................................... 3-6
Opening angle ............................................................ 3-7
Tools for thin sheets ...................................................... 3-11
System segmentation of tools ....................................... 3-13
3.
Laser hardening........................................................... 3-15
4.
Imprint-free bending.................................................... 3-16
5.
Special tools................................................................. 3-18
Table of Contents
0-7
Chapter 4
0-8
Table of Contents
Index
T488EN00.DOC
Chapter 1
Machine technology
TruBend Series 5000
1.
Machine concept............................................................ 1-3
2.
2.1
Technical data................................................................ 1-4
Axes of the TruBend Series 5000.................................... 1-6
3.
3.1
3.2
3.3
3.4
Sub-assemblies ............................................................. 1-7
Machine frame ................................................................. 1-8
Ram and downstroking drive ......................................... 1-10
Bed with crowning.......................................................... 1-11
Tool holder..................................................................... 1-13
Lower tool adjustment, I axis .................................... 1-14
Lower tool adjustment by example of
„Flattening“................................................................ 1-15
CNC-controlled lower tool adjustment (Option)........ 1-18
Bending aid (optional)............................................... 1-19
TASC 6000 control ........................................................ 1-22
Control panel ............................................................ 1-23
Operating station ...................................................... 1-24
Additional footswitch................................................. 1-25
3.5
T488EN01.DOC
Machine technology TruBend Series 5000
1-1
1-2
4.
4.1
4.2
4.3
Backgauge.................................................................... 1-26
Backgauge axis system ................................................. 1-29
Technical data: Backgauge ........................................... 1-31
Stop fingers and stop positions ..................................... 1-33
Micrometer stop fingers (Option) .............................. 1-35
5.
TRUMPF BendGuard ................................................... 1-36
Machine technology TruBend Series 5000
T488EN01.DOC
1.
Machine concept
Die TruBend Series 5000 comprises CNC-controlled press brakes
for bending flat metal workpieces.
The machines are designed for a great variety of bending tasks
and are distinguished by the following features:
T488EN01.DOC
•
CNC backgauge system.
•
Downstroking drive with two tandem cylinders.
•
Lower tool adjustment (hemming without tool change).
•
Self-centering tool holder.
•
Quick and easy operation and programming.
•
High level of work safety.
•
•
Defined tilt of the ram.
Automatic crowning.
Machine concept
1-3
2.
Technical data
B
C
D
E
A
Machine layout
Fig. 44112
TruBend
5050
5085
5085 S
5130
Tonnage
[kN]
500
850
850
1300
Machine dimensions Bending length (A)
[mm]
1275
2210
2720
3230
Width between columns (B)
[mm]
1040
1750
2260
2690
Throat (C)
[mm]
420
420
420
420
Bed width
[mm]
100
120
120
120
Open height (die space) (D)
[mm]
385
385 (615)
385 (615)
385 (615)
Working height with 100 mm
lower tool (E)
[mm]
1050
1050
1050
1050
Y rapid down speed
[mm/s]
220
220
220
220
Y press speed
[mm/s]
0.1 - 10
0.1 - 10
0.1 - 10
0.1 - 10
Y rapid up speed
[mm/s]
220
220
220
220
Stroke
[mm]
215
215 (445)
215 (445)
215 (445)
Ram positioning
accuracy
[mm]
0.005
0.005
0.005
0.005
Ram tilt
[mm]
±10
±10
±10
±10
Speeds
Y axis
Y axis (ram)
The values in brackets apply to enlarged versions (options)
1-4
Technical data
Tab. 1-1
T488EN01.DOC
TruBend
Tonnage
[kN]
Machine dimensions Bending length (A)
Speeds
Y axis
Y axis (ram)
5170
5170 S
5230
5230 S
5320
1700
1700
2300
2300
3200
[mm]
3230
4250
3230
4250
4420
Width between columns (B)
[mm]
2690
3680
3690
3680
3680
Throat (C)
[mm]
420
420
420
420
420
Bed width
[mm]
120
180
180
180
200
Open height (die space) (D)
[mm]
615
615
615
615
615
Working height with 100 mm
lower tool (E)
[mm]
1050
1050
1050
1050
1050
Y rapid down speed
[mm/s]
220
220
220
220
220
Y press speed
[mm/s]
0.1 - 10
0.1 - 10
0.1 - 10
0.1 - 10
0.1 - 10
Y rapid up speed
[mm/s]
220
220
220
220
220
Stroke
[mm]
445
445
445
445
445
Ram positioning
accuracy
[mm]
0.005
0.005
0.005
0.005
0.005
Ram tilt
[mm]
±10
±10
±10
±10
±10
Tab. 1-2
T488EN01.DOC
Technical data
1-5
2.1
Axes of the TruBend Series 5000
Y2
Y1
X2
X1
R1
R2
Z2
Z1
V
I
Axes of the TruBend Series 5000
Fig. 38803
Axis
Description
TruBend 5050
TruBend 5085 – 5320
I axis
Lower tool adjustment
(forward and back)
Pneumatic or
CNC controlled*
Pneumatic or
CNC controlled*
R axis
Height adjustment of stop
fingers
CNC controlled
CNC controlled
V axis
Crowning
Not available
Manual or
CNC controlled*
X axis
Backgauge travel
and stop fingers forward
and back
CNC controlled
CNC controlled
Y axis
Ram motion and ram tilt
CNC controlled
CNC controlled
Z axis
Stop finger travel (left and
right)
Manual or
CNC controlled*
Manual or
CNC controlled*
Bending aid (BH1/BH2)*
Workpiece support
Not available
CNC controlled
*Options
1-6
Tab. 1-3
Technical data
T488EN01.DOC
3.
Sub-assemblies
1
5
2
6
3
4
7
8
10
9
1
Y drive and hydraulics
5
Hydraulic cylinder
9
2
Control panel
6
Ram
10 Operating station
Machine body
3
Upper tool clamp
7
TRUMPF BendGuard
4
Backgauge
8
Lower tool clamp
Sub-assemblies, TruBend Series 5000 machine
T488EN01.DOC
Fig. 44068
Sub-assemblies
1-7
3.1
Machine frame
The machine frame is a C-frame comprising two side frames
(housings), the bed and connection support.
The pressure cylinders and the ram are mounted on the upper part
of the C-frame. Due to this arrangement, the C-frame spreads
apart during the bending process (C-frame deflection).
This inevitable physical principle is compensated for by the control
(deflection compensation). There is therefore no negative impact
on the bending results.
Frame deflection
Y Ist > Y Soll
Soll
Aktio
Y
Y Ist
Reaktio
Frame deflection
•
•
•
1-8
Sub-assemblies
Fig. 32203
The press force acts upon the machine bed during the bending
process (action).
This leads to a counter-force arising in the C-frame of the side
housings (reaction).
Deflection occurs, despite the robust construction of the side
housings. This is the reason why the upper tool penetrates less
deeply into the lower tool than the hydraulic cylinders travel on
the stroke.
T488EN01.DOC
Deflection compensation
On the TruBend 5050 – 5320, C-frame deflection is compensated
for by the machine control.
Two machine parameters are available for deflection
compensation:
• The compensation value [bar], with which the counter-pressure
is compensated.
• The deflection constant [µm/bar], with which the pressuredependent deflection is equalized.
These machine parameters can be checked or adapted at any time
using a service program.
T488EN01.DOC
Sub-assemblies
1-9
3.2
Ram and downstroking drive
The ram is guided by means of adjustable cam followers. The ram
is highly rigid and is spherically suspended, allowing it to be tilted.
The downstroking drive is an electro-hydraulic drive featuring two
tandem cylinders (left / right) each. The cylinders are controlled by
means of proportional valves.
Features:
• Exact synchronous motion of both cylinders pairs (Y1/Y2).
• Long service life of the guides and sealing elements.
• High positioning accuracy of the ram. The machine is equipped
with an incremental path measurement system.
1
2
3
1
Control block on cylinder pair Y1
2
Control block on cylinder pair Y2
Ram and downstroking drive
ACB busbar
1-10
Sub-assemblies
3
Pump block
Fig. 43679
Embedded at the front of the ram is a busbar (CAN bus) for
connecting the modules of the ACB angle sensor.
T488EN01.DOC
3.3
Machine bed
Bed with crowning
The bed, or press table, is parallel and at right angles to the
mounting surfaces of the hydraulic cylinders and the guideways of
the backgauge. It has a milled surface for the crowning motor.
A movable wedge plate and the lower tool holder are mounted
above the crowning motor.
Force distribution
during bending
Under load, the ram, with the two hydraulic cylinder axes Y1 and
Y2, acts like a beam on two supports. Despite the high moment of
resistance, the ram bows under load, i.e. during the bending
process.
Directly beneath the hydraulic cylinders, therefore, the upper tool
plunges deeper into the die than it does at ram center.
This effect varies with the length of the bend and the press
tonnage. As a result, ram deflection increases with higher
tonnages and longer bends.
With crowning
Without crowning
Y1
Y1
Y2
Y2
1
1
Crowning
---
Deformation
Fig. 32205, 32206
T488EN01.DOC
Sub-assemblies
1-11
Purpose of crowning
Crowning refers to the calculated and mechanically adjusted
curvature of the machine bed. Crowning provides for parallelism
between the ram and the bed (press table).
Since the press tonnage, the distance between cylinder pairs Y1
and Y2, the geometry and the material properties of the ram, and
thus the resistance moment, are known, the expected bowing can
be calculated.
Bowing is the vertical deviation from the horizontal bending line.
This deviation is compensated for by crowning (V axis).
