Principles of Rotary Bending

Technology
&
Use of Rotary Bending
Technology for Processing of
Advanced, High-Strength Steels
(AHSS)
L. Ray Osborne
rosborne@anchordanly.com
Mechanical Engineer / Business Development Manager

What is Rotary Bending?

Rotary Benders are rotating
rocker-lever devices that work on
the principle of mechanical
advantage, and are used to
simplify tooling, improve part
quality and reduce tooling costs.

Rotary Bending provides tool

designers, tool builders and metal
formers a consistent means for
holding angular part tolerances
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Where is Rotary Bending Used?

Progressive Stamping Dies

Value Proposition:
Reduced Part Marking
Precise Control of Final Bend Angles

Press Brake Tooling

Value Proposition:
Ergonomics and Safety
Reduced Part Marking
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How Does Rotary Bending Work?

Step 2

Step 1
Downward
force clamps
the part.

Induced
rotation of the
Rocker bends
material around
the anvil while
requiring less
force
Step 4

Step 3
Rocker bends material beyond
final part angle to compensate
for material-memory springback

Rocker releases
material to allow
springback to
desired final part
angle
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Rotary Bending Replaces Wipe-Action Tooling

Part Hold-Down

Wiping Action

Wipe
Punch

Hold-Down

Bottoming Action

Coining
Part

Stripper

Surface of part is
scraped, leaving long
marks

Rotary Bending replaces V-type Brake Tooling

Brake Punch

Work
Piece

Minimal shine marks

with standard polished
Rocker and no marks
with Delrin Insert

Back Stop

Brake Die

Press brake V-dies require

higher tonnages

Pronounced tool marks

from press brake V-die
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Most Common Bend Types (cross sections)

90 Bend

Channel Bend

Over Square

Zee Bend

Other Bend Types

Short Leg

Hat Bend

Large Radius

Under Square

Return Bend

Open Zee

Common Rotary Bender Sizes

Capability of Common Rocker Diameters

20mm:

25 19 gauge material (mild CRS)

25mm:

19 14 gauge material (mild CRS)

35mm:

14 11 gauge material (mild CRS)

50mm:

11 8 gauge material (mild CRS)

65mm and 80mm are available for thicker and/or

high-strength materials

Common Construction Materials

LINER = Self-Lubricating C95400 Aluminum Bronze

SADDLE = Hardened AISI 4140 Steel

ROCKER = Induction-Hardened S7 Shock-Resistant Tool

Steel
10

Common Construction Materials

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Rotary Bender Options

Dart Stiffeners can be produced

in the bent part with the simple
addition of hardened dowels
spaced as needed across the
throat of the Rocker.

Dart Stiffeners create an integral

gusset in the part and give it
rigidity.

12

Rotary Bender Options

Delrin is a special polymer which
can be inserted in the hardened
steel Rocker to bend pre-painted
materials, soft materials or stainless
steel without leaving tool marks.
Delrin provides long-lasting
durability with little to no abrasive
effect during part contact.
Delrin is mounted to the Rocker
using screws and can be easily
replaced.

13

Market Segments for Rotary Bending

Appliance 40%
Specialty
Equipment 20%
HVAC 10%
Transportation 5%
Furniture 10%
Aerospace 5%
Electrical
Enclosures 10%

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Application Engineering

Technical Data Required:

Material Properties
Material Thickness
Part Length
Bent Leg (Part Height)
Bend Radius
Part Angle (and Tolerance)
Areas Where Marks Are Unacceptable
Part Channel Dimensions, if Applicable

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Test Bending Services

For Application Verification:

Determine Extent of Part Marking (if any)
Determine Amount of Material Springback
Guarantee Final Bend Angle and Desired Part
Geometry

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AHSS Springback Study

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AHSS Springback Study

Vertical
clearance

The effective strain field of

rotary bending is shown here
at the overbending stage.

Springback from FEM simulations

using elastic modulus E=150 and
210 Gpa is compared with
springback from experiments at
Anchor Danly in bending DP1000
at different vertical clearances.

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Special Applications

Material = DP1000
Ultimate Tensile Strength (min.) = 1,000 MPa
(145,000 psi)

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Special Applications

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Special Applications

Interlaced, TwoStage Bending

Concept

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Special Applications

Rotary-Bender
on Pressure Pad
+ Conventional
Aerial Cam

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Special Applications

Rotary-Bender
on Pressure Pad
+ Conventional
Aerial Cam

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Special Applications

Rotary-Bender on
Pressure Pad +
Roller-Actuated
Cam

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