Established in Melbourne, Delahenty Machinery specialises in tube manipulation, cutting machinery automation & machine tooling for a wide range of industries.
We are honored to have been awarded a silver award in the sixth edition of Australian Industrial Businesses magazine for Bringing the most innovative industrial and manufacturing solutions to our valued customers.
A big thanks to Industry inMotion for recognising our efforts in the manufacturing industry. And Congratulations to all the winners of the 2022 Australian Business Award winners.
We are a prominent importer and supplier of machinery solutions for the metal forming, manipulation, and cutting industries. We offer a wide range of top quality machines from some of the top international manufacturers.
Contact us today and experience the best service in the industry.
Are you planning to use a Ball mandrel and Wiper die to bend the pipe but do not know the process? Here is the guide to bending tubes with ball mandrel and wiper die.
Why Use a Ball Mandrel and Wiper Die to Bend Tubing?
One of the oldest methods for bending tubing is using a ball-mandrel and Wiper die. A wiper die has a stationary wiper that wipes the ball as it rolls against it, making a near-perfect radius every time. This will ultimately help improve the bend quality of your bends.
A ball mandrel supports the tube throughout the tube bending process and is used to produce flares, tees, and reducers. The ball-end reduces friction and oxidation during bending, allowing the workpiece to be held in a tight radius while not marring the surface or allowing distortion. The result is precise bending that produces better flare control and dimensional consistency.
How to Bend Tubing with a Ball Mandrel and Wiper Die
Firstly, you must make a successful plan to bend the tube with a ball mandrel and wiper die. You need to consider the material you are going to bend. Try to source the entire material from one supplier. It will help in maintaining the consistency of the tubing dimensions and characteristics.
Start considering the machines you are going to use. The bending machine should be in the right condition and should have good quality because poor quality tooling leads to longer set-up times, more scrap, poorly bent tubes, and unacceptable bends. You need an experienced one to operate that machine.
When performing this type of bend, the piece of tooling, the Wiper Die should be accurate. The groove must be slightly larger than the O.D. of the tube ñ 10% of wall thickness as being minimum. It must be of high polish lubricated with thin oil. Too much fat or too heavy oil in this area will cause wrinkles. Wiper Dies fit to bend die groove must be 85% contact from 12:00 o’clock to 6:00 and for at least 15-20 degrees back from tangent. When the bend die does not support the Wiper Die. It will spring away from the mandrel. It can cause the tube to wrinkle.
Wrapping Up
These tools are excellent aids for bending tubing. It allows you to make consistent tapers on tubing, whether you want a tight or loose fit. The mandrels and dies will enable you to make different-sized bends and give you those custom curves that your other tools do not allow.
Delahenty Machinery is a leading manufacturer of tube bending machinery, ball mandrel and wiper die. Many industries use our machines to process tubes and pipes, from ultra-pure copper and brass to hardened steel, stainless steel, aluminum, and titanium.
How to Use Machine Lubricants effectively is crucial for ensuring long machinery life, efficient performance, and minimal downtime. In this guide, you’ll learn how to use machine lubricants by choosing the correct viscosity and additives, storing and handling oils properly, applying lubricants using best techniques, monitoring oil condition with ISO-standard analysis, and implementing machine lubrication best practices. Follow these tips to avoid common lubrication mistakes and maximise your machinery’s reliability.
Machine lubricants, like any other oil, reduce the friction between moving parts in machines and equipment through a lubricating film applied onto surfaces where contact occurs. Friction is the force that opposes motion between surfaces and results in heat and wear of both surfaces.
Some machine lubricants are cooled to prevent additional heat as they work. You can apply cooling machine lubricants to increase its performance while adding some complexity concerning maintenance that involves handling and disposal.
Lubricants have a variety of uses on machinery. The primary purpose of a lubricant is to reduce wear, help bearings roll more freely, and reduce rust or corrosion over time. Many types of lubricants are available for machinery, with some common types including grease, oil, and wax. They also come in various viscosities to suit the use case. We’ll look at all four lubricants and their applications in this guide.
Oil Machine Lubricant
When dealing with any machinery, you must ensure that it runs efficiently and effectively. This is especially true when it comes to your oil drilling equipment. Without proper lubrication, you could have a situation where equipment breaks down rather than working correctly. Oil machine lubricants can do everything from prolonging the life of the machinery to reducing downtime to simply making the most efficient use of your fuel.
Oil is a lubricant used to reduce friction and wear between moving parts. Installing oil machine lubricants can make equipment more efficient and life expectancy longer.
Oil machine lubricants come in various viscosities, thicknesses, and performance levels. Using lubricants in an oil rig is integral to operating the machine.
When selecting your next lubricant for industrial uses, it’s essential to consider the oil’s properties and what you’ll be using it for. Each oil machine lubricant has its own unique set of characteristics.
Greases Machine Lubricants
A grease lubricant machine is a piece of special machinery used for smooth operation. In the commercial automobile industry, there are many heavy-duty machines and vehicles where these greased lubricants play an essential role in their smooth operation.
Greases are thickened lubricants designed to lubricate bearings, joints, and other moving parts. It is produced in several forms, such as wheel bearing grease, chain and belt lubricant, industrial gearbox grease, and molybdenum disulfide greases, which are used as a solid lubricant in parts of machinery that cannot accommodate more fluid lubricants.
This lubricate moving parts in engines, pumps, fans and other mechanisms. Grease has the advantage over oil because it remains in place, whereas oil circulates the engine. This is why you should use grease to lubricate certain parts of a machine – particularly those that usually need re-lubrication, such as gears and bearings.