90°
90°
90°
> 90°
90°
90°
Bending results with/without crowning
Fig. 32207
Crowning
The crowning mechanism consists of two wedge plates milled in a
wave pattern. The lower tool holder is mounted on the upper
wedge plate. The lower wedge plate is worked (milled) directly into
the bed.
The gradient angle of these wedge plates increases towards the
center.
The curvature (crowning value) in the bed needed to compensate
for the bowing of the ram is achieved by shifting the upper wedge
plate horizontally.
Adjustment takes place manually or CNC-controlled via the gear
motors integrated in the bed.
α1
α2
α3
α4
α4
α3
α2
α1
α1 < α2 < α3 < α4
X
X
Bowing
Principle of crowning
1-12
Sub-assemblies
Fig. 51623
T488EN01.DOC
3.4
Tool holder
The tool holder is suitable for the use of head and shoulder-bearing
tools. The press force is evenly transferred through the tool to the
workpiece, even in case of large tool heights or lateral forces (e.g.
in hemming). Angle accuracy is not affected.
The upper and lower tool holders are machined and aligned in
such a way that the upper and lower tools are automatically
centered after clamping.
Head-bearing
In the case of head-bearing tools, the punch butts against the
inside of the upper tool holder.
Shoulder-bearing
In the case of shoulder-bearing tools, the punch butts against the
outside of the upper tool holder.
Shoulder-bearing tool
Head-bearing tool
Tool types
Fig. 35647, 35648
Upper tool holder
Lower tool holder
Modufix clamping
Clamping via short-stroke cylinder
Hydraulic clamping
Tools can be used in reverse
Clamping pressure: 50 bar
Tab. 1-4
T488EN01.DOC
Sub-assemblies
1-13
Lower tool adjustment, I axis
The lower tool holder is mounted on the machine bed in such a
way that it can be shifted in X direction.
This adjustment is performed using pneumatic cylinders. The end
positions (fixed stops) are defined by means of various spacers
which are adapted to the widths of the lower tools.
The position of the adjustment path in front of or behind the lower
tool is set by means of the pivoting element.
Lower tool adjustment enables:
• Hemming (flattening) without tool change.
• Positioning of special dies.
• Station operation with tools of different heights.
• Work with lower tool adapters (e.g. two lower tools).
• Production of Z-bends with tool holder systems.
• Facilitates removal of complex parts.
1
1
Fixation of adjustment path,
2
Spacer for the length of the
cannot be modified
2
3
3
1
Pivoting element for position
of the adjustment path
adjustment path
I axis
1-14
Sub-assemblies
Fig. 29259
T488EN01.DOC
Lower tool adjustment by example of
„Flattening“
Program-controlled adjustment of the lower tool holder to fixed
stop.
Two positions:
Flattening in rear tool position:
Flattening in rear tool position Flattening in front tool position:
(without punch support):
I axis is at the front.
I axis is at the front.
I axis is at the rear.
Flatting at front and rear
Fig. 43700
The fixed stop depends on the tool width of a 30° lower tool. The
following spacers are available for this:
Die widths
Spacers
W6, W8, W10
30 mm
W12
27.5 mm
W16
25 mm
W20
22.5 mm
W24 1
20 mm
Tab. 1-5
In addition to this, specially configured spacers are also available
for special dies.
1
T488EN01.DOC
The spacer for die width W24 is also suited for lower tool holder EV70 (holder
for Z inserts).
Sub-assemblies
1-15
Flattening at the front
Prerequisite
• The pivoting element butts against the rear fixed stop.
• Appropriate spacer for lower tool has been loaded at the front.
Fig. 29860
1. Bend to an angle of 30°.
I axis is located in the front position.
Fig. 29861
2. Flatten.
I axis is located in the rear position.
1-16
Sub-assemblies
T488EN01.DOC
Flattening at the rear
Prerequisite
• The pivoting element butts against the front fixed stop.
• Appropriate spacer for lower tool has been loaded at the rear.
Fig. 29858
1. Bend to an angle of 30°.
I axis is located in the rear position.
Fig. 29859
2. Flatten.
I axis is located in the front position.
T488EN01.DOC
Sub-assemblies
1-17
CNC-controlled lower tool adjustment
(Option)
CNC-controlled adjustment of lower tools allows tool designs that
were previously impossible.
In CNC-controlled lower tool adjustment, a CNC-controlled
stepping motor is used for adjustment in X direction.
The lower tool can therefore be shifted to any position within the
entire travel range without having to interrupt production for
retooling (pivoting element/spacer).
Compressed air is therefore no longer required for press brake
operation. (Exception: Stop finger clamping at the 2-axes
backgauge).)
1-18
Sub-assemblies
CNC-controlled lower tool adjustment
Fig. 44066
Stepping motor unit
Fig. 44065
T488EN01.DOC
Bending aid (optional)
Electromechanical bending aid for the TruBend 5085 - 5320.
The bending aid can be moved manually parallel to the bed, in
order to adjust it to the bending length and/or to bending stations. It
can also be adapted to different lower tool heights and widths by
means of 2 adjusting screws.
Maximum 2 bending aids can be used on a machine.
Advantages
Technical data
•
•
Relieve the operator when working with large and heavy parts.
No counter-bending effects when bending thin workpieces with
large flange lengths.
Capacities
Dimensions
Max. swivel angle [°]
47
Max. working speed [°/s]
45
Max. support weight per arm [kg]
100
Max. Y speed [mm/s]
for die width 6 mm
for die width 8 mm
for die width 10 mm
for die width 12 mm
for die width 18 mm
for die width 20 mm
2.5
3.5
4.0
5.0
6.5
8.5
Weight per arm [kg]
330
Table width [mm]
275
Supported flange length [mm]
1000
Setting range for lower tool height [mm]
30 - 150
Setting range for die width [mm]
6 - 100
Max. workpiece weight in the table
extension area [kg]
10
Technical data for the bending aid
Tab. 1-6
Note
The ram speed is automatically adapted for the chosen die width.
T488EN01.DOC
Sub-assemblies
1-19
Reduced ram speed
Example
Die width
6
The smaller the die width of a lower tool, the less vertical travel by
the ram is needed to achieve a defined bending angle. Since the
swivel motion of the bending aid is synchronized with the vertical
travel of the ram and hence is also synchronized or parallel to the
motion of the bending flange, the press speed must be reduced for
small die widths.
Mild steel, bending angle 90°
Reduced ram speed [mm/s]
2.5
Travel in case of sheet deformation (from clamping
point to Y-nominal) [mm]
s = 1 mm
s = 2 mm
2.407
-
8
3.5
3.541
3.173
10
4
4.432
3.972
12
5
5.539
4.807
Tab. 1-7
Options for the bending aid
The following options are available for the bending aid:
• Table extension.
• Table widening.
• Support table for table length extension.
Bending aid with two table widening sections and two
table extensions.
1-20
Sub-assemblies
Fig. 29651
T488EN01.DOC
Support brackets
The support brackets assist the operator when processing heavy
and unwieldy workpieces. The support brackets are mounted on
the same guide system as the bending aid. They can however be
detached as required.
The support brackets can be used in combination with the bending
aid.
Support brackets
T488EN01.DOC
Fig. 38539
Sub-assemblies
1-21
3.5
TASC 6000 control
The TASC 6000 control is distinguished by the following features:
• Bend sequence calculation.
• Tonnage calculation.
• Y parallelism calculation (station bending).
• Setup plan.
• Automatic crowning.
• Automatic stop finger positioning.
• Pre-selection, number of workpieces.
• Axes positioning from the operating station.
• Access to bending factors.
• 3D visualization.
• 2D programming.
• Teach function for all axes.
• Collision check with visualization.
1-22
Sub-assemblies
T488EN01.DOC
Control panel
1
2
3
4
5
6
7
8
9
1
User interface / Touch screen
6
STOP button
2
E-STOP impact switch
7
Height adjustment lock
3
Numeric keyboard
8
USB ports
4
Cursor key
9
Keyboard and mouse
5
START button
Control panel
Fig. 42581
The TruBend Series 5000 can be operated per Touch screen as
well as per keyboard/mouse combinations and numerical input
fields. In addition to this, two USB ports located on the right side of
the panel can be used for data transfer (bending programs /
software updates).
The operating panel has a large pivot and swing area and can also
be adjusted in height.
Consequently, the bending space is not obstructed by the panel,
allowing the operator to assume an ergonomically correct work
position at all times.
T488EN01.DOC
Sub-assemblies
1-23
Operating station
1
LCD key pad
5
Control lamp
2
EMERGENCY UP foot switch
6
E-STOP release
3
Storage tray
7
RAM DOWN foot switch with
4
E-STOP impact switch
Operating station
1-24
Sub-assemblies
E-STOP function
Fig. 40676
T488EN01.DOC
Additional footswitch
1
Connector
4
Indicator lamp
2
EMERGENCY UP foot switch
5
E-STOP impact switch
RAM DOWN foot switch with
6
E-STOP release
3
E-STOP function
Additional footswitch
T488EN01.DOC
Fig. 42390
Sub-assemblies
1-25
4.
Backgauge
The backgauge defines the flange size of a bend. The available
backgauge systems are described in brief below.
2-axis backgauge
Only parts with bending lines that are parallel to the indexing edge
can be bent with the 2-axis backgauge.
2-axis backgauge
•
•
•
4-axis backgauge
X drive (forward/back) by means of racks and pinions:
high precision and dynamics.
R drive (up/down) by means of ball screws.
No Z drive (left/right): Stop fingers can only be offset manually.
The stop fingers are pneumatically clamped.
