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Feldmann Machines And Flexible Systems For Sheet Metal Fabricating


Bend Methods
 

 

FOLD ACTION FOR SHARP RADIUS provides the sharpest bends with no material marking and scuffing. The tooling pivots as shown in the illustration. Variations of this action are the beam-on-beam and beam-on-beam with wipe action.

 

FOLD ACTION FOR LARGE RADIUS BENDS use the same pivot point as the straight fold action, but is combined with a radius die to provide a rounded bend. It is recommended for flat stock only. In any fold action forming, if the part being formed has an edge flange, it must be notched at the bend line.

 

TANGENT BEND—RACK AND PINION RADIUS TOOLING uses a sliding plate to interface with the material being formed to prevent scuffing and marring during forming. Bending at the tangent point makes a uniform bend and is ideal for parts with preformed flanges that must be stretch formed or compressed.

 

FOLD AND WIPE Z-BEND TOOLING makes a 90 degree bend then a reverse bend. This tooling combines fold action with conventional press wipe tooling.

 

FOLD AND WIPE C-BEND TOOLING makes a 90 degree bend then a second bend wiping the material across the top die. This tooling combines fold action with conventional press wipe tooling.

 

BEAM ON BEAM FOLD ACTION TOOLING completes two action bends in the same cycle by using an elbow hinging action on the bend beam and a corresponding die, usually specified for precoated material.

 

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Dual Head Forming Machines

The concept of clamp-then-form bending of sheet metal is not new. Developed in the early 1900's, the method has been specified in machine tools for a variety of bending requirements.

FELDMANN has evolved the clamp-then-form method to satisfy the most stringent sheet metal bending and forming requirements in their Dual Head forming machines.

A sheet metal blank is inserted in the machine and positioned against the gauging system, manually or automatically.

When the machine is cycled, one or more pneumatic heads lowers to clamp the sheet metal blank in position against the bottom die. A beam with tooling then pivots upward forming the sheet metal around the open die.

Since the operator's hands do not touch or hold the material at any time throughout the bending cycle, the result is consistent and accurate parts throughout the production run.

The clamp-and-form method of bending and forming sheet metal is implemented in a variety of machines designed and built by FELDMANN. Dual Head, Sequence Bender or Line Bender machines are usually specified, although a Fixture or Special Machine may be designed to fit the application.

The Dual Head is unsurpassed in fabrication of individual wrappers, box sections, and U-shaped parts. The Dual Head is especially suited for forming a family of parts with minimum changeover time.

The standard Dual Head machine is designed with two heads. One head may be fixed with the second head adjustable to vary the width of bends, both heads may be fixed for stationary widths, or both heads adjustable, depending on the application. This adjustment can be manual, semi-automatic, or even servo mechanism controlled.

DUAL HEAD — FLEXIBILITY AND VERSATILITY
The Dual Head machine with clamp-then-form method of bending is the basis for highly flexible and versatile machines for all volumes, depending on application.

CHANGEOVER—tool change from one part size to another may be done manually or semi-automatically. Typical manual changeover including tooling and gauge change is 10-15 minutes. With the adjustable head, a width change can be made in less than a minute.

MATERIAL HANDLING—sheet stock may be inserted or removed from the machine manually, semi-automatically with assist, or with automatic material handling devices.

TOOLING—most machines are tooled with sectional type tooling to accommodate various bend sizes and can have capability for different thickness and bend configurations.

CONTROLS—controls range from manual operation to servo motors operated by computer.

VARIATIONS—Dual Head machines are used as stand alone machines, incorporated in Work Cells, or are included as part of an automated System.

ALL MACHINES—use the proven clamp-then-form bending method for accurate and consistent fabrication. Cantilever designs make deep U-bends, complete wrap arounds, form ends of pans, or form all four sides of pans.

DUAL HEAD PARAMETERS
 
PARTS PER HOUR UP TO
500
(ONE OPERATOR)
BEND LENGTH 12" TO 48"
BETWEEN BEND ADJUSTMENT 10" TO 60" *
MATERIAL THICKNESS RANGE 26 GA. T0 16 GA. * *
INSIDE BEND RADII ONE TIMES MATERIAL
THICKNESS, AND LARGER...
DEPENDS UPON THICKNESS
AND MATERIAL TYPE.
 
 *   The distance between bends is virtually unlimited,
     based on practicality.
 
 * * Machines do not normally cover this wide range
     —the machines are built to a grouping of gauges.


FORMING
SEQUENCE FORMING
(pictured right, large picture)
The Sequence Former usually has four heads on a single base. Additional heads may be included depending on the application.
The major advantage of the Sequence Former is that the part is positioned once in the machine to complete all bending. In its normal bend sequence, the outer two forming heads operate first, followed by the inner two forming heads.
Sequence Formers perform multiple bends in an automatic or semiautomatic mode to completely form a part in a single machine cycle.
The Sequence Former is ideal for volume, same-part runs. Easily adjusted, the machine fabricates a family of parts with one or more dimension changes. The machine may be used independently or as part of an in-line system.

