In the mass production of products from galvanized sheet, automatic machines with high productivity, roll-rolling units, edge benders, devices for rolling seams of downpipes are used. For the manufacture of metal products and galvanized sheet in small portions, intended, for example, for private construction or a small industrial workshop, it is cost-effective to use a manual bender.
What is a plate bending machine?
The new equipment is designed to facilitate manual production in the manufacture of metal gutter elements, galvanized aprons, gutters, and other small roofing elements. The sheet bender is a metal rolling machine used for bending brass, steel, aluminum, corrugated board, and other flat sheets. A manual roller bender is able to bend the metal at the required angle, while not violating the plane of the material.
For work in the courtyard of a private house, you should not purchase an expensive bending unit, it is much more profitable to make manual bending machines with your own hands. Reviews say that a home-made device works with metal up to 2 mm thick, the length of the passingthe workpiece is 4 m, the profile can be bent at an angle of up to 180º. Structural details include crimping device with lever, base and clamping mechanism.
Where are industrial bending machines used?
Machines are used for the manufacture of bent parts in the national economy:
- flat metal structures of complex configuration are used in construction as wired elements of water and sewer communications, roofing, drainage, window openings;
- in furniture production for the manufacture of boxes, boxes, cones;
- in the engineering industry, sheets are bent for spare parts, car bodies, trailers;
- for the production of electronic equipment;
- in the construction of ships, aircraft and rockets.
Varieties of bending machines for flat metal
The bending machine has the same principle of working torque, the difference is in the drive with which the force is carried out:
- pneumatic;
- hydraulic;
- mechanical;
- electromechanical;
- manual bender.
Feed sheets into the workspace in manual or automatic mode, the size setting also differs in these two parameters.
Mechanical bending machine
The operation of the equipment is carried out from the flywheel, which provides energy to turn the lever. When you press it, the part is bent at a given angle, an increase in the lever arm leads to a change in the required force.
Electro-mechanical sheet bending equipment
It is an improved version of the mechanical version. Power is supplied to the lever by an electric motor. These machines are most common among professionals due to their convenient use and versatile operation. All bending processes take place automatically, the operator only presses the button, having previously set the parameters.
Many machines can withstand forces of hundreds of kilograms, there are powerful machines that work with loads up to a ton. Electromechanical units are small, operate with low noise, bend a large number of parts in a short time, approximately several hundred elements per minute.
Design of manual bending machine
Manual roller bender contains many elements in its design that ensure its operation. Tin sheet, corrugated board or metal is fixed in working position using a pressure beam. Giving the desired shape of the part is made by a special beam. The bending angle is set by the worker and differs in different models of machines.
Goniometer is made in the form of a disk with markings, allowing you to set the desired amount of curvature. The placement and movement of the material takes place on the rear table with the feed limiter installed. The clamping beam is brought into working position by means of a handle. The shape of a high-quality bend is set by the tensioning device of the main and bending beams. As an option, brakes are installed on a swivel block with wheels, LGS moves on it. The manual bender is fixed in the working position before starting work.
Segment machine
In manual machines, metal bending occurs due to the physical strength of the worker by pressing on the rotary beam. Some models are made with a pedal. With the help of a manual machine, it is possible to process a sheet that is not too thick and at small angles. A device of this type is often found in a private courtyard for the manufacture of bent parts intended for household needs. The fact that the manual sheet bender does not contain rubbing and sliding elements makes the machine strong and durable. Craftsmen use the machine with brackets on the support beams and a selected corner radius to create intricate parts.
Segment manual bender
It carries out contour bending of piece products from sheet steel, this procedure becomes possible due to the use of a set of standard segments. For efficient operation, a clamping mechanism is placed in it. It has a place to install segments and a rotary bender. With the help of a manual lever, the beam is rotated by a given angle size, if the power of the machine is large, then a foot drive is provided to transfer force.
The production of manual sheet benders provides for the fastening of all structural units on the frame according to the type of frame assembled from rolled metal. To ensure that the movement is rectilinear and does not move to the side, guide devices are attached. Used as fastenersmechanical or magnetic devices. The uniform movement of the workpiece and mechanical parts is due to the springs to compensate for vibration.
Material of segment bender
The best alloyed tool steel grade KhVG or 9XC is considered, from which a high-quality machine is made. The manual sheet bender has a set of working segments for planting and bending the product. The seat is designed for fastening, and the working part is made taking into account the most common bending options. In manual machines, the height of the segment tool remains unchanged and is made the same for all types of equipment.
Specifications
The operating parameters for approximately all types of manual bending machines are the same and look like this:
- bending thin sheets of metal up to one and a half meters long;
- bend non-ferrous metals and alloys up to 3 mm thick, up to 4 m long;
- the angle that can be expected when bending varies from 140º to 180º for different models;
- manual roller bender enables accurate bending of the installed semi-finished product with already existing folded edges and edges.