Only parts with bending lines that are parallel to the indexing edge
can be bent with the 4-axis backgauge.
4 -axis backgauge
•
1-26
Backgauge
Fig. 45301
Fig. 45302
X drive (forward/back) by means of racks and pinions:
high precision and dynamics.
T488EN01.DOC
•
•
5-axis backgauge
R drive (up/down) by means of ball screws.
Z drive (left/right), Z1 and Z2 stop fingers by means of toothed
belt drive: high dynamics when positioning light-weight parts.
With the 5-axis backgauge, it is also possible to bend parts which
have no bending lines parallel to the indexing edge.
Backgauge with relative X axis
•
•
•
T488EN01.DOC
Fig. 45303
X drive (forward/back) by means of racks and pinions:
high precision and dynamics.
R drive (up/down) by means of ball screws.
Z drive (left/right), Z1 and Z2 stop fingers by means of toothed
belt drive: high dynamics when positioning light-weight
parts.
Z2 stop finger can be moved ±75 mm in X direction via CNC
control.
Backgauge
1-27
6-axis backgauge
With the 6-axis backgauge, it is also possible to bend parts which
have no bending lines parallel to the indexing edge.
6-axis backgauge
•
•
•
Fig. 45304
X drives (forward/back), X1 and X2 by means of racks and
pinions: high precision and dynamics.
R-drives (up/down), R1 and R2 by means of ball screws.
Z-drives (left/right), Z1 and Z2 by means of racks and pinions:
high precision and dynamics.
The 6-axis backgauge is not available for the TruBend 5050.
Technological aspects
2-axis backgauge
Bending lines run parallel to the indexing edge.
4-axis backgauge
Bending lines run parallel to the indexing edge.
5-axis backgauge
Bending lines need not run parallel to the
indexing edge in X-direction (horizontal).
6-axis backgauge
Bending lines need not run parallel to indexing
edge in X and R-direction (horizontal / vertical).
Tab. 1-8
1-28
Backgauge
T488EN01.DOC
4.1
X axis and R axis
Backgauge axis system
Dimension R0 refers to the top of the lower tool clamp. In normal
bending (Manual mode, Production, Programming), however, the
stop finger is always 0.2 – 0.3 mm above R0 (top of lower tool).
This means that both the lower tool height and the calculated or
adjusted crowning value is taken into account by means of an
appropriate zero point offset.
This zero offset is not displayed.
X0
X+
R+
R0
R-
X axis, R axis
T488EN01.DOC
Fig. 23738
Backgauge
1-29
Z axis
1
2
Z+
Z0
Z2
1
Sheet
Z axis
Z1
2
Machine bed
Fig. 51624
The reference edges for the stop finger positions are at the outside
left and right.
Clamping (5 and 6 axis
backgauge)
In the "Clamping" indexing method, the workpiece is aligned
exactly against the backgauge in both X and Z directions.
The following clamping possibilities are supported:
• Clamping on one side
• Clamping on both sides
Clamping on both sides
Clamping functions
1-30
Backgauge
Clamping on one side
Fig. 35065
T488EN01.DOC
4.2
Technical data: Backgauge
X2
X1
R2
R1
Z2
Z1
Axes: Backgauge
TruBend
Travel range
5050
5085
5850 S
5130
5170
[mm]
600
600
600
600
600
[mm]
-50
+200
-50
+200
-50
+200
-50
+200
-50
+200
4 axis
[mm]
753
1463
1973
2403
2403
5 axis
[mm]
670
1380
1890
2320
2320
6 axis
[mm]
-
1340
1850
2280
2280
[mm]
860
860
860
860
860
4 /5 axis
[mm]
929.5
1640
2150
2580
2580
6 axis
[mm]
-
1530
2040
2470
2470
X1/X2 axis
[mm/s]
0 - 1000
0 - 1000
0 - 1000
0 - 1000
0 - 1000
R1/R2 axis
[mm/s]
0 - 330
0 - 330
0 - 330
0 - 330
0 - 330
Z1/Z2 axis
[mm/s]
0 - 1000
0 - 1000
0 - 1000
0 - 1000
0 - 1000
X1/X2 axis
[mm]
0.04
0.04
0.04
0.04
0.04
R1/R2 axis
[mm]
0.08
0.08
0.08
0.08
0.08
Z1/Z2 axis
[mm]
0.06
0.06
0.06
0.06
0.06
4/5 axis
[mm]
25
25
25
25
25
6 axis
[mm]
10
10
10
10
10
Finger – Side 4 axis
element
5 axis
[mm]
60
60
60
60
60
[mm]
25
25
25
25
25
6 axis
[mm]
115
115
115
115
115
X1/X2 axis
R1/R2 axis
2
Z1/Z2 axis
Max. stop range
In X direction
In
Z direction
Speeds
Positioning accuracy
Distance
Fig. 44111
Finger –
Finger
Technical data: Backgauge 5050 – 5170
Tab. 1-9
2
T488EN01.DOC
Reference edge R0
Backgauge
1-31
TruBend
Travel range
5170 S
5230
5230 S
5320
[mm]
600
600
600
600
[mm]
-50
+200
-50
+200
-50
+200
-50
+200
4 axis
[mm]
3393
2403
3393
3393
5 axis
[mm]
3310
2320
3310
3310
6 axis
[mm]
3270
2280
3270
3270
[mm]
860
860
860
860
4/5 axis
[mm]
3570
2580
3570
3570
6 axis
[mm]
3460
2470
3460
3460
X1/X2 axis
[mm/s]
0 - 1000
0 - 1000
0 - 1000
0 - 1000
R1/R2 axis
[mm/s]
0 - 330
0 - 330
0 - 330
0 - 330
Z1/Z2 axis
[mm/s]
0 - 1000
0 - 1000
0 - 1000
0 - 1000
X1/X2 axis
[mm]
0.04
0.04
0.04
0.04
R1/R2 axis
[mm]
0.08
0.08
0.08
0.08
Z1/Z2 axis
[mm]
0.06
0.06
0.06
0.06
X1/X2 axis
R1/R2 axis
3
Z1/Z2 axis
Max. stop range
In X direction
In
Z direction
Speeds
Positioning accuracy
Distance
Finger –
Finger
4-/5 axis
[mm]
25
25
25
25
6 axis
[mm]
10
10
10
10
Finger – Side
element
4 axis
[mm]
60
60
60
60
5 axis
[mm]
25
25
25
25
6 axis
[mm]
115
115
115
115
Technical data: Backgauge 5170 S – 5320
3
1-32
Backgauge
Tab. 1-10
Reference edge R0
T488EN01.DOC
4.3
Stop fingers and stop positions
Stop positions for standard stop fingers
Standard
Option
Fig. 32228
The stop fingers of all backgauge systems have three different stop
positions:
• Stop position 0: Workpiece is indexed at the stop finger. At
the max. X position (X = 600), flanges 600 mm long can be
indexed.
• Stop position 30: Workpiece is placed on the lower support of
the stop finger and indexed. At the max. X position (X = 600),
flanges 630 mm long can be indexed.
• Stop position 260: Workpiece is placed on the upper support
of the gauge finger and indexed. At the max. X position (X =
600), flanges 860 mm long can be indexed.
•
Stop position 400: The workpiece is placed on the upper
support of the gauge finger and indexed. At the max. X position
(X = 600), flanges 1000 mm long can be indexed
1
1
1
Stop position 1000 mm
Fig. 32301
T488EN01.DOC
Backgauge
1-33
0
30
260
400
Stop positions
1-34
Backgauge
Fig. 44110
T488EN01.DOC
Micrometer stop fingers (Option)
Micrometer stop fingers are available in 3 different versions:
•
Micrometer stop fingers for 2-axis backgauge.
•
Micrometer stop fingers for 4-axis backgauge.
•
Detachable micrometer stop fingers for 4-axis backgauge.
Fig. 45307
Fig. 45305
Fig. 45306
Micrometer stop finger for
2 axis backgauge.
Detachable
micrometer stop finger
for 4-axis backgauge.
Micrometer stop finger for
4 axis backgauge.
Tab. 1-11
It is possible to use several stop fingers simultaneously.
Micrometer stop fingers are ideal when processing workpieces with
steps.
Travel paths are limited to ±15 mm.
T488EN01.DOC
Backgauge
1-35
5.
TRUMPF BendGuard
Note
Work at a rapid speed higher than 10 mm/s is permitted only if an
opto-electronic safety device is used. The TRUMPF BendGuard is
such an opto-electronic safety device.
Background
In practice, TruBend press brakes are normally loaded by hand. In
accordance with the valid safety regulations, the following concepts
of operation exist to avoid accidents
• Two-hand operation at working speed. Disadvantage: the part
must be put down before approaching the bending position;
longer cycle times
• Foot operation at working speed. Disadvantage: longer cycle
times.
• Operation with light curtain at rapid speed. Disadvantage: can
only be used with certain part geometries.
TRUMPF BendGuard
TRUMPF BendGuard enables you to work at rapid speed without
jeopardizing the safety of the operating personnel and without
restrictions in parts handling. TRUMPF BendGuard monitors the
area under the upper tool by means of two laser light bands. The
rapid downward motion of the ram is halted if the light beams are
interrupted.
TRUMPF BendGuard is a non-contact safety protection device
(BWS) Type 4 according to EN954 with integrated tracking control
unit. A safety level in accordance with EN12622 (2001) 5.3.2(f) is
achieved.
1-36
TRUMPF BendGuard
T488EN01.DOC
14 mm
Located at a distance of 4 mm (beam array A) and 14 mm (beam
array B) beneath the upper tool tip, two parallel beams of laser light
shine in front of the upper tool and provide protection for hands
and fingers. The effective overall width of the laser lights is 40 mm,
i.e. 20 mm in front of and 20 mm behind the upper tool tip.
