Mazon Elmar Jr., H.

Workshop Theory & Practice Lab

BS ME-201210743 Prof. Walter A. Joaquin
Assignment # 2

BENDING MACHINE
A bending machine is a forming machine tool (DIN 8586). Its purpose is to assemble a
bend on a workpiece. A bends is manufactured by using a bending tool during a linear or rotating
move. The detailed classification can be done with the help of the kinematics.

BENDING TOOLS
Standard Bends
All bends without an extraordinary geometry belong to standard bends. The distance between
a bend and the material end is quite high providing an adequate bearing area. The same with one
bend to the next. Typical tools are a so-called bending former combined with a prisms with
electronic angular measurement or an ordinary prism.
U-Bending
For U-bends where tight and narrow bends are necessary, the bending former is replaced by a
bending mandrel. A bending mandrel has a narrow geometry.
Offset Bending
Offset bending tools are used to assembly two bends with a small distance between in one
step.
Edgewise Bending
Edge bending tools are used, if the bending axis is placed parallel to the tight side of the
work piece. Tools for bending on edge may include electronic angular measurement allowing a
high bending accuracy.
Torsion Bending
Torsion tools are able to rotate the work piece on the longitudinal axis. Alternatives are
complex assembly groups with standard bends.

ANGULAR MEASUREMENT AND SPRING BACK COMPENSATION

Operating Mode Angular Measurement

Bending prisms with electronic angular measurement technology are equipped with two
flattened bending bolds. That bold rotate while bending giving a signal to the angle
measurement. The measuring accuracy is about 0.1. The computer then calculates the required
final stroke and spring back of every bend is compensated regardless of material type. A high
angle accuracy of +/- 0.2 is achieved instantly with the first work piece without adjustments.
Compared to adjustment by reference, material waste amounts are decreased, because even
inconsistencies within a single piece of material are automatically adjusted.
Operating Mode Stroke Measurement

Wherever Bending prisms with electronic angular measurement are not suitable, a small
distance between to bends might be a reason, bending prisms without electronic angle
measurement are applied. In that case the control unit can be switched from angular
measurement to stroke measurement. This method allows the pre-selection of the stroke of the
bending ram in mm and therefore the immersion depth of the punch into the prism. Setting
accuracy is +/- 0.1 mm. A final stroke is usually not required. Further development of the stroke
system enables the user to specify an angle from which the stroke is calculated by using stored
stroke functions. Bending accuracy in that case is dependent on material properties such as
thickness, hardness, etc. which may differ from one work piece to another.









DRILL PRESS
A drill press is preferable to a hand drill when the location and orientation of the hole must
be controlled accurately. A drill press is composed of a base that supports a column; the column
in turn supports a table. Work can be supported on the table with a vise or hold down clamps, or
the table can be swiveled out of the way to allow tall work to be supported directly on the base.
Height of the table can be adjusted with a table lift crank than locked in place with a table lock.
The column also supports a head containing a motor. The motor turns the spindle at a speed
controlled by a variable speed control dial. The spindle holds a drill chuck to hold the cutting
tools (drill bits, center drills, debarring tools, etc.)
Using a Center Finder
A center finder is useful for setting the spindle of a drill press or mill accurately over a
known point. A center finder is made of two separate pieces spring loaded together.

The center finder is used by installing it in the chuck, placing the pointed end into a
center punch mark, and pressing down lightly on the quill. At first, the two parts will probably
not be concentric.

The bed of the drill or mill can then be adjusted to until the two halves are concentric.
Check for concentricity by running your fingers up and down the center finder. You should
detect no steps. You should be able to locate the desired position to within .001 inches using this
technique. Now the hole is ready to be drilled.

Drilling a Hole
First, a center drill should be used. A center drill has a thick shaft and very short flutes. It
is therefore very stiff and won't walk as the hole is getting started. It doesn't cut as easily as a
drill bit, so you should use cutting fluid.
Now the hole can be drilled. If the hole is large, its a good idea to drill a smaller pilot
hole before drilling the final one. Your hole will be more accurately positioned, rounder, and the
bits will last longer. If the hole is deeper than it is wide. Use coolant and back off occasionally to
clear the chips. As you step up in drill size, you will need to reduce the spindle speed. If drilling
a through hole, ensure that the bit will not drill the table after moving through your work. To set
a desired depth of hole, there is a depth stop on the quill.
Debarring a Hole
Usually, the top edge of the hole will be fairly clean, but the bottom edge will have
substantial burrs. To remove them, insert a debarring tool into the hole and run the tool about the
edge of the hole with moderate pressure.

Reaming a Hole
A drilled hole will be accurate to about two thousandths of an inch in diameter. If greater
precision is required for slip fits or interference fits, a reamer must be used. The straight flutes of
a reamer cannot drill a hole. You must drill a hole slightly undersize to start. Be sure to drive the
reamer down with a constant, slow speed.
Thread Standards
The threads cut by taps and dies conform to a standard for the shape of the threads. Often
it is the American National Standard in National Coarse (NC) or National Fine (NF). NC has
fewer threads per inch than NF. NC is most common while NF is favored in precision
assemblies. Also in common use is the Unified Thread System with UNC (coarse) and UNF
(fine). The only difference between National and Unified threads is the shape of the root and
crest. The threads in the two different standards will mate. Fasteners are designated by their
diameter, number of threads per inch, and shape. For example, 1/4-20NC means 1/4 inch
diameter, 20 threads per inch, and National Standard. Threads smaller than 1/4 inch are
designated by number from 0 (smallest) to 12 (largest). To convert number to diameter multiply
by 0.013 and add 0.060.
Tapping a Hole
If you want to cut threads in a hole, use a tap. The picture below shows what a tap looks
like. It has cutting edges to cut the threads and straight flutes to allow chips to be expelled. Note
that the end is tapered slightly to help the tap get started. Taps and dies are hard and brittle so
you should be careful working with them (try not to drop them or force them into a hole when
stuck). Be sure that the hole you drilled is the correct size for the tap you're using or it may break
inside your part. Refer to a chart or machinist's handbook. The die in the picture is for cutting
external threads on a shaft.