Steel bending is a critical process in the production of semi-finished products and assemblies, allowing flat steel sheets to be shaped—even into complex forms—without altering their mechanical properties.
In this article, we’ll explore the details of steel bending, including its characteristics, advantages, various bending techniques, and the specialized machinery used to achieve products tailored to specific requirements.
What is steel bending? Features and benefits of the process
Steel bending is a metalworking process that enables the creation of precise and uniform curves or angles on the material without compromising its strength and durability. The area subjected to bending is also known as the neutral axis of the metal, which refers to the section where the steel is not negatively affected by external forces and can undergo permanent deformation, minimizing the risk of material fractures.
Bending can be performed on various types of steel – such as stainless steel, carbon steel, and low- or high-alloy steel—to meet the needs of different industries, including the food and medical sectors. Each piece can be customized according to the specific requirements of the project and the client, with a tailored bend designed to achieve precise angles and shapes capable of adapting to diverse applications.
The advantages of steel bending
Steel bending is used to give a precise shape to a workpiece, allowing for the following benefits:
- Preservation of mechanical properties: Ensures the material retains its strength and durability over time.
- Versatility: Offers a wide range of shapes and angles to meet the needs of various industries and markets.
- Reduction in joints and welds: Enhances the product’s aesthetic appeal and reduces the risk of defects that may arise from welding.
Applications and types of steel bending
Steel bending is a widely used manufacturing process, applied in the production of semi-finished and complex assemblies for companies operating in various industries, including food service, packaging, and medical sectors.
There are several types of steel bending processes, including:
- Air Bending: In this method, the material is placed on the supports of the machinery and deformed using a punch. It is highly versatile, allowing for variable angles without changing the die, and is suitable for working with even very thick panels.
- Coining: This process compresses the steel entirely into the die to achieve the desired bend. It is commonly used for producing specific, consistent angles with tight tolerances.
- Flattening: A two-step procedure involving an initial pre-bend at 26°/35° (achieved through air bending) followed by flattening. In the final phase, the sheet metal is fully or partially pressed flat.
Precision: a critical factor in steel bending
Steel bending requires the use of advanced machinery, such as presses and benders, which enable accurate programming of the desired curvature or angle.
At Metal’s, we use AMADA bending machines, which are innovative and highly precise, allowing us to develop offline programming for bending operations. Unlike traditional devices, where operators perform bending procedures manually, these advanced tools enable us to pre-design the execution of angles or bends. This allows us to verify the feasibility of the process beforehand, ensuring the workpiece doesn’t break during production. Using specialized software, we can predict potential collision points, identifying and addressing issues in advance. Additionally, the system autonomously adjusts power and descent based on angle control, creating perfect angles and accelerating the production process. The precision of this equipment is measured in millimeters, ensuring the finished product matches the client-approved design.
Thanks to these cutting-edge tools in our machinery lineup, the manufacturing process becomes automated and faster. Scrap is minimized, and specialized personnel for piece positioning and monitoring are no longer needed—only trained staff from Metal’s Academy are required to maximize the potential of these new technologies.
Finally, automation ensures consistent production, supported by regular maintenance of systems and equipment (scheduled weekly or monthly). As the bending machines are network-connected and linked to external support services, we can prevent and quickly resolve any anomalies, avoiding delays in production. These features significantly enhance efficiency, reduce costs, and streamline production timelines.
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