4 mm
Principle
A
1
2
3
B
20 mm
20 mm
1A Monitoring range 1A
2B Monitoring range 2B
(in front of the upper tool tip,
(with circular cross-section,
laser light A)
laser light B)
1B Monitoring range 1B
3A Monitoring range 3A
(in front of the upper tool tip,
(laser light B)
(behind the upper tool tip,
laser light A)
2A Monitoring range 2A
3B Monitoring range 3B
(with circular cross-section,
(behind the upper tool tip,
laser light A)
(laser light B)
Laser beam and tools
Fig. 31003
With the two 40 mm wide bands of laser light, three areas are
monitored at a distance of 4 and 14 mm beneath the upper tool tip:
Monitoring range 1
20 mm in front of the upper tool tip.
Monitoring range 2
Exactly under the upper tool tip (circular crosssection).
Monitoring range 3
20 mm behind the upper tool tip.
Tab. 1-12
T488EN01.DOC
TRUMPF BendGuard
1-37
BendGuard modes
1-38
TRUMPF BendGuard
There are 6 different BendGuard modes:
• BendGuard Mode 1:
Both laser bands as well as the point-shaped laser beam
directly under the tool tip are active during rapid downward ram
motion. If either of the two laser lines or the point-shaped beam
is interrupted, ram motion stops.
• BendGuard Mode 2:
Initially, all laser bands are active. The machine stops at the
first interruption of laser band B (e.g. by the side wall of a box).
The two laser bands front and rear of the tool tip are no longer
monitored from here on. The two laser beams with circular
cross-section directly under the upper tool tip may not,
however, be interrupted.
• BendGuard Mode 3:
Like BendGuard mode 1, except that the ram stops at the mute
point and has to be restarted using the foot switch.
• BendGuard Mode 4:
Like BendGuard mode 2, except that the ram stops at the mute
point and has to be restarted using the foot switch.
• BendGuard Mode 5: (BendGuard not active) Downward ram
motion only at working speed.
• BendGuard Mode 6: (BendGuard not active with stop at mute
point)
Like BendGuard mode 5, except that the ram stops at the mute
point and has to be restarted using the foot switch.
T488EN01.DOC
Chapter 2
Technology
(Application technology)
T488EN02.DOC
1.
1.1
1.2
1.3
1.4
1.5
Bending methods: Overview ........................................ 2-3
Air bending....................................................................... 2-3
Coining............................................................................. 2-5
Hemming.......................................................................... 2-7
Flattening ......................................................................... 2-8
Sensor bending................................................................ 2-9
Overview: Sensor bending ....................................... 2-13
Learned bend............................................................ 2-13
2.
2.1
2.2
2.3
2.4
2.5
2.6
Calculations ................................................................. 2-14
Press tonnage................................................................ 2-14
Box height...................................................................... 2-17
Inside radius .................................................................. 2-19
Selecting the die width................................................... 2-21
Shortest flange length.................................................... 2-23
Flat length ...................................................................... 2-26
Calculating the flat length in case of large bend
radii ........................................................................... 2-27
Technology (Application technology)
2-1
2.7
2.8
2-2
Calculating the flat length in case of small bend
radii ........................................................................... 2-29
Use of the compensation value in the machine
controller ................................................................... 2-33
Minimum distances and lengths .................................... 2-34
Different bending flange shapes.................................... 2-35
Technology (Application technology)
T488EN02.DOC
1.
Bending methods: Overview
The following bending methods can be used on machines of the
TruBend Series 5000:
• Air bending
• Coining
• Hemming
• Flattening
• Air bending + ACB
1.1
Air bending
Air bending
Fig. 34902
Air bending is a frequently used, flexible bending method. In air
bending, the workpiece is in contact with the upper and lower tools
at three different points:
• At the tip of the upper tool.
• At both working radii of the lower tool.
In air bending, the bent angle is achieved "in air", or "freely". The
bending angle is dependent on the material data (material, sheet
thickness) and tool data (die widths, working radii). It is determined
by the position of the upper tool (depth by which the upper tool
plunges into the lower tool).
No uniform bend radius is formed in air bending, but rather a
curvature line with the smallest curvature in the bending apex.
T488EN02.DOC
Bending methods: Overview
2-3
Advantages of air bending
•
•
Air bending
on the TruBend
Any angle between approx. 32° and 180° can be produced
without changing tools.
Low bending tonnage.
Air bending is a path-dependent bending method
The ram travels to the programmed Y axis position at the
calculated pressure.
If the pressure is insufficient, the ram does not reach the lowest
nominal Y axis position and stops at the point where the opposing
forces are in equilibrium. This is usually the case when the tensile
strength and thickness of the material being bent differs
considerably from the data used by the control system in its
calculations.
2-4
Bending methods: Overview
T488EN02.DOC
1.2
Coining
Coining
Fig. 34903
In coining, the bend angle is produced in a form locking manner,
i.e. by pressing the workpiece into a defined form (lower tool, or
die). The angles of the upper and lower tools must be identical,
they determine the workpiece angle.
Important notes on
coining
•
•
•
•
•
T488EN02.DOC
Coining is used:
If the required inside radius of the workpiece is less than
the sheet thickness
–
If holes, cutouts or angled edges are located near or on the
bending line.
–
Extreme contour accuracy (radius RI).
Each specific angle and inside radius requires a dedicated tool
set (upper and lower tool).
Coining requires at least 3 times more tonnage than does air
bending, depending on the material and sheet thickness.
The cost-efficiency of coining (tool costs/tool set-up time) is
often attained only in large-series production.
Springback can be influenced only by changing the press
tonnage.
–
Bending methods: Overview
2-5
•
Coining on the TruBend
The decisive parameters for coining are:
–
Material.
–
Sheet thickness.
–
Inside radius.
–
Shortest flange length.
–
Bending angle.
–
Angle accuracy.
–
Sheet thickness tolerance.
–
Max. tensile strength.
Coining is the pressure-dependent bending method.
The ram descends at a pre-determined pressure until this pressure
has been present for at least 0.3 s. This pressure equilibrium
should not be achieved until positive contact between upper tool,
material and lower tool has been established.
For this reason, the nominal Y axis position in coining is approx.
2 mm beneath the bottom of the die (positive locking).
If pressure equilibrium sets in before the positive lock is achieved,
then the press tonnage has to be increased manually.
This is usually the case when the tensile strength and the
thickness of the material being bent differs considerably from the
data used by the control system in its calculations.
2-6
Bending methods: Overview
T488EN02.DOC
1.3
Hemming
Hemming
Fig. 34901
In hemming, a seam is produced along a sheet edge using special
tools (e.g. upper tool OW 210/S and hemming tool FWZ).
Important notes on
hemming
•
•
As in air bending, hemming is a path-dependent bending
method.
Hemming is used:
–
If a seam does not need to be pressed completely flat.
–
To minimize the counter-bend effect in long seam flanges.
–
If a defined dimension needs to be produced between the
flanges.
X
X
Defined dimension between the seam flanges
Fig. 35066
T488EN02.DOC
Bending methods: Overview
2-7
1.4
Flattening
Flattening
Fig. 34900
In flattening, a seam is produced along a sheet edge using special
tools (e.g. upper tool OW 210/S and hemming tool FWZ).
Important notes on
flattening
•
•
Analog to coining, flattening is a pressure-dependent bending
method.
Flattening is used when a seam is to be pressed completely
flat:
1
1
2-8
Teardrop
Completely flattened seam
Fig. 51627
Counter-bend effect in hemming
Fig. 35067
Bending methods: Overview
T488EN02.DOC
1.5
Sensor bending
Sensor bending with the ACB® angle sensor is based on air
bending.
To obtain an accurate bend angle in air bending, the workpiece is
over-bent by an amount equal to the elastic springback. Several
trial bends are usually necessary to determine the exact bending
parameters. This can waste time in small lot sizes and does not
guarantee that larger lot sizes will stay within the production
tolerances.
In sensor bending, it is not only the actual value of a bend angle
that is measured; different springback angles and varying material
properties are also recorded. The nominal value of the bend angle
is controlled with the aid of this information.
The advantages:
• High-precision bend angles through automatic measurement
and control, regardless of the …
–
Grain
–
Tensile strength
–
Sheet thickness deviations
• Complicated trial runs are no longer necessary.
• Less material is used as there are no rejects.
• Shorter machining times. The workpieces, having accurate
angles, do not need to be refinished or measured for quality
assurance.
The ACB® angle sensor includes the following:
• Sensor module
• Sensor tool.
• Various accessories (not illustrated).
T488EN02.DOC
Bending methods: Overview
2-9
1
2
1
Sensor module
Angle sensor ACB
Angle sensing in the
upper tool
Sensor tool
Fig. 36824
The angle sensing system is integrated in the upper tool and is
loaded with the conventional upper tools in the respective bending
stations.
Sensor tool
2-10
2
Bending methods: Overview
Fig. 14869
T488EN02.DOC
Four-point measurement with
sensor disks
Located in the sensor tool are two measuring or sensor disks of
different diameters which center themselves in the bending
flanges. 4 contact points on the inside of the bend are measured
by the disks during the bending process at working speed. The
distance between the center points of the disks changes with the
penetration depth of the disks. The system continuously calculates
the actual angle based on this distance.
