Aluminum sheet bending is an important process in the production and processing of aluminum sheets and represents a job with a high level of technical skill. Bending aluminum sheets is a standard process for any shaped aluminum sheet, unless otherwise specified by the customer. Bending conventional aluminum sheets is relatively straightforward, but bending curved aluminum sheets increases the difficulty significantly, sometimes doubling or even tripling it. This process is crucial for ensuring the overall accuracy of the aluminum sheet and must be carried out with extreme precision and accuracy.
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Conventional aluminum sheet thicknesses typically range from 1.5mm to 3.0mm, with most falling between 1.5mm to 2.0mm. Prior to bending, suitable molds must be selected and adjusted for positioning. Additionally, protective film should be applied to the grooves of the bending machine to prevent damage to the aluminum sheet during the bending process.
The standard process for bending aluminum sheets involves several steps:
1. Carefully review the aluminum sheet processing drawings and requirements to determine the bending sequence before proceeding with the bending process. Adjustments to the machine settings should be made based on the size of the internal angles to ensure that the products meet the required dimensions and quality standards.
2. Special precautions should be taken for unique situations, such as bending large-shaped aluminum sheets, which may require supporting the workpiece during bending to prevent the bending moment from causing damage to the sheet. Extra attention should also be given when bending punched, carved, or hollow aluminum sheets, as mishandling can result in cracking.
Bending serves several purposes:
1. Increasing rigidity: Bending creates an "L" structure that enhances the rigidity of the aluminum sheet. This is akin to folding a piece of paper, which prevents it from bending easily afterward.
2. Aesthetics: Aluminum sheets without bending often lack visual appeal. Bending the edges of the sheet adds height and a sense of sophistication.
3. Installation considerations: Bending creates connection points for installing aluminum sheets on wall studs or ceiling supports, ensuring that connection components are not exposed on the surface.
4. Joining: When connecting two aluminum sheets, whether with seams or flush, the edges are often bent to facilitate a seamless connection. This ensures a smooth surface when assembling the sheets.
When bending aluminum sheets, attention should be paid to four key details:
1. Operator proficiency: Operators must be highly skilled in machine operation and undergo specialized training before performing bending tasks to ensure safety.
2. Edge size: The minimum edge size must consider the dimensions of the bending machine's jaws. If the edge is too small, the jaws may not be able to grip the aluminum sheet properly for bending. The commonly accepted minimum edge size for bending equipment is 9.5mm.
3. Length of the edge: The bending machine's typical size limits the length of aluminum sheets to 6m. If longer sheets are required, grooving and manual bending techniques may be employed. However, precise calculations are necessary when employing these methods.
4. Edge radii: During bending, the inside of the aluminum sheet is compressed, while the outside is stretched, resulting in unequal radii on both sides. The radius of the edge is typically equal to the thickness of the sheet. Actual dimensions may vary slightly due to equipment, processes, and the skill level of technicians.
After bending aluminum sheets, attention should be paid to the following:
1. Handle the bent aluminum sheets with care to avoid collisions or scratches, and place them on carts according to designated areas for subsequent processes.
2. Conduct a thorough inspection to ensure that the bent aluminum sheets are free from noticeable scratches or abrasions, with the angle error within specifications and the bending height error controlled within 0.5mm.
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When thinking of the metal fabrication industry, one’s mind may conjure images of a dirty shop floor with workers handling dangerous equipment. In reality, modern metal fabricators like Badger Sheet Metal Works have become leaders in innovation and using emerging technology, making the shop floor one of the cleanest and safest places to be employed.
Metal fabrication companies have also become a major national economic player, employing a whopping 1.4 million people. The industry, which continues to see consistent growth paired with the departure of the Baby Boomer generation, is poised to hire hundreds of thousands of workers every year. Among those needed positions are press brake operators.
What is a press brake?
Today’s press brakes use advanced computer technology to bend sheet metal and other materials into straight lines or complex shapes, such as cylinders, cones and more. The CNC technology delivers incredible precision, but it still requires assistance and intervention from a machine operator.
What are the duties of a press brake operator?
Press brake operators are responsible for the daily setup and operation of the machine. Tasks often required by the job include:
Press brake operators employ a lot of problem solving while on the job. One must be able to carry out equipment maintenance, check materials for imperfections and quickly repair a machine when it malfunctions.
To achieve optimum results, press brake operators must have at least a basic knowledge and understanding of fabrication, press brake and/or punch operations and setup. They should also demonstrate prowess in math, computers, communication, and time management.
Most press brake operators find the position to be incredibly rewarding. Below, we’ve laid out some of the reasons why:
Metal fabrication often provides a stable, life-long career with paths of advancement. The entry-level work as a press brake operator opens the door for career growth within the industry. After dedicating some time to hone your skills, roles within the supervisory, quality assurance or business development arms of the company will likely be there if you choose to take them. Most companies much prefer to promote from within their ranks than seek to fill positions from the outside.
Metal fabrication offers competitive pay and benefits packages. A press brake operator’s pay rate, for example, has far outpaced minimum wage. On average, those in manufacturing-related jobs in the U.S. earn 13 percent more in hourly compensation (wages and benefits) than comparable workers earn in the rest of the private sector. Workers in manufacturing also have the highest tenure among major industries.
In many jobs, a worker’s output is measured in words, ideas or the input of data into a computer. Conversely, a career as a press brake operator gives you the opportunity to create something tangible every day. Whether working on a mining or food grade equipment project, you can point to the part or product and feel the satisfaction of knowing you helped make it. In this line of work, you turn projects and raw material into a usable, finished product.
Modern metal fabrication has been driven by the innovations brought by the Industrial Internet of Things, automation, robotics, big data, and so much more. The industry implements new technologies well before they are ramped to full-scale consumer production. This makes metal fabrication and press brake operating jobs an ideal fit for early adopters of technology who enjoy exploring new, revolutionary equipment and their use in the workplace.
Manufacturing is by far the most important sector of the U.S. economy in terms of total output and employment. Consider this: The National Association of Manufacturers indicates that, for every dollar spent in manufacturing, another $1.81 is added to the economy—the highest multiplier effect of any economic sector.
Working as a press brake operator has a direct impact on the quality of life in America, which is a primary point of pride for many who pursue it as a career.
Ready for a job in a dynamic environment where the work produces tangible results? Are you looking to start a career instead of just taking another job? Whether you’re a seasoned expert or a young professional ready to make a real impact, there’s a lot to love about working as a press brake operator!
For more information on becoming a press brake operator at Badger Sheet Metal Works or other job opportunities, visit BSMW’s Careers page today.
ABOUT BADGER SHEET METAL WORKS
Badger Sheet Metal Works is a custom and OEM metal fabrication partner for a wide range of industries including food and dairy, mining, petroleum, material handling, medical and pharmaceutical. The company employs approximately 100 people in a custom-designed plant in Green Bay, Wisconsin. The facility includes a 70 by 320-foot main assembly bay with four crane rails featuring a total lifting capacity of 30 tons and a 22-foot under-hook height.
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