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Principles of Rotary Bending Technology
&Use of Rotary Bending
Technology for Processing of Advanced, High-Strength Steels
(AHSS)L. Ray Osborne
[email protected] Engineer / Business Development Manager
2Rotary Benders are rotating rocker-lever devices that work on
the principle of mechanical advantage, and are used to
simplify tooling, improve part quality and reduce tooling costs.
Rotary Bending provides tool designers, tool builders and metal
formers a consistent means for holding angular part tolerances
What is Rotary Bending?
3Progressive Progressive Stamping DiesStamping DiesValue Value Proposition:Proposition:
Reduced Part MarkingReduced Part Marking
Precise Control of Final Bend AnglesPrecise Control of Final Bend Angles
Press Press Brake Tooling Brake Tooling Value Value PropositionProposition::
Ergonomics and SafetyErgonomics and Safety
Reduced Part MarkingReduced Part Marking
Where is Rotary Bending Used?
4Step 3
Rocker bends Rocker bends material material beyond beyond final part angle to compensate final part angle to compensate for for materialmaterial--memory memory springbackspringback
Step 1
Downward Downward force force clamps clamps the part.the part.
Step 4
Rocker releases Rocker releases material to allow material to allow springback to springback to desired desired final part final part angleangle
Step 2
Induced Induced rotation of the rotation of the Rocker Rocker bends bends material around material around the anvil while the anvil while requiring less requiring less force force
How Does Rotary Bending Work?
5Part Hold-Down
Hold-Down Stripper
Surface of part is Surface of part is scraped, scraped, leaving long leaving long
marksmarks
Coining Part
Wipe Punch
Rotary Bending Replaces Wipe-Action Tooling
Wiping Action Bottoming Action
6Press brake VPress brake V--dies require dies require higher tonnageshigher tonnages
Brake PunchBrake Punch
Work Work PiecePiece
Brake DieBrake Die
Back StopBack Stop
Minimal shine marks Minimal shine marks with standard polished with standard polished Rocker Rocker and no marks and no marks with Delrinwith Delrin InsertInsert
Pronounced tool marks Pronounced tool marks from press brake from press brake VV--diedie
Rotary Bending replaces V-type Brake Tooling
79090 BendBend Over SquareOver Square
Channel BendChannel Bend Zee BendZee Bend
Most Common Bend Types (cross sections)
8Short LegShort Leg Hat BendHat Bend Return BendReturn Bend
Under SquareUnder SquareLarge RadiusLarge Radius Open ZeeOpen Zee
Other Bend Types
9Capability of Common Rocker Diameters 20mm: 25 19 gauge material (mild CRS) 25mm: 19 14 gauge material (mild CRS) 35mm: 14 11 gauge material (mild CRS) 50mm: 11 8 gauge material (mild CRS) 65mm and 80mm are available for thicker and/or
high-strength materials
Common Rotary Bender Sizes
10
ROCKER = Induction-Hardened S7 Shock-Resistant Tool Steel
SADDLE = Hardened AISI 4140 Steel
LINER = Self-Lubricating C95400 Aluminum Bronze
Common Construction Materials
11
Common Construction Materials
12
Dart StiffenersDart Stiffeners can be produced can be produced in the bent part with the simple in the bent part with the simple addition of hardened addition of hardened dowels dowels spaced as spaced as needed across the needed across the throat of the Rockerthroat of the Rocker. .
Dart StiffenersDart Stiffeners create an integral create an integral gusset in the gusset in the part and give it part and give it rigidity.rigidity.
Rotary Bender Options
13
DelrinDelrin is a special is a special polymer which polymer which can be inserted in the hardened can be inserted in the hardened steel steel Rocker Rocker to bend to bend prepre--painted painted materials, soft materials or stainless materials, soft materials or stainless steel without leaving tool steel without leaving tool marks.marks.
DelrinDelrin provides longprovides long--lasting lasting durability with little to no abrasive durability with little to no abrasive effect effect during part contact.during part contact.
DelrinDelrin is mounted is mounted to the Rocker to the Rocker using using screws screws and and can can be easily be easily replacedreplaced..
Rotary Bender Options
14
Appliance 40%
SpecialtyEquipment 20%
HVAC 10%
Transportation 5%
Furniture 10%
Aerospace 5%
ElectricalEnclosures 10%
Market Segments for Rotary Bending
15
Application Engineering
Technical Data Required: Material Properties Material Thickness Part Length Bent Leg (Part Height) Bend Radius Part Angle (and Tolerance) Areas Where Marks Are Unacceptable Part Channel Dimensions, if Applicable
16
For Application Verification:
Determine Extent of Part Marking (if any) Determine Amount of Material Springback Guarantee Final Bend Angle and Desired Part
Geometry
Test Bending Services
17
AHSS Springback Study
18
Vertical clearance
The effective strain field of rotary bending is shown here at the overbending stage.
Springback from FEM simulations using elastic modulus E=150 and 210 Gpa is compared with springback from experiments at Anchor Danly in bending DP1000 at different vertical clearances.
AHSS Springback Study
19
Special Applications
Material = DP1000Ultimate Tensile Strength (min.) = 1,000 MPa
(145,000 psi)
20
Special Applications
21
Special Applications
Interlaced, Two-Stage Bending Concept
22
Special Applications
Rotary-Bender on Pressure Pad + Conventional Aerial Cam
23
Special Applications
Rotary-Bender on Pressure Pad + Conventional Aerial Cam
24
Special Applications
Rotary-Bender on Pressure Pad + Roller-Actuated Cam
www.anchordanly.com