Four-point measurement by means of sensor disks
Two-dimensional angle
sensing
T488EN02.DOC
Fig. 14755
Disk displacement is evaluated two-dimensionally by means of
intelligent signal processing. This means that the bending angle as
well as a possible tilt angle of the workpiece in X direction are
measured. The tilt angle is eliminated as a possible source of error
when the actual angle is calculated.
Bending methods: Overview
2-11
Technical data
Current sensor tools
All common
standard upper tools.
(Special radii on request)
Tool width [mm]
25
Max. number of sensor tools per
sensor electronic unit
1
Max. number of electronic sensor units
per press brake
8
Max. number of sensors per bend
3
Measurement range [°]
(dependent on type of sensor, material
and sensor disks)
42 - 135
Angle accuracy [°]
±0.3
Tab. 2-1
α1
α3
α5
±0,3°
α2
α4
A
B
C
D
E
0
A
Pre-bending
B
Measure springback + monitor
the tilt angle
C
D
t
Finish bend (required angle +
E
Measure final angle
springback angle)
t
Time
Pressure relief + monitor the tilt
angle
Schematic sequence of a complete sensor bend
2-12
Bending methods: Overview
Fig. 32785
T488EN02.DOC
Overview: Sensor bending
TASC 6000 settings and
programming
Function
For each bend…
• the springback is calculated
• the nominal angle regulated
• tilting is checked.
For the first bend in an active program…
• the springback is calculated
• the nominal angle regulated
• tilting is checked.
Each further identical bend (with referral to a reference bend) is bent with angle
regulation.
The established Y-position for an ACB bend is adopted for each further identical
bend (position regulation)
For each bend…
• the nominal angle is approached with angle regulation,
• springback and tilting are not measured.
Tab. 2-2
Learned bend
In learned bends, bending is accomplished using the Y axis data of
a previously completed sensor bend. In this case, the sensor tool
has neither a measuring nor a controlling function, i.e. it is not
active. It can however remain loaded in the workstation during the
bending process.
If the sensor bend was performed with 2 sensors, the Y-parallelism
correction is also applied.
If sensor bending was performed with 3 sensors, the crowning
correction will also be applied.
Application
Taught bending is implemented whenever the same angles in the
same grain of the material are required in one single product. This
allows for more economical production.
A detailed description of learned bends is found in the ACB® angle
sensor manual.
T488EN02.DOC
Bending methods: Overview
2-13
2.
Calculations
2.1
Press tonnage
The press tonnage for air bending can be calculated using a
formula determined empirically by TRUMPF:
Press tonnage calculation for air bending
Fig. 2857
1.33 × l × Rm × s 2
F=
W − (2 × cos 45° × rOW )
1.33 Frictional resistance between material and lower tool (determined
empirically)
F
Press tonnage [N]
l
Bend length [mm]
Rm Maximum tensile strength of the material [N/mm2]
s
Sheet thickness [mm]
W
Die width [mm]
rOW Radius of upper tool [mm]
cos 45° ≈ 0.7
The formula value (2*cos45°*rOW) has a decisive impact only for large
upper tool radii; it can be ignored for TRUMPF standard tools where
rOW = 1 mm.
2-14
Calculations
T488EN02.DOC
The tonnage can also be determined using the TRUMPF bending
slide rule or with the press tonnage table:
Example: Length of bend 1 m - Sheet thickness 3 mm - Die width 24 mm - Material tensile strength 400 N/mm2
Result: Press tonnage 200 kN
TRUMPF Bending slide rule - Front
T488EN02.DOC
Fig. 35615
Calculations
2-15
Press tonnage table (Material tensile strength 400 N/mm2)
s
W
6
8
10
12
16
20
24
30
40
50
60
70
80
90
100
120
b
4.5
6
7.5
9
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
8
9.6
11
13
14
16
19
0.75
52
39
31
26
1
93
70
56
47
35
1.25
145
109
87
73
55
44
1.5
209
157
126
105
79
63
214
171
143
107
86
71
223
186
140
112
93
291
218
175
145
116
3
314
251
209
168
126
3.5
428
342
285
228
171
137
4
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
5
466
349
279
233
200
175
6
670
503
402
335
287
251
223
684
547
456
391
342
304
274
715
596
511
447
397
358
298
798
698
621
559
466
1005 894
804
670
1.75
2
2.5
7
8
10
12
Tab. 2-3
W
Die width [mm]
b
Shortest flange length [mm]
Ri
Inside radius [mm]
s
Sheet thickness [mm]
Tonnage [kN/m] at optimal die width W
Example:
Result:
2-16
Calculations
Sheet thickness s = 3 mm - Die width W = 24 mm
Press tonnage F = 209 kN/m
T488EN02.DOC
2.2
Box height
The maximum box height for a bend angle of 90° can be calculated
using the following formula:
SHi
B
OWH
Calculating the maximum box height
SH i =
OWH − B
× 0.95
1.414
OWH =
SHi
Fig. 33329
SH i
× 1.414 + B
0.95
Box height (inside) [mm]
OWH Upper tool height [mm]
B
T488EN02.DOC
Ram center to outside edge of Modufix = 24 mm
Calculations
2-17
The following rounded, maximum box heights result for the
standard tool heights:
Upper tool height [mm]
Maximum box height [mm]
120
65
140
78
220
131
240
145
Tab. 2-4
2-18
Calculations
T488EN02.DOC
2.3
Inside radius
The inside radius Ri is primarily dependent on the die width W.
Given an upper tool radius of 1 mm and a 90° bend angle, this will
result in the following inside radius Ri:
Ri ≈ 0.16 x W
Ri
Inside radius [mm]
W
Die width [mm]
The inside radius can also be determined using the TRUMPF
bending slide rule:
Example: Sheet thickness 3 mm - Die width 24 mm
Result: Inside radius (bend radius) 3.8 mm
TRUMPF Bending slide rule - Rear
T488EN02.DOC
Fig. 34663
Calculations
2-19
Press tonnage table (Material tensile strength 400 N/mm2)
s
W
6
8
10
12
16
20
24
30
40
50
60
70
80
90
100
120
b
4.5
6
7.5
9
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
8
9.6
11
13
14
16
19
0.75
52
39
31
26
1
93
70
56
47
35
1.25
145
109
87
73
55
44
1.5
209
157
126
105
79
63
214
171
143
107
86
71
223
186
140
112
93
291
218
175
145
116
3
314
251
209
168
126
3.5
428
342
285
228
171
137
4
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
5
466
349
279
233
200
175
6
670
503
402
335
287
251
223
684
547
456
391
342
304
274
715
596
511
447
397
358
298
798
698
621
559
466
1005 894
804
670
1.75
2
2.5
7
8
10
12
Tab. 2-5
W
Die width [mm]
b
Shortest flange length[mm]
Ri
Inside radius [mm]
s
Sheet thickness [mm]
Tonnage [kN/m] with optimal die width W
Example:
Result:
2-20
Calculations
Sheet thickness s = 3 mm - Die width W = 24 mm
Inside radius Ri = 3.8 mm
T488EN02.DOC
2.4
Selecting the die width
The die width of a lower tool depends on the type of material, sheet
thickness, upper tool radius, the tool load and on the tonnage
required.
In practice, die width W is calculated according to the following rule
of thumb:
W = (6 to 10) x s
Sheet thickness s [mm]
Die width W [mm]
0.5 - 2.5
6*s
3.0 - 6.0
8*s
≥8.0
10*s
Tab. 2-6
The optimum die width can also be determined using the TRUMPF
bending slide rule or the tonnage table:
Example: Sheet thickness 3 mm
Result: Possible die widths (the ones behind which a bending radius is indicated): 16 mm, 20 mm, 24 mm, 30 mm,
40 mm
The middle value is the ideal die width (in this case: W = 24 mm).
TRUMPF Bending slide rule - Rear
T488EN02.DOC
Fig. 34663
Calculations
2-21
Press tonnage table (Material tensile strength 400 N/mm2)
s
W
6
8
10
12
16
20
24
30
40
50
60
70
80
90
100
120
b
4.5
6
7.5
9
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
8
9.6
11
13
14
16
19
0.75
52
39
31
26
1
93
70
56
47
35
1.25
145
109
87
73
55
44
1.5
209
157
126
105
79
63
214
171
143
107
86
71
223
186
140
112
93
291
218
175
145
116
3
314
251
209
168
126
3.5
428
342
285
228
171
137
4
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
5
466
349
279
233
200
175
6
670
503
402
335
287
251
223
684
547
456
391
342
304
274
715
596
511
447
397
358
298
798
698
621
559
466
1005 894
804
670
1.75
2
2.5
7
8
10
12
Tab. 2-7
W
Die width [mm]
b
Shortest flange length [mm]
Ri
Inside radius [mm]
s
Sheet thickness [mm]
Tonnage [kN/m] with optimal die width W
Example:
Result:
2-22
Calculations
Sheet thickness s = 3 mm
Possible die widths (those for which a tonnage is listed):
W = 16 mm, 20 mm, 24 mm, 30 mm, 40 mm.
The middle value is the ideal die width (in this case W = 24 mm).
