Professional Documents
Culture Documents
Bending Technology
Technical information
Bending Technology
Edition: 05/2007
Ordering Information
T488EN00.DOC
0-5
Table of Contents
Chapter 1
2.
2.1
3.
3.1
3.2
3.3
3.4
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.
0-6
Table of Contents
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
2.7
2.8
Chapter 3
T488EN00.DOC
Tool system
1.
2.
2.1
2.2
2.3
2.4
2.5
3.
4.
5.
Table of Contents
0-7
Chapter 4
0-8
Table of Contents
Index
T488EN00.DOC
Chapter 1
Machine technology
TruBend Series 5000
1.
2.
2.1
3.
3.1
3.2
3.3
3.4
3.5
T488EN01.DOC
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.
T488EN01.DOC
1.
Machine concept
T488EN01.DOC
Machine concept
1-3
2.
Technical data
C
D
E
Machine layout
Fig. 44112
TruBend
5050
5085
5085 S
5130
Tonnage
[kN]
500
850
850
1300
[mm]
1275
2210
2720
3230
[mm]
1040
1750
2260
2690
Throat (C)
[mm]
420
420
420
420
Bed width
[mm]
100
120
120
120
[mm]
385
385 (615)
385 (615)
385 (615)
[mm]
1050
1050
1050
1050
[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)
1-4
Technical data
Tab. 1-1
T488EN01.DOC
TruBend
Tonnage
[kN]
Speeds
Y axis
Y axis (ram)
5170
5170 S
5230
5230 S
5320
1700
1700
2300
2300
3200
[mm]
3230
4250
3230
4250
4420
[mm]
2690
3680
3690
3680
3680
Throat (C)
[mm]
420
420
420
420
420
Bed width
[mm]
120
180
180
180
200
[mm]
615
615
615
615
615
[mm]
1050
1050
1050
1050
1050
[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
Y2
Y1
X2
X1
R1
R2
Z2
Z1
V
Fig. 38803
Axis
Description
TruBend 5050
I axis
Pneumatic or
CNC controlled*
Pneumatic or
CNC controlled*
R axis
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
CNC controlled
CNC controlled
Z axis
Manual or
CNC controlled*
Manual or
CNC controlled*
Workpiece support
Not available
CNC controlled
*Options
1-6
Tab. 1-3
Technical data
T488EN01.DOC
3.
Sub-assemblies
5
2
6
3
4
7
8
10
Hydraulic cylinder
Control panel
Ram
10 Operating station
Machine body
TRUMPF BendGuard
Backgauge
T488EN01.DOC
Fig. 44068
Sub-assemblies
1-7
3.1
Machine frame
Soll
Aktio
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
T488EN01.DOC
Sub-assemblies
1-9
3.2
3
1
ACB busbar
1-10
Sub-assemblies
Pump block
Fig. 43679
T488EN01.DOC
3.3
Machine bed
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
Crowning
---
Deformation
Fig. 32205, 32206
T488EN01.DOC
Sub-assemblies
1-11
Purpose of crowning
90
90
> 90
90
90
Fig. 32207
Crowning
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
Shoulder-bearing
Shoulder-bearing tool
Head-bearing tool
Tool types
Modufix clamping
T488EN01.DOC
Sub-assemblies
1-13
1
1
cannot be modified
3
3
adjustment path
I axis
1-14
Sub-assemblies
Fig. 29259
T488EN01.DOC
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
30 mm
W12
27.5 mm
W16
25 mm
W20
22.5 mm
W24 1
20 mm
Tab. 1-5
T488EN01.DOC
The spacer for die width W24 is also suited for lower tool holder EV70 (holder
for Z inserts).
Sub-assemblies
1-15
Prerequisite
The pivoting element butts against the rear fixed stop.
Appropriate spacer for lower tool has been loaded at the front.
Fig. 29860
Fig. 29861
2. Flatten.
I axis is located in the rear position.
1-16
Sub-assemblies
T488EN01.DOC
Prerequisite
The pivoting element butts against the front fixed stop.
Appropriate spacer for lower tool has been loaded at the rear.