Making a bending machine for sheet steels with your own hands
For processing by bending metal sheets in a private household, it is quite enough to make manual sheet benders with your own hands. Drawings before cutting rolled metal and assembling the frameshould be made mandatory. Sketches with applied dimensions will allow you to design the machine in such a way that the most enduring parts of the machine will serve as the main load.
The purpose of homemade bending machines
The choice of the scheme of bending equipment depends on its purpose:
In the first case, the sheets are bent at 90º. Almost all homemade machines provide for pressing the traverse more in its lower part, while moving it forward a little
- The second option is a professional sheet metal bending press. This equipment works on industrial sites, requires a lot of money and the work of a qualified specialist.
- In the third version, a broaching version of the machine is made, in which the radius is set by changing the position of the feed rolls. These elements are multifunctional and are used for the manufacture of casings, connecting sections of wide pipelines, shells. A manual sheet bender from corrugated board is performed with profiled rollers for pulling roofing materials, ridges, valleys, drain elements.
The first option is the most suitable for a standard home bender.
To determine the power and type of machine, you should study its technical description:
- the machine effectively works with metal with a thickness of galvanized sheet up to 0.6 mm, copper - up to 1 mm, aluminum bending with a thickness of up to 0.7mm;
- sheet must be no more than 1 m wide;
- bendable wall slope - not less than 120º;
- maximum number of work cycles without interruption reaches 1200;
- difficult to work with non-standard parts and blanks, they require rebuilding.
Required Materials
For the device of the bed, a channel height No. 12 is used. The lining pillow is made of a wooden beam of a certain size, depending on the design. For the manufacture of the right cheek, sheet metal of 6-9 mm is suitable. For the design of the pressure beam, a corner No. 60-80 is taken, reinforcement with a diameter of 10 mm is prepared for the axis of the punch. Drawings of a manual bender provide for a punch of the second option corner No. 80-100 or channel No. 10. The lever is made of reinforcement with a diameter of 10 mm.
For the design of the punch, it is better to use not a corner, but a channel, since the load on this element is distributed in such a way that the corner will bend in the middle part, which will lead to its premature wear. The additional shelf of the channel will take over the tensile force during operation. Equipment with a channel punch can withstand about 1200 bends, and a machine with an applied angle will go wrong after 250 cycles.
Bending equipment assembly sequence
Manual bender is assembled in the sequence provided in the description of the drawings. One after another, a clamp is assembled, consisting of a collar, a heel and a screw, based on a corner No. 60, then a cheek is designed. Next, they make a base with a bracket from corner No. 110, on which they arrangeclamping bar. All parts, together with the punch on the axis, are mounted on the bed.
The bottom pressure beam is milled after assembly by welding the entire structural unit. It is not recommended to use grinding with a grinder or filing with a file to give a smooth surface. The pressure beam should be additionally reinforced with rolled metal, and the length should be 5 cm shorter than the base.
At the ends of the clamp, stoppers are made from the scraps of the corner. Clamping parts related to the workpiece material are milled. The center of the shelf on the brackets is equipped with a hole with a diameter of 8 mm. The drawings of the manual bending machine provide that the punch is made shorter than the clamp by 100 mm. The lever is made of reinforcement and welded to the punch by welding. For the manufacture of cheeks, a steel sheet is taken and holes of 1 cm are drilled in it to install the axles. On the edge, a chamfer is removed from the ends with a depth of 0.6 cm, its length is 3.2 cm.
Safety
The machine belongs to the equipment with a high degree of danger, so compliance with the rules should come first. Before starting work, they study the instructions, determine the technological sequence for manufacturing the product and strictly follow it. Homemade machine or production, work should begin with the necessary steps:
- put on work clothes and check for hanging and protruding parts, it should not have torn buttons, non-working zippers,cuffs buttoned;
- check the condition of the working structures and their fastening on the frame, all faults are eliminated before starting the machine;
- for work provide a distance of 1 meter from the machine, the passage to the equipment must not be cluttered with foreign objects;
- the workplace should have sufficient lighting, it is forbidden to work in the twilight;
- for each machine there are permissible parameters for the thickness of the metal, it is impossible to bend workpieces over the specified dimensions and standards;
- it is strictly forbidden to leave the workplace and be absent from it when the machine is turned on.
Conclusion
In the mass production of bent products, a lot of waste remains in the production process, which the economic owners of private houses use to equip the site and the building itself. The made bending machine with your own hands will be a real help for craftsmen and their neighbors. It is not difficult to design and assemble such a machine, the main thing is that it will become a real find for home construction.