T488EN02.DOC
2.5
Shortest flange length
Determining the shortest flange length
Fig. 3856
The following equation can be used to determine the shortest
flange length b for a 90° lower tool:
b=
2
×W
2
b
Shortest flange length [mm]
W
Die width [mm]
The shortest flange length can also be determined using the
TRUMPF bending slide rule or the tonnage table:
T488EN02.DOC
Calculations
2-23
Example: Sheet thickness 3 mm - Die width 24 mm
Result: Shortest flange length 18 mm
TRUMPF Bending slide rule - Rear
2-24
Calculations
Fig. 34663
T488EN02.DOC
Press tonnage table (Material tensile strength 400 N/mm2)
s
W
6
8
10
12
16
20
24
30
40
50
60
70
80
90
100
120
b
4.5
6
7.5
9
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
8
9.6
11
13
14
16
19
0.75
52
39
31
26
1
93
70
56
47
35
1.25
145
109
87
73
55
44
1.5
209
157
126
105
79
63
214
171
143
107
86
71
223
186
140
112
93
291
218
175
145
116
3
314
251
209
168
126
3.5
428
342
285
228
171
137
4
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
5
466
349
279
233
200
175
6
670
503
402
335
287
251
223
684
547
456
391
342
304
274
715
596
511
447
397
358
298
798
698
621
559
466
1005 894
804
670
1.75
2
2.5
7
8
10
12
Tab. 2-8
W
Die width [mm]
b
Shortest flange length [mm]
Ri
Inside radius [mm]
s
Sheet thickness [mm]
Tonnage [kN/m] with optimum die width W
Example:
Result:
T488EN02.DOC
Sheet thickness s = 3 mm - Die width W = 24 mm
Shortest flange length b = 18 mm
Calculations
2-25
2.6
Flat length
The outside surface of the bend is subjected to tension, i.e. it is
stretched during bending, while the inside surface (facing the upper
tool) is compressed (inside radius Ri).
1
2
1
Tension (stretching)
2
Compression
Fig. 51629
Located between these two areas is the so-called "neutral axis". In
a part with small bend radii (R < 20 mm), the neutral axis migrates
towards the inside radius (Ri).
The run of the "neutral axis" corresponds to the length of a bend
part when it is unfolded (flat length).
Inside radius
2-26
Calculations
The inside radius is decisive for the flat length (length of the flat
blank) of a bending part. The inside radius is dependent on the
following variables:
• Tool parameters
–
Die width of lower tool
–
Radius of upper tool
• Material parameters
–
Sheet thickness s
–
Tensile strength Rm
–
Grain
• Workpiece parameters
–
Bend angle
T488EN02.DOC
Example
120 (A)
0
A
40 (A)
35 (B)
110 (B)
34.75
Outside dimension
144.26
B
179.01
Inside dimension
S = 5 mm
Fig. 51628
Calculating the flat length in case of large
bend radii
When calculating the flat length for parts with a bend radius 20 mm
and greater, one can assume that the "neutral axis" runs through
the middle of the sheet cross-section.
The flat length L can be calculated with the following formula:
L = L1 + L2 + L3 + ...
T488EN02.DOC
L
Flat length [mm]
Lx
Length of individual segments [mm]
Calculations
2-27
Example
L2
45°
=1
L1
L3
2
R4
Sheet thickness s = 4 mm
Calculating the flat length in case of large bend radii
L1
L2 =
Fig. 38662
= 30 mm
π × d ×α
360°
=
s
2
360°
π × 2( R + ) × α
L2
= 113.62 mm
L3
= 80 mm
L
= L 1 + L2 + L3
=
π × 2(42)mm × (145°)
360°
= (30 + 113.62 + 80) mm
= 223.62 mm
2-28
Calculations
T488EN02.DOC
Calculating the flat length in case of small
bend radii
If the part has a bend radius of ≤20 mm, the "neutral axis" no
longer runs precisely through the middle of the sheet cross-section.
A compensation value therefore needs to be taken into account
when calculating the flat length.
b
a
Fig. 38663
The flat length L can be calculated with the following formula:
L=a+b-v
T488EN02.DOC
L
Flat length [mm]
a
Flange length 1 [mm]
b
Flange length 2 [mm]
v
Compensation value [mm]
Calculations
2-29
Calculating the compensation value v
b
Compensation value for
opening angle 0° - 90°
r
β
s
s.k
2
a
Fig. 50534
v = 2(r + s ) − π ×
v
180° − β
s
× (r + × k )
180°
2
Compensation value [mm]
r
Bend radius [mm]
s
Sheet thickness [mm]
ß
Bend angle [°]
k
Correction factor
The correction factor k, a variable of the bend factor v, is calculated
using the following formula:
k = 0.65 + 0.5 × log
2-30
Calculations
r
s
k
Correction factor
r
Bend radius [mm]
s
Sheet thickness [mm]
T488EN02.DOC
Compensation value for
opening angle 90° - 165°
r
β
s
b
s
2
a
Fig. 50535
v = 2(r + s ) × tan
180° − β
180° − β
s
× (r + × k )
−π ×
2
180°
2
v
Compensation value [mm]
r
Bend radius [mm]
s
Sheet thickness [mm]
ß
Bend angle [°]
k
Correction factor
Correction factor k indicates the deviation of the location of the
neutral axis s/2 and is calculated as follows:
k = 0.65 + 0.5 × log
k
r
s
Correction factor
r
Bend radius [mm]
s
Sheet thickness [mm]
Note
The bend factor v can also be obtained from Supplement 2 of
DIN 6935.
T488EN02.DOC
Calculations
2-31
Compensation value for
opening angle 165° - 180°
s
r
β
b
a
Fig. 50536
v=0
v
Compensation value [mm]
Note
The values here for v are minimal, the accuracy suffices in
practice.
2-32
Calculations
T488EN02.DOC
Use of the compensation value in the
machine controller
The TASC 6000 control accesses the TruToPsBend database for
technology data. This database contains the compensation values
for all conventional material-tool combinations.
These values can be called up in both manual and programming
modes.
Icons
Icon
Function / Significance
Compensation value, can be overwritten.
Compensation value from TRUMPF database.
No compensation values present in the database.
Tab. 2-9
Retrieving a correction
value
¾ Double click the icon to the left of the X-correction input field.
Bend allowance / Correction value will be displayed.
Note
Another double click re-enables the X correction input field.
When working with the TruToPsBend Profile Editor, the flat length
is calculated on the basis of the tool, material and product angle,
and then displayed on the screen.
T488EN02.DOC
Calculations
2-33
2.7
Minimum distances and lengths
When bending parts which in their flat state have a hole or a notch
close to the bending line, a minimum distance must be observed
between the edge of the hole or notch and the bend itself to avoid
deforming the shape of the hole or notch.
Workpieces with holes or notches
Fig. 1411
The minimum distance x1 (for holes) or x2 (for notches) is
calculated as follows:
x1 = 0.75 xW
x 2 = 0.75 xW
x1, x2
Minimum distance of bend from hole or notch [mm]
W
Die width
A quick method for determining the minimum distance in the
workshop is to calculate the shortest flange length (see Page 2-23,
slide rule, tonnage table). Notches and holes can be produced
without deformation if the distance between them and the bending
line is greater than the shortest flange length.
2-34
Calculations
T488EN02.DOC
2.8
Different bending flange shapes
Deformation and compression in the bending zone occur during
the bending process and need to be taken into account in the
workpiece design.
Especially in air bending, such deformation and compression can
have a negative impact on the workpiece shape.
Correct and incorrect
workpiece design
Incorrect design:
Correct design:
1
2
3
4
Fig. 51630
T488EN02.DOC
Calculations
2-35
Number
Description
Remedy
1.
The bending lines should not form any
shared points of intersection in the
material. This would otherwise hinder
tension and compression in the
bending zone, resulting in cracks.
Notches measuring
x = 1.5 x s
2.
Avoid edges at an angle to the bending •
line.
•
3.
4.
Instead of a short bending flange y,
•
move the edge of the other flange back
•
by an amount equal to x.
Instead of the short bending flange y,
make the cutout around the bending
line.
Vertical distance to
the bending line,
measuring
lmin = 0.75 x W
Notch the angled
edge.
xmin = (1 to 1.5) x s
Notch the angled
edge.
xmin = (1 to 1.5) x s
Significance:
s
Sheet thickness [mm]
W
Die width [mm]
•
•
Tab. 2-10
Note
If flange shapes such as those in Nos. 2, 3 and 4 cannot be
avoided because of design considerations, then a different bending
method should be used – change from air bending to coining.
2-36
Calculations
T488EN02.DOC
Chapter 3
Tool system
T488EN03.DOC
1.
Terminology ................................................................... 3-2
2.
2.1
2.2
2.3
2.4
2.5
Tools from TRUMPF ...................................................... 3-3
Tool identification............................................................. 3-3
Upper tools ...................................................................... 3-4
Lower tools ...................................................................... 3-6
Die width ..................................................................... 3-6
Opening angle ............................................................ 3-7
Tools for thin sheets ...................................................... 3-11
System segmentation of tools ....................................... 3-13
3.
Laser hardening........................................................... 3-15
4.
Imprint-free bending.................................................... 3-16
5.
Special tools................................................................. 3-18
Tool system
3-1
1.
Terminology
1
2
6
3
4
7
5
8
1
Upper tool (punch)
5
Die width (W)
2
Workpiece
6
Lower tool radius
3
Inside workpiece radius (Ri)
7
Upper tool radius
4
Outside workpiece radius (Ra)
8
Lower tool (die)
Fig. 12763
3-2
Terminology
T488EN03.DOC
2.
Tools from TRUMPF
2.1
Tool identification
Identification codes provide information about the tools. The letters
identify a certain type of tool or a important tool characteristic.
Code
Upper tool (punch)
OW
Upper tool
Lower tool (die)
UW
Lower tool
EV
Single V die
KEV
Plastic single-Vee die
S
Shoulder-bearing tool
K
Head-bearing tool
H
Upper tool height
R
Radius (punch tip)
W
ZM
Narrow die (30° dies are narrow on
one side whereas 84° dies are narrow
on both sides).