Fig. 29858
Fig. 29859
2. Flatten.
I axis is located in the front position.
T488EN01.DOC
Sub-assemblies
1-17
1-18
Sub-assemblies
Fig. 44066
Fig. 44065
T488EN01.DOC
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
47
45
100
2.5
3.5
4.0
5.0
6.5
8.5
330
275
1000
30 - 150
6 - 100
10
Tab. 1-6
Note
The ram speed is automatically adapted for the chosen die width.
T488EN01.DOC
Sub-assemblies
1-19
Example
Die width
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
2.5
s = 2 mm
2.407
3.5
3.541
3.173
10
4.432
3.972
12
5.539
4.807
Tab. 1-7
1-20
Sub-assemblies
Fig. 29651
T488EN01.DOC
Support brackets
Support brackets
T488EN01.DOC
Fig. 38539
Sub-assemblies
1-21
3.5
1-22
Sub-assemblies
T488EN01.DOC
Control panel
1
4
5
6
7
8
9
1
STOP button
Numeric keyboard
USB ports
Cursor key
START button
Control panel
Fig. 42581
T488EN01.DOC
Sub-assemblies
1-23
Operating station
Control lamp
E-STOP release
Storage tray
Operating station
1-24
Sub-assemblies
E-STOP function
Fig. 40676
T488EN01.DOC
Additional footswitch
Connector
Indicator lamp
E-STOP release
E-STOP function
Additional footswitch
T488EN01.DOC
Fig. 42390
Sub-assemblies
1-25
4.
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
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
T488EN01.DOC
5-axis backgauge
T488EN01.DOC
Fig. 45303
Backgauge
1-27
6-axis backgauge
6-axis backgauge
Fig. 45304
2-axis backgauge
4-axis backgauge
5-axis backgauge
6-axis backgauge
1-28
Backgauge
T488EN01.DOC
4.1
X axis and R axis
X0
X+
R+
R0
R-
X axis, R axis
T488EN01.DOC
Fig. 23738
Backgauge
1-29
Z axis
1
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)
1-30
Backgauge
T488EN01.DOC
4.2
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
[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
Z1/Z2 axis
In X direction
In
Z direction
Speeds
Positioning accuracy
Distance
Fig. 44111
Finger
Finger
Tab. 1-9
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
Z1/Z2 axis
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
1-32
Backgauge
Tab. 1-10
Reference edge R0
T488EN01.DOC
4.3
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.
T488EN01.DOC
Backgauge
1-33
30
260
400
Stop positions
1-34
Backgauge
Fig. 44110
T488EN01.DOC
Fig. 45307
Fig. 45305
Fig. 45306
Detachable
micrometer stop finger
for 4-axis backgauge.
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
TRUMPF BendGuard
1-36
TRUMPF BendGuard
T488EN01.DOC
14 mm
4 mm
Principle
A
1
B
20 mm
20 mm
1A Monitoring range 1A
2B Monitoring range 2B
laser light A)
laser light B)
1B Monitoring range 1B
3A Monitoring range 3A
2A Monitoring range 2A
3B Monitoring range 3B
laser light A)
(laser light B)
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
Monitoring range 2
Monitoring range 3
T488EN01.DOC
TRUMPF BendGuard
1-37
BendGuard modes
1-38
TRUMPF BendGuard
T488EN01.DOC
Chapter 2
Technology
(Application technology)
T488EN02.DOC
1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2
2.3
2.4
2.5
2.6
2-1
2.7
2.8
2-2
T488EN02.DOC
1.
1.1
Air bending
Air bending
Fig. 34902
T488EN02.DOC
2-3
Air bending
on the TruBend
2-4
T488EN02.DOC
1.2
Coining
Coining
Fig. 34903
T488EN02.DOC
Coining is used:
If the required inside radius of the workpiece is less than
the sheet thickness
2-5
Material.
Sheet thickness.
Inside radius.
Bending angle.
Angle accuracy.