LINE BENDER (pictured right, large picture)
While the Line Bender uses the same clamp-then-form method of positive clamping control throughout the bending cycle, bend application is different from the Dual Head.
The Line Bender is used to form long, in-line parts, generally shallow cross sections.
The machine allows parts to be transferred inline, therefore it is well designed for automated
systems.

CLAM SHELL DESIGN (pictured right, large picture)
The Clam Shell design is another variation of the Dual Head forming machine, using the clamp-then-form method of bending sheet metal.
The Clam Shell Former is used for 90 degree bends on parts requiring a bend length up to 60 inches.
The Clam Shell design is also available as a Sequence Former, which can form a complete part in a single station with one machine cycle.

TOOLING

(diagrams above, large diagram)
Single hinged (shown above), sectional 90 degree/sharp radius tooling, with hinged finger for full support of bend and easy withdrawal of tooling.

Parallelogram hinged (shown above), sectional 90 degree/sharp radius tooling for two bends. The parallelogram hinged finger gives full support of bend at the corner. The use of double parallelogram tooling (die hinge and finger hinge) allows easy removal of the tooling.

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CNC/Versaform

CNC/VERSAFORM
Feldmann Precision Forming Center


MODEL VF 36/10 TECHNICAL DATA
(pictured right, large picture)
• Bend length max.—36" (915mm)
• Part length max.—120" (3050mm)
• Material thickness max.— .0598 (1.5mm) optional
—up to 10 ga.
• Minimum wrapper 10" x 10" (254mm x 254mm)
• Cycle time position & form— 6 seconds
• Up to 6-bends per part
• Program capacity—200 parts

SINGLE AXIS FORMING CENTER FOR:
• Wrappers
• Wrap Arounds
• Enclosures
• Boxes
• "U" Shapes
• "L" Shapes
• Tanks


PERFORMANCE:
• Predictable Quality
• Reduction in Labor
• Eliminate Skilled Operators
• Reduce or Eliminate Press Brake Operations
• Reduction in Fit-up & Weld Costs
• Easy Part Handling


TYPICAL CNC/VERSAFORM PART SEQUENCES

(large picture)
A typical enclosure with 4-bends is made in 30-40 seconds floor to floor time.

 

Forming And Bending Machines

(samples pictured below)
Forming and bending machines are designed in a variety of configurations to accommodate a wide range of part size and material thickness.

Forming & Bending Machine samples
large picture

FIXTURES are designed for specific bending and part size applications, generally as single purpose tools for higher output applications.

DUAL HEAD FORMING MACHINES are available in a wide range of size capacities for a variety of metal thickness. Consisting of two forming units, one fixed and one adjustable, the machines are generally used to form a family or group of related parts.
This machine style lends itself to many parts such as: panel designs, "U" shape parts, and complete wraparound configurations.

FELDMANN SEQUENCE FORMERS consist of three or more adjustable forming units that form the "U" bend and "toe" flange configurations in one sequential operation. These machines are often used for wrapper/cabinet type parts.
All FELDMANN machines can be tooled for 90-degree single or multiple bends, sharp or radius bending.

SPECIAL MACHINES are built for unique forming applications. For example, the adjacent machine fabricates range hoods, utilizing multiple forming techniques to complete a complex cross section in a single machine cycle.

MATERIALS that may be formed include: mild steel, stainless, and pre-coated stock.
SPECIAL PURPOSE MACHINE FOR RANGE HOODS

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MULTIPLE MACHINES AND WORK CELLS
Multiple machines and work cells fabricate a variety of bend configurations with precision and a minimum of material handling.

The machines are engineered to give a choice of multiple machines working together, or as individual forming or punching/notching work cells. With automation creativity, labor input is minimized.

PUNCHING AND NOTCHING equipment is generally integrated into a work cell or system. Designs include gang punch or C-frame systems primarily used for peripheral punching and notching. Bridge or press units are utilized for mid-sheet holes and large die-cut areas. All Feldmann press systems can be designed to operate in automatic, semi-automatic, or manual mode.

MATERIAL HANDLING equipment is designed to control the part from one operation to the next. Included in the design array for positive control of the part in-process are: stacking or destacking devices for sheet metal blanks, magnetic roller conveyors, belts, and transfer beams, etc. The actual process is designed to suit the application.

MICROPROCESSORS assist in controlling the punching, forming and handling operations. FELDMANN's use of electronic interlocked sensors ensures accurate positioning of the part.

FELDMANN's use of micro-processors simplifies maintenance and machine change-over for different operational modes.

Work Cell - Two dual head forming machines, Single operator.

WORK CELL(pictured left)—two dual head machines are combined into a work cell for forming a variety of finished panels from pre-punched blanks. Typical production rate is 200 parts per hour with a single operator. large picture
 

 

SEMI AUTOMATED WORK CELL(pictured below)—two dual heads used in conjunction with a gang punch. It fabricate a variety of panel parts from blanks. Typical production rate is 300 parts per hour with a single operator.

C-FRAME PRESSES are mounted in the gang punch with "x" and "y" axis adjustment. Die sets are positively located within each C-frame for easy changeover or for maintenance.


large picture

 

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