Height of lower tool (die)
If the letter H is missing, the lower tool
height is 100 mm. If only Clamp …/H
is specified, then the lower tool height
is 150 mm. Code H+number refers to
tools with defined special heights.
Working radius
Die width
Any high (>140 mm) special tool with
tension spring and Multi-LEDs
MF/S
Modufix adapter, shoulder-bearing
ZE
Insert for Z bends
Insert for Z bends
FWZ
Hemming tool
MST
Torque support
ZDL
Flattening bar
FEV
Hemming bar and single-V die
Combination lower tool for hemming
without I-axis adjustment.
Tab. 3-1
T488EN03.DOC
Tool system
3-3
2.2
Upper tools
OW200/S
Upper tools Type OW200
OW200/K
Fig. 23589; 23588
Note
Both head and shoulder bearing upper tools can be used on the
TruBend Series 5000.
Upper tool heights
Standard upper tools are available in two different heights. Lower
upper tools (working height ≤120 mm) are head-bearing, high
upper tools (working height ≥220 mm) are shoulder-bearing.
In the case of special upper tools, it is not the tool height alone that
determines whether the upper tool is head-bearing or shoulderbearing. The press tonnage exerted on the tool is also a decisive
factor, in addition to the geometric shape, which might lead to offcenter loads during the bending process.
3-4
Tools from TRUMPF
T488EN03.DOC
Shoulder-bearing tool
Head-bearing tool
Tool types
Fig. 35647, 35648
Note
In upper tool type OW210/S, both punches, the higher and the
lower one, are shoulder-bearing.
OW 210/S H240
Upper tools OW 210/S
Load-bearing capacity of
upper tool clamp
•
•
•
T488EN03.DOC
OW 210/S H140
Fig. 22942; 22882
When using head-bearing upper tools, the tool clamping can
be loaded with maximum 1350 kN/m.
In the case of shoulder-bearing upper tools, the tool clamping
can be loaded with maximum 1870 kN/m.
Higher loads apply for tool lengths greater than 500 mm:
–
head-bearing upper tools: max. 1800 kN/m.
–
shoulder-bearing upper tools max. 2500 kN/m.
Tool system
3-5
2.3
Lower tools
Overview of lower tools
EV 001
EV 001/H
EV001/S
Lower tools
KEV ...
Fig. 31183; 31182;
33330; 33331
Die width
Where the die width is concerned, a distinction is made between
the nominal width and the width which is relevant for calculating
the penetration depth.
Nominal width
The nominal width is specified on the lower tool, e.g. W = 6 for
EV001. The nominal width is measured at the point where the
radius of the lower tool becomes the straight line of the V-opening.
Technically important width
for penetration depth
This width Wt is measured at the intersecting point of the tangents.
The difference between the nominal width and the technical die
width becomes more obvious the larger the working radii are.
Note
The Wt value is calculated by the control based on the lower tool
data and factored in for bend sequence calculation.
⎛
⎛α ⎞
⎛ α ⎞⎞
Wt = W + 2 × tan⎜ ⎟ × R × ⎜⎜1 − sin ⎜ ⎟ ⎟⎟
⎝2⎠
⎝ 2 ⎠⎠
⎝
3-6
Tools from TRUMPF
T488EN03.DOC
Wt
W
R
α
W
Specified die width
= nominal width
Wt Technically important width for
calculating the penetration depth
Die width
Fig. 33333
Opening angle
TRUMPF lower tools come with 5 different opening angles:
• 30°
• 80°
• 84°
• 86°
• 90°
The question of which opening angle needs to be used depends on
the application in question.
30° lower tool
In air bending, a lower tool with an opening angle of 30° is usually
utilized. Maximum bending flexibility is achieved with this kind of
tool because (providing the corresponding upper tool is available)
any angle between 180° and almost 30° can be bent.
30° lower tools are available in widths W = 4 mm to 24 mm. The
tools with die widths W = 4 mm and 5 mm are thin sheet tools
designed for sheet thickness s ≤1 mm, see page 3-11.
T488EN03.DOC
Tool system
3-7
Lower tool
Die width W [mm]
EV/S-W4/30°
4
EV/S-W5/30°
5
EV001
6
EV002
8
EV003
10
EV004
12
EV005
16
EV006
20
EV007
24
Tab. 3-2
80° lower tool
Lower tools with an opening angle of 80° are used for thick sheets,
allowing angles ≥90° to be bent. When bending thick material, the
springback can be so great that coining would result if a 84° lower
tool were used for producing 90° angles.
This can cause two problems:
• The required Y axis position is not attained after an angle
correction is made while air bending.
• The ACB® angle sensor cannot be used.
80° lower tools are available in die widths W = 24 mm to 100 mm.
Lower tool
Die width W [mm]
EV W24/80°
24
EV W30/80°
30
EV W40/80°
40
EV W50/80°
50
EV W60/80°
60
EV W70/80°
70
EV W80/80°
80
EV W90/80°
90
EV W100/80°
100
Tab. 3-3
3-8
Tools from TRUMPF
T488EN03.DOC
84° lower tool
Lower tools with an opening angle of 84° are used to bend
workpieces containing holes or cutouts near the bending line,
(distance ≤ shortest flange length). The holes/cutouts are not
deformed in the process (see Chapter 2).
Only ≥90° angles can be bent with 84° lower tools.
The 84° lower tool is suitable for use with the ACB® sensor in all
conventional materials (mild steel, stainless steel, aluminum).
84° lower tools are available in die widths W = 4 mm to 20 mm.
The lower tools with die widths W = 4 mm and 5 mm are thin sheet
tools for sheet thicknesses s ≤1 mm, see page 3-11.
Lower tool
Die width W [mm]
EV/S-W4/84°
4
EV/S-W5/84°
5
EV W8/84°
8
EV W10/84°
10
EV W12/84°
12
EV W16/84°
16
EV W20/84°
20
Tab. 3-4
86° lower tool
Lower tools with an opening angle of 86° are the predecessors of
the 84° lower tools.
However, as the springback is so great when bending stainless
steel and various aluminum alloys, coining is performed with an
86° lower tool to produce a 90° angle. The ACB® angle sensor
cannot be utilized in such cases.
86° lower tools are available in die widths of W = 6 mm to 50 mm.
Note:
A coining effect is achieved when 80°, 84° and 86° lower tools are
used for bending 90° angles.
T488EN03.DOC
Tool system
3-9
Lower tool
Die width W [mm]
EV020
6
EV021
8
EV022
10
EV023
12
EV024
16
EV025
20
EV026
24
EV027
30
EV028
40
EV029
50
Tab. 3-5
Note
86° lower tools should now be purchased only in order to
supplement an existing set of tools. When purchasing new tools,
preference should instead be given to 84° lower tools.
90° lower tool
Lower tools with an opening angle of 90° are used for coining.
90° lower tools are available in die widths W = 4 mm to 16 mm.
The lower tools with die widths W = 4 mm and 5 mm are thin sheet
tools for sheet thickness s ≤1 mm, see page 3-11.
Lower tool
Die width W [mm]
EV/S-W4/90°
4
EV/S-W5/90°
5
EV040
6
EV041
8
EV042
10
EV043
12
EV044
16
Tab. 3-6
3-10
Tools from TRUMPF
T488EN03.DOC
2.4
Tools for thin sheets
Tools for thin sheets offer the highest precision in conjunction with
narrow die widths in sheet thickness ≤1 mm.
Advantages
•
•
The small upper tool radii and small die widths make the
smallest bending radii possible.
Thanks to the slim tool geometry, short flange lengths can also
be achieved.
Bending with thin sheet tools
T488EN03.DOC
Fig. 31178
Tool system
3-11
Upper tool
There are 3 upper tools for thin sheets, 2 of which are upper tool
inserts for tool holders OW/K 80 and OW/K 130:
• OW280/K (complete tool).
• OW390 (upper tool insert).
• OW391 (upper tool insert).
All thin sheet tools are head-bearing, regardless of the working
height.
Upper tool
Working height [mm]
OW280/K
140
OW390
170 (with OW/K 80)
220 (with OW/K130)
OW391
170 (with OW/K 80)
220 (with OW/K130)
Tab. 3-7
Lower tool
For thin materials, lower tools are offered with die widths of W =
4 mm and 5 mm and opening angles of 30°, 84° and 90°.
These lower tools come only in a narrow version (see Page 3-6) in
order to produce narrow Z bends.
3-12
Tools from TRUMPF
T488EN03.DOC
2.5
System segmentation of tools
Tools are available in different segmentations and lengths.
With the system segmentations A and B offered, any bending
length, from 25 mm all the way to the bending length of the
machine, can be produced in 5 mm increments.
In addition to this, upper tools are also available in left gooseneck
and right gooseneck versions. Gooseneck tools are 100 mm long.
Tool sets:
Length [mm],
variant
Segment, standard dimension:
Length [mm]
25
30
35
40
45
50
100
H100L 1 H100R 200 2
3002
5002
Basic division
250
2
1
1
1
1
1
1
-
-
-
-
-
1250, A
2
1
1
1
1
1
8
1
1
-
-
-
1250, B
2
1
1
1
1
1
1
1
1
2
1
-
2050, A
2
1
1
1
1
1
16
1
1
-
-
-
2050, B
2
1
1
1
1
1
1
1
1
1
1
2
2550, A
2
1
1
1
1
1
21
1
1
-
-
-
2550, B
2
1
1
1
1
1
1
1
1
1
1
3
3050, A
2
1
1
1
1
1
26
1
1
-
-
-
3050, B
2
1
1
1
1
1
1
1
1
1
1
4
4050, A
2
1
1
1
1
1
36
1
1
-
-
-
4050, B
2
1
1
1
1
1
1
1
1
1
1
6
Tab. 3-8
1
2
T488EN03.DOC
Gooseneck tools (H100L, H100R) are available only in upper tool sets. In
lower tool sets, gooseneck tools are substituted by 2 lower tools, each
100 mm in length.