2-6
T488EN02.DOC
1.3
Hemming
Hemming
Fig. 34901
T488EN02.DOC
2-7
1.4
Flattening
Flattening
Fig. 34900
2-8
Teardrop
Fig. 51627
Fig. 35067
T488EN02.DOC
1.5
Sensor bending
Grain
Tensile strength
T488EN02.DOC
2-9
Sensor module
Sensor tool
Fig. 36824
Sensor tool
2-10
Fig. 14869
T488EN02.DOC
Two-dimensional angle
sensing
T488EN02.DOC
Fig. 14755
2-11
Technical data
All common
standard upper tools.
(Special radii on request)
25
Measurement range []
(dependent on type of sensor, material
and sensor disks)
42 - 135
Angle accuracy []
0.3
Tab. 2-1
1
3
5
0,3
2
4
0
A
Pre-bending
C
D
springback angle)
Time
2-12
Fig. 32785
T488EN02.DOC
Function
For each bend
the springback is calculated
the nominal angle regulated
tilting is checked.
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
T488EN02.DOC
2-13
2.
Calculations
2.1
Press tonnage
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
2-14
Calculations
T488EN02.DOC
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
10
12
16
20
24
30
40
50
60
70
80
90
100
120
4.5
7.5
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
9.6
11
13
14
16
19
0.75
52
39
31
26
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
314
251
209
168
126
3.5
428
342
285
228
171
137
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
466
349
279
233
200
175
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
Ri
Example:
Result:
2-16
Calculations
T488EN02.DOC
2.2
Box height
SHi
OWH
SH i =
OWH B
0.95
1.414
OWH =
SHi
Fig. 33329
SH i
1.414 + B
0.95
T488EN02.DOC
Calculations
2-17
120
65
140
78
220
131
240
145
Tab. 2-4
2-18
Calculations
T488EN02.DOC
2.3
Inside radius
T488EN02.DOC
Fig. 34663
Calculations
2-19
10
12
16
20
24
30
40
50
60
70
80
90
100
120
4.5
7.5
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
9.6
11
13
14
16
19
0.75
52
39
31
26
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
314
251
209
168
126
3.5
428
342
285
228
171
137
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
466
349
279
233
200
175
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
Ri
Example:
Result:
2-20
Calculations
T488EN02.DOC
2.4
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]
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:
T488EN02.DOC
Fig. 34663
Calculations
2-21
10
12
16
20
24
30
40
50
60
70
80
90
100
120
4.5
7.5
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
9.6
11
13
14
16
19
0.75
52
39
31
26
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
314
251
209
168
126
3.5
428
342
285
228
171
137
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
466
349
279
233
200
175
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
Ri
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
Fig. 3856
b=
2
W
2
T488EN02.DOC
Calculations
2-23
2-24
Calculations
Fig. 34663
T488EN02.DOC
10
12
16
20
24
30
40
50
60
70
80
90
100
120
4.5
7.5
12
15
18
22.5
30
37.5
45
52.5
60
67.5
75
90
Ri
1.3
1.6
1.9
2.6
3.2
3.8
4.8
6.4
9.6
11
13
14
16
19
0.75
52
39
31
26
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
314
251
209
168
126
3.5
428
342
285
228
171
137
447
372
298
223
179
149
4.5
566
471
377
283
226
189
162
466
349
279
233
200
175
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
Ri
Example:
Result:
T488EN02.DOC
Calculations
2-25
2.6
Flat length
Tension (stretching)
Compression
Fig. 51629
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
Sheet thickness s
Tensile strength Rm
Grain
Workpiece parameters
Bend angle
T488EN02.DOC
Example
120 (A)
40 (A)
35 (B)
110 (B)
34.75
Outside dimension
144.26
179.01
Inside dimension
S = 5 mm
Fig. 51628
T488EN02.DOC
Lx
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
d
360
s
2
360
2( R + )
L2
= 113.62 mm
L3
= 80 mm
= L 1 + L2 + L3
2(42)mm (145)
360
2-28
Calculations
T488EN02.DOC
Fig. 38663
T488EN02.DOC
Calculations
2-29
s.k
2
a
Fig. 50534
v = 2(r + s )
v
180
s
(r + k )
180
2
Bend angle []
Correction factor
2-30
Calculations
r
s
Correction factor
T488EN02.DOC
b
s
2
Fig. 50535
v = 2(r + s ) tan
180
180
s
(r + k )
2
180
2
Bend angle []
Correction factor
r
s
Correction factor
Note
The bend factor v can also be obtained from Supplement 2 of
DIN 6935.
