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Benders and Bending Which bender is best? How do you use a bender? How do you calculate bends? Everything Bender related...


Benders and Bending Which bender is best? How do you use a bender? How do you calculate bends? Everything Bender related...

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  #1  
Old 11-03-2015, 09:28 PM
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how would you bend this?

Hi all-

I have a project I am doing where I have to bend a lot of these (500-600).

I was planning on buying one of the JD2 horizontal benders, but when I went to order one, they are no longer made.

With the bender I currently have, I can bend 2 90 degree bends, but then I would have to weld all the parts together, then grind all the welds flat.

That is why I want to bend the + part in one piece. This way I only have 1 weld to worry about.

I am thinking about making a simple horizontal bender, but not sure if that is the best option.


Any ideas???


The material is 1 x 1/8 flat bar

Steve

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  #2  
Old 11-03-2015, 09:43 PM
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Hossfeld bender or the like. Horrible Freight also makes a bender that would do the job, but no where near as versatile as the Hossfeld.

Jaysin
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  #3  
Old 11-04-2015, 10:49 AM
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A Hossfield is versatile to be sure, but is through-loaded so every time you want to flip the part you have to feed it out and feed it back in. Also if you bend it into a closed shape, you have take the bender apart to get it out.

For that part, you might consider a top-loaded flat-bar bender like the style below. Check to see if the minimum distance between bends is compatible with the part you're trying to make.


Link


Link

There are less expensive versions out there if you search around. There are also machines like this for making scroll bends to do ornamental iron work if you want to get a more versatile machine for future projects.
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Last edited by TheBandit; 11-04-2015 at 10:51 AM.
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Old 11-04-2015, 04:19 PM
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For that quantity I would look into building a simple hydraulic bender. Something similar to a log splitter, but on a smaller scale as .125 x 1 is fairly easy to bend. You could probably build one for $1500-2000 if not less.
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Old 11-04-2015, 05:52 PM
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I glossed over the quantity. For that many you might consider subbing this out for CNC bending. I don't know if a hydraulic bender is going to make this much faster since most of the time is going to be in positioning and flipping the part. The bending action is going to be quick on a lever bender like the one I posted. I'd try to get smart with setup stops so you can quickly feed the parts.
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Old 11-09-2015, 12:42 PM
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I agree with Clint on potentially subbing this out to somewhere that could do it with CNC.

If you are doing it yourself, I would look into a #1A or #2 DiAcro bender. I have wanted one for a long time, they're really versatile and you can set stops to help with all of the repeats you're doing.
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  #7  
Old 11-09-2015, 05:22 PM
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I have an AMADA iron worker that has a NC controlled stop.

I am going to test bend some flatbar next week or so. I think I can only do 3 bends, then weld these together.

It might work, but with my luck- don't count on it


Steve
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  #8  
Old 11-09-2015, 06:44 PM
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That is going to be a lot of welding. I would think hard about how to bend the whole thing in one go or do at least 8 of the 11 bends on the NC bender and come back to do the other 3 via a top-load bender like the one I posted.

Here are the bends you should be able to do freely on a press-brake style bender without crashing. You could then go back and do the remaining bends on the style bender I posted above.
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File Type: jpg cross bending.jpg (22.2 KB, 95 views)
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Old 11-09-2015, 06:57 PM
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Clint-

I just saw the pictures of the benders you posted. I like the one design.

I am going to search for more information on that design.

I don't plan on starting the panels until the first of the year. So I have a few days to figure something out.

Steve
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  #10  
Old 11-10-2015, 01:39 AM
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I would set up TWO benders like Bandit showed, so that you could bend the first two bends ( 1 and 2 ) with one set-up, then reset and bend 4 and 5, reset ...etc. Have a third bender for the 3,6,9 bends or do those after doing a batch of the first bends.
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  #11  
Old 11-10-2015, 10:18 AM
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Somehow I missed the total number of parts you need to bend when I posted the Hossfeld bender idea and Bandit is right it would be a pain since it isn't open on top like what he posted. That said though 500-600 of those equates to pulling a manual bender handle 5000-6000 times. I might start looking into something that is powered, if I had that many to do and I was getting paid to do it.

Jaysin
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  #12  
Old 11-10-2015, 11:19 AM
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A machine like this might be useful: https://www.youtube.com/watch?v=8Y7WPI-I35Y
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Last edited by TheBandit; 11-10-2015 at 11:21 AM.
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  #13  
Old 11-10-2015, 11:45 AM
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What is the tolerance?

If it is tight I hate to say this, but, at the qty you are looking at it is going to be tough to do this without precision CNC equipment with back gauging and ram depth control. I would recommend that if you do not have this kind of equipment to find the cost of someone who does to bend it into 4 or 5 pieces and then you do the welding.
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  #14  
Old 11-10-2015, 12:56 PM
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Considering the shape and quantity, I'm guessing these are decorative and therefore would not require tight tolerances?
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Old 11-10-2015, 01:36 PM
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Why not buy another brand of horizontal press?
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  #16  
Old 11-10-2015, 03:46 PM
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I have a couple of other thoughts for you. I think this will look better if you do all the corners as bends and put the weld/seam in the middle of one of the flats. This way all the corner/bend radii will match and if you want you can grind the weld flat. Basically like this (notice the split at the bottom):



You could also make a dedicated press stamping tool to form half of the shape, make two halves, then do two welds to join them. Perhaps you could do this as a single stamping but maybe it would need progressive/staged stamping - I dunno. If you go this route it may spring back too much and come out wonky. It might also end up with some drag marks / wear on the tooling. But perhaps it's worth a try?

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File Type: jpg crossbending.jpg (25.1 KB, 1073 views)
File Type: jpg crossbending2.jpg (23.8 KB, 1041 views)
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Last edited by TheBandit; 11-10-2015 at 04:04 PM.
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  #17  
Old 11-10-2015, 07:54 PM
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Here is what I am making. I have 37 panels, 1 22 foot slide gate, 2 4 foot man gates.

Everything has the same pattern, just different lengths.

As long as they are the same, I don't think it really matters.




Steve
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  #18  
Old 11-10-2015, 09:18 PM
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This. Just build one. I would like to build one myself. After I finish my tube bender of course.

Jaysin
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  #19  
Old 11-10-2015, 09:36 PM
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Jaysin-

I was all set to buy the horizontal bender from JD2. I think it was the HP100?

I called to get more information after I got the purchase order for the handrail. It is no longer being made. OOPS

I should have checked that part out, but did not. That is why I am in panic mode.

I have all the stuff to build one except the base plate. I might go that route. just depending on time. I am supposed to deliver everything in June 2016.

We shall see.


Steve
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  #20  
Old 11-10-2015, 10:09 PM
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That bender is pretty cool!

Love the huge pins!
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