The max. weight of the segments is limited to 25 kg. If this weight is
exceeded, the respective tools are replaced by shorter (=lighter) segments.
Tool system
3-13
System segmentation
versions
All tools can be ordered either as complete tool sets or as single
tools.
The following tool set versions are possible:
• Basic segmentation 250 mm.
• Tool sets 1250 mm, 2050 mm, 2550 mm, 3050 mm or
4050 mm:
–
System segmentation version A:
Longest tool 100 mm (see Tab. 3-8, Page 3-13).
–
System segmentation B:
Longest tool max. 500 mm (see Tab. 3-8, Page 3-13).
Locking element
"Safety-Click"
3-14
Tools from TRUMPF
All upper tools up to 100 mm in length are equipped with "SafetyClick". "Safety-Click" is a safety locking mechanism integrated in
the tool to prevent it from falling out of the tool holder. The lock can
be released by pressing a button.
• The upper tool can be exchanged vertically - quickly but still
safely.
• Shorter tool set-up times as the tools no longer have to be
removed sideways out of the upper tool holder.
T488EN03.DOC
3.
Laser hardening
TRUMPF tools are laser-hardened. Thanks to the use of a
TRUMPF TruFlow high-powered laser with innovative special
hardening optics, a greater hardening depth and a wider hardened
zone are achieved as compared to earlier laser hardening
methods:
• Degree of hardness 63-64 HRC.
• Hardening depth 3-4 mm.
Hardened work zones
Safety of laser-hardened
tools
Fig. 33334
Only the surface of the tool is hardened in laser hardening; the
interior of the tool remains "soft".
The tool does not splinter under excessive load; instead, either the
tool splits or the hard layer is pressed into the soft core.
T488EN03.DOC
Tool system
3-15
4.
Imprint-free bending
During bending, imprints and abrasion result on the workpiece at
the support points of the lower tool.
In order to avoid marks and abrasion on high-quality or painted
sheets and on visible parts, one can choose among the following
standardized technologies:
• Use a KEV die.
• Use bending foil.
• Use lower tools with radius R = 3 mm (e.g. with foil-coated
sheets).
KEV die
Bending foil
Fig. 33340; 33338
KEV die
In the case of KEV dies, a plastic strip is inserted in the area of the
radius so that the workpiece lies on the plastic strip and not on
metal. This prevents marks on the workpiece due to friction
between metal (die) and metal (workpiece).
Die
Die width W [mm]
KEV W8/30°
8
KEV W10/30°
10
KEV W12/30°
12
KEV W16/30°
16
KEV W20/30°
20
KEV W24/30°
24
Tab. 3-9
Note
As a general rule, the service life of the plastic strips is
considerably greater if calculations are made with the formula W =
≥8*s when selecting the die width.
3-16
Imprint-free bending
T488EN03.DOC
Bending foil
The bending foil is made of plastic, 0.4 mm thick and 100 mm
wide. It is laid loosely over the lower tool and for that reason is able
to prevent marks on the workpiece which could arise from the
rubbing of metal against metal.
Bending with bending foil
Fig. 33339
Note
As a rule, the bending foil lasts much longer if calculations are
made with the formula W = ≥8*s when selecting the die width.
Lower tool with
Radius R = 3 mm
Lower tools with standard radii are of limited suitability for bending
film-coated sheets without bending marks being visible on the
workpiece surface after the foil has been removed. The danger
when using lower tools with standard radii is that the foil may be
cut through, leaving imprints on the workpiece.
A lower tool with a radius of R = 3 mm can be used in such cases.
Thanks to the large radius, the foil on the workpiece will not be
destroyed.
Note
The shortest flange length that can be bent increases if a lower tool
with a larger radius is used (see Chapter 2).
T488EN03.DOC
Tool system
3-17
5.
Special tools
Customized special tools can be designed in collaboration with
TRUMPF at any time. A wide array of special tool solutions are
listed and illustrated in the "TruBend - Working examples for
bending tools" technical information brochure.
3-18
Special tools
T488EN03.DOC
Index
2
A
2-axis backgauge ...................................... 1-26
Air bending................................................... 2-3
•
Press tonnage ..................................... 2-14
3
30°lower tool................................................ 3-7
4
4-axis backgauge ...................................... 1-26
5
5-axis backgauge ...................................... 1-27
6
6-axis backgauge ...................................... 1-28
8
80°lower tool................................................ 3-8
84°lower tool................................................ 3-9
86°lower tool................................................ 3-9
B
Backgauge ................................................. 1-26
•
2-axis backgauge ................................ 1-26
•
4-axis backgauge ................................ 1-26
•
5-axis backgauge ................................ 1-27
•
6-axis backgauge ................................ 1-28
BendGuard................................................. 1-36
•
Mode.................................................... 1-38
•
Safety concept..................................... 1-36
Bending
•
imprint-free .......................................... 3-16
Bending aid ................................................ 1-19
•
Options ................................................ 1-20
Bending flange shapes .............................. 2-35
Bending foil ................................................ 3-17
Bending method
•
0............................................................. 2-3
•
1............................................................. 2-5
•
11........................................................... 2-8
•
3............................................................. 2-9
•
4........................................................... 2-13
•
Air bending ............................................ 2-3
•
Coining .................................................. 2-5
•
Flattening with coining........................... 2-8
•
Learned bend ...................................... 2-13
•
Sensor bending ..................................... 2-9
Bending slide rule .......... 2-15, 2-19, 2-21, 2-24
Box height .................................................. 2-17
•
maximum ............................................. 2-17
C
9
90° lower tool............................................. 3-10
T488EN04.DOC
Coining......................................................... 2-5
•
Press tonnage ....................................... 2-5
Crowning.................................................... 1-12
Index
0-1
D
L
Die ............................................................... 3-2
Die width ...................................... 2-23, 3-2, 3-6
•
Selection ............................................. 2-21
Downstroking drive .................................... 1-10
Laser hardening ......................................... 3-15
•
Degree of hardness............................. 3-15
•
Hardening depth.................................. 3-15
Learned bend............................................. 2-13
Load-bearing capacity.................................. 3-5
Lower tool .............................................3-2, 3-6
•
Coining ................................................ 3-10
•
Designation............................................ 3-6
•
Die width................................................ 3-6
•
Opening angle ....................................... 3-7
•
Radius ................................................... 3-2
•
Radius 3 .............................................. 3-17
•
Thick sheet ............................................ 3-8
•
Thin sheet............................................ 3-12
Lower tool adjustment................................ 1-14
F
Flange length.................................... 2-23, 3-17
Flat length .................................................. 2-26
•
Calculation by the control.................... 2-33
•
Large bend radii .................................. 2-27
•
Small bend radii .................................. 2-29
Flattening
•
Flattening front .................................... 1-16
•
Flattening rear ..................................... 1-17
Flattening with coining ................................. 2-8
M
Gooseneck tools........................................ 3-13
Machine
•
Speeds ...........................................1-4, 1-5
Machine bed .............................................. 1-12
Machine dimensions .............................1-4, 1-5
Machine frame ............................................. 1-8
H
O
Height
•
Upper tool.............................................. 3-4
Operating station........................................ 1-24
G
I
I axis .......................................................... 1-14
Identification ................................................ 2-9
Imprint-free bending .................................. 3-16
Inside radius .............................................. 2-19
P
Press tonnage............................................ 2-14
Press tonnage table ....... 2-16, 2-20, 2-22, 2-25
Punch ........................................................... 3-2
R
K
KEV die...................................................... 3-16
0-2
R axis ......................................................... 1-29
Ram............................................................ 1-10
Regulation.................................................... 2-9
T488EN04.DOC
S
U
Safety concept........................................... 1-36
Safety element "Safety-Click".................... 3-14
Sensor bending ........................................... 2-9
Sensor tool................................................... 2-9
Special tools .............................................. 3-18
Speeds.................................................. 1-4, 1-5
•
Press speed ................................... 1-4, 1-5
•
Rapid speed ................................... 1-4, 1-5
•
Rapid up speed .............................. 1-4, 1-5
Support brackets ....................................... 1-21
Upper tool .............................................3-2, 3-4
•
Height .................................................... 3-4
•
Load-bearing capacity ........................... 3-5
•
Radius ................................................... 3-2
•
Thin sheet............................................ 3-12
Upper tool height........................................ 2-17
W
T
Technical data
•
Bending aid ......................................... 1-19
Thin sheet tool
•
Lower tool............................................ 3-12
•
Upper tool............................................ 3-12
Tool.............................................................. 3-2
•
Length ................................................. 3-13
•
Locking element .................................. 3-14
•
Lower tool....................................... 3-2, 3-6
•
System segmentation ......................... 3-13
•
Tools for thin sheets............................ 3-11
•
Upper .................................................... 3-4
•
Upper tool.............................................. 3-2
Tool holder................................................. 1-13
Tool lengths ............................................... 3-13
Tool:........................................................... 3-13
Tools for thin sheets .................................. 3-11
T488EN04.DOC
Working height ......................................1-4, 1-5
Workpiece .................................................... 3-2
•
Minimum distance ............................... 2-34
•
Minimum length ................................... 2-34
Workpiece radius ......................................... 3-2
X
X axis ......................................................... 1-29
Z
Z axis.......................................................... 1-30
0-3