T488EN02.DOC
Calculations
2-31
a
Fig. 50536
v=0
v
Note
The values here for v are minimal, the accuracy suffices in
practice.
2-32
Calculations
T488EN02.DOC
Icon
Function / Significance
Compensation value, can be overwritten.
Tab. 2-9
Retrieving a correction
value
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
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.
Fig. 1411
x1 = 0.75 xW
x 2 = 0.75 xW
x1, x2
Die width
2-34
Calculations
T488EN02.DOC
2.8
Incorrect design:
Correct design:
Fig. 51630
T488EN02.DOC
Calculations
2-35
Number
Description
Remedy
1.
Notches measuring
x = 1.5 x s
2.
3.
4.
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.
2.
2.1
2.2
2.3
2.4
2.5
3.
4.
5.
Tool system
3-1
1.
Terminology
3
4
Workpiece
3-2
Terminology
T488EN03.DOC
2.
2.1
Tool identification
OW
Upper tool
UW
Lower tool
EV
Single V die
KEV
Shoulder-bearing tool
Head-bearing tool
W
ZM
MF/S
ZE
FWZ
Hemming tool
MST
Torque support
ZDL
Flattening bar
FEV
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
3-4
T488EN03.DOC
Shoulder-bearing tool
Head-bearing tool
Tool types
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
Tool system
3-5
2.3
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
Wt = W + 2 tan R 1 sin
2
2
3-6
T488EN03.DOC
Wt
W
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
T488EN03.DOC
Tool system
3-7
Lower tool
EV/S-W4/30
EV/S-W5/30
EV001
EV002
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
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
T488EN03.DOC
84 lower tool
EV/S-W4/84
EV/S-W5/84
EV W8/84
EV W10/84
10
EV W12/84
12
EV W16/84
16
EV W20/84
20
Tab. 3-4
86 lower tool
T488EN03.DOC
Tool system
3-9
Lower tool
EV020
EV021
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
EV/S-W4/90
EV/S-W5/90
EV040
EV041
EV042
10
EV043
12
EV044
16
Tab. 3-6
3-10
T488EN03.DOC
2.4
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.
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
OW280/K
140
OW390
OW391
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
T488EN03.DOC
2.5
30
35
40
45
50
100
3002
5002
Basic division
250
1250, A
1250, B
2050, A
16
2050, B
2550, A
21
2550, B
3050, A
26
3050, B
4050, A
36
4050, B
6
Tab. 3-8
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
System segmentation B:
Longest tool max. 500 mm (see Tab. 3-8, Page 3-13).
Locking element
"Safety-Click"
3-14
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
Safety of laser-hardened
tools
Fig. 33334
T488EN03.DOC
Tool system
3-15
4.
Imprint-free bending
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
KEV W8/30
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
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
3-18
Special tools
T488EN03.DOC
Index
2
3
30lower tool................................................ 3-7
4
4-axis backgauge ...................................... 1-26
5
5-axis backgauge ...................................... 1-27
6
6-axis backgauge ...................................... 1-28
8
80lower tool................................................ 3-8
84lower tool................................................ 3-9
86lower tool................................................ 3-9
B
Backgauge ................................................. 1-26
Mode.................................................... 1-38
0............................................................. 2-3
1............................................................. 2-5
11........................................................... 2-8
3............................................................. 2-9
4........................................................... 2-13
C
9
90 lower tool............................................. 3-10
T488EN04.DOC
Coining......................................................... 2-5
Index
0-1
Designation............................................ 3-6
F
Flange length.................................... 2-23, 3-17
Flat length .................................................. 2-26
Machine
Height
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
T488EN04.DOC
W
T
Technical data
T488EN04.DOC
X
X axis ......................................................... 1-29
Z
Z axis.......................................................... 1-30
0-3