Rotary Benders - Examples and Options

1. using internal stripper plate

• Reduction/ Elimination of tool markings in case of using an internal stripper plate

Channel Bends

• Channel bend is done with two benders side by side in one operation
• min. channel width PC = 2x Dimension B (see table)

3. interlaced Benders

• for channel bends, where minimum dimension PC of Standard / Compact Units is not narrow enough
• Custom interlacing to required channel dimension PC
• use of stripper is recommended to prevent part from bulging

4. Z-Bends

• Z-Bend= 2 bendings are realized by one bender in one operation (including over bend)
• Pressure pad is used optionally to make up the difference between part height and dimension l of the rocker
• Over bend is possible, rocker shape is designed according to customer requirements
• Bending lobe for second bend is used as anvil, the radius of the bending lobe is designed based on the required part radius

5. Double Z- Bends or Hat-Bends

• two benders including internal pressure pad are used
• for adjustment benders can be moved horizontally against each other
• Pressure pad is used to make up the difference between part height and dimension l of the rocker

• Over bend is possible, rocker shape is designed according to customer requirements
• Bending lobe for second bend is used as anvil, the radius of the bending lobe is designed based on the required part radius

6. overbends up to 120°

• over square bends up to 120° are possible, the rocker angle and shape is designed accordingly
• the use of a pressure pad is suggested for over square bends over 110° to keep the rocker from sticking to the part

7. Under square (bending angle less than 90°)

• for bending under square the rocker angle and shape is designed accordingly
• bending angle of minimum 60° (equals 120° rocker angle) possible, smaller bending angles on request
•  generally it is recommended to use a pressure pad, but mandatory for bending angles smaller than 70°, in order to prevent part from sticking to the rocker when tool is opening

8. short leg bends

• short leg bends require a recessed step in the bending lobe of the rocker
• as compared to a standard rocker-shape the required tonnage will increase (reduced lever dimension G)

9. large bend radius

• a bend radius exceeding 2 times part thickness
• choose larger size rocker than standard choice (table) to accomplish part clamping at large radius bends
• Please consider :
  • The larger the bend radius the larger is the material spring back!

example: PT= 3,2mm R=8mm

• per Standard catalogue choice MB40-Bender is possible,  but use MB50-Bender

10. Dart Stiffener

• dart stiffeners in the part are possible with ACCU-BendTM Rotary benders
• size of the dart can be designed into the rocker based on customer requirement
• dart stiffener included in rocker geometry
• Please consider: less spring back

11. Delrin- inserts

• Delrin- ® is a hard, low-friction polymer used as contact material for those applications where slight tool marks are not acceptable
• for rocker diameter 25mm- 115mm Delrin ®- inserts in tool steel rocker
• use pressure pad to prevent tool marks on stripper side
• use only for low production volumes < 100K parts

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