How to avoid wasting material when bending sheet metal.

As we have previously mentioned, sheet metal bending is a complex process, to be dealt with by the operators with professionalism and care. This will allow to reduce tolerance issues in following production phases, like welding or assembly.

Poor accuracy in the dimensions (angle, measures of flanges) during the bending operations might lead to defective material being thrown away. This, obviously, implies a waste of time and money which companies should and would rather avoid.

How to avoid waste?

There are many reasons why we might be throwing away a bent piece, let us see some of them.

The first cause is a mistake in the project: this is usually related to the development of the sheet metal to be bent, or to the position of other features on the workpiece (holes, slots, notches, etc.). Today, modern press brakes and 3D sheet metal softwares can actually contribute to reducing this risk. However, there are still some factors that might result in differences between the drawing and the final bent product. As we know, a specific ratio between the sheet metal thickness and the die opening width should be respected, but this does not always occur. This might cause differences between the calculations and the final result.

Another factor that might cause wasted material is human error. What are the most frequent errors for a press brake operator? Two of the most common errors are carrying out the wrong bending sequence and misinterpreting the drawing. Choosing the wrong tooling might also lead to problems. While we cannot find a solution to this problem, we can remind you that properly training operators is key. Effective communication among departments (technical office, press brake operators) is also important to bring benefits and improve final results.

Another reason for wasting material is related to aesthetic finishings, especially when working on delicate materials such as aluminum or stainless steel. These materials are often used to manufacture aesthetic details or furniture, so they cannot have scratches or marks on the surface. In this case, it is necessary to carefully clean all the contact areas between the sheet metal and the tooling. Choosing the right dimensions of the V-opening radius can also help reduce this problem.

Finally, we can add that having accurate and high-performing press brakes does not always ensure that the final product is free from issues. The quality of a bent workpiece largely depends on the status of the company's tool range, as the tools are the parts that actually form sheet metal.

How can Eurostamp Tooling help you solve - partially or totally - the problem of wasted material?

Since 1970 we have been manufacturing and selling press brake tooling. We have always been in touch with our customers to give advice and offer solutions, in order to provide the highest level of quality, precision and productivity. In addition to this, warehouse availability and fast delivery are our strengths.

Contact us.