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Many metal fabricating workshops have no way of knowing what the next job will be or what tooling it may require, so they must have the most flexible press brake tooling available at all times.
Most of fabricators will try to air bending as much as they can because it allows greater versatility over a range of material thicknesses. This allows them to keep a smaller tooling inventory to handle many different operations. But because they don’t have a lot of control over what prints and parts their customers will request, air bending alone isn’t enough.
This requires more than just the 90-degree bends for the corners of the box. All these components require various louvers, flanges, offsets, card guides, and other complex forms. Offsets and flanges often must be bent over and then flattened.
Traditional bending practices require a separate press brake setup for each and every form. From start to finish, the bending process might require as many as five different press brake setups. Alternatively, the job could be completed with multiple machines: One operator performs the first bend series with one tool set, and then passes the part on to an adjacent operator to perform the next at another press brake. Both arrangements have tradeoffs. The latter ties up multiple operators and machines; the former requires the operator to repeatedly set up the machine.
Staged bending requires that press brake tools have a common shut height to avoid collisions. Early adopters of the practice accomplished this by using a series of shims and risers to create that common shut height.