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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
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.
(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.
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(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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