Penetrating Machine Lubricants
An Overview of Penetrating Machine LubricantsLubrication is one of industrial machines’ most essential and overlooked maintenance aspects. Factories and manufacturing plants must ensure that their machines have adequate lubrication to prevent wear, reduce downtime, and provide proper operation.
While old-fashioned grease has been a trusted form of lubricant for many years, penetrant oils has brought significant changes in both cost savings and environmental concerns.
Penetrating oils are a great way to stop everyday problems dead in their tracks. They are also great to use if you have been working on a project but haven’t finished it yet. This oil is fast drying, which means it applies quickly and penetrates deep into the metal pores (or any other surface) without leaving a greasy surface behind.
In addition, they are easy to clean up after and won’t leave any residue behind. Penetrating lubricants, in general, can be great for many different things such as unlocking stuck locks, freeing stuck parts, removing beetles, moving stuck or rusted nuts or bolts, and even forming non-marring thread lock systems.
Dry Lubricants
The dry lubricant for heavy machinery is what replaces hard unions in old equipment. These new unions require no maintenance, do not leak, and provide less friction. So the machine operates faster and more efficiently.
Dry lubricants are generally used in large-sized industrial equipment that operates under heavy load conditions with temperatures ranging from 500C to above 1000C.
It is very economical and can reduce operating costs. Dry lubricants reduce frictional losses in all your rolling elements by 0.2% to 3%. That translates into a lot of savings and a lot less wear. It is perfect for excess, shock, heavy, and hard-to-quench applications like mining and off-road equipment.
Final Note
Be sure to look for compatibility with your specific application. You should properly apply the lubricant at the correct locations of your machinery. This should help prevent your machine from wearing out quickly. With proper lubrication, you can ensure that it will last longer.
We recommend to inspect your machinery regularly. Particularly when dealing with machinery that carries a high load or produces a lot of friction. Ensure that all components move freely and do not rub against each other.
Delahenty Machinery provides our customers with the best lubricants and services of the highest quality; we have trained and experienced staff who will make your experience with us pleasant. Contact us for more details.
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We are a prominent importer and supplier of machinery solutions for the metal forming, manipulation, and cutting industries. We offer a wide range of top quality machines from some of the top international manufacturers.
Contact us today and experience the best service in the industry.
Sheet Metal design is a complex task that involves several disciplines that include flexible mechanical and thermal behavior, aesthetics, manufacturing, and assembly process.
A product designed with a compromise of these areas can cause severe issues down the line, affecting the performance and the end-user satisfaction.
Below are a few mistakes manufacturers often encounter when designing Sheet Metal products and ways to avoid them.
Having a Tight Bend Radius
The bend radius is necessary to notice when drawing up your design. Because when the bend radius is too tight, it becomes a weak point in the sheet metal product.
A near-perpendicular bend area can cause your part to break easily. It can also deformity the dimensions of the sheet metal part you’re trying to create.
You need to understand the bend ratios and quality of the sheet metal product. If you cannot understand, you will most likely get a crack in the metal.
In this case, you need to redesign and refabricate your metal product, and it will enhance your production cost.
Making Excess Holes
Holes, in particular, are daunting to add in large quantities in sheet metal products. It can add complexity to the process, and each hole has a solid chance of breaking the sheet metal product.
Moreover, placing these notches and other features too close to your bent edges can affect the function of the sheet metal part.
If you place the holes near a bend radius, they may lose their capacity to hold hardware or withstand tension.
The best practice is not to put any cut features near any bends. If you need to add one near a turn, try to add them past the bend line.
Not Including Hardware Specs
Including all details is essential when compiling your hardware specifications in your CAD file. Every sheet metal product fabrication process begins with a CAD file.
Without the proper hardware specifications, you will have extended lead times for your fabrication.
You need to note which types of nuts, studs, bolts, and other components you require in your sheet metal product. With a comprehensive CAD file, you will acquire precisely what you want in lesser time.
Using The Wrong Sheet Metals
Selecting the suitable sheet materials for your project is very important. When in the designing stage, consider the type of environment your product will face daily.
If your design is based on mechanical properties alone, your product may become unusable in a short amount of time. Such as, untreated steel would not last very long in a high-salt, damp environment.
You can avoid enhanced manufacturing costs by considering resistance to heat, corrosion, and other environmental factors.
For instance, mechanical features like tensile strength or malleability, Conductivity of electricity and heat, Toughness and wear resistance, Weight, and manufacturability and Cosmetic look.
Picking The Wrong Finish
Apart from the base materials, the sheet metal finish also serves an essential purpose for your final product. Some finishes protect steel, while others add decorative features to their surface.
Aesthetic finishes usually don’t provide any corrosion protection. But powder coating does give some protection against water and other elements.
Chemical finishes alter the properties of the steel surface. And add additional features to make it more corrosion resistant.
When selecting a finish, there are many options to check. So, check which one will give results that suit your need.
Being Unaware of Machine Capabilities
Another common mistake when designing sheet metal products for manufacturing is a general lack of knowledge of the machines.
When talking with a manufacturer, take the time to ask them about their devices and their capabilities early on.
You can ask for a guided tour around their facility. It enables you to make the appropriate adjustments to your design to meet these constraints better.
Final note
The most important thing to remember when designing metal components is that the metal part will always be bent into shape.
This means you need to consider this in your design. Most design engineers tend to design Sheet Metal parts using a flat pattern, but this can result in poor formability and reduced yield.
Always consider the surface finish required for your product and the requirements for special finishes such as electroplating or heat treatment.
Delahenty Machinery
At Delahenty Machinery, we endeavor to be the one-stop shop for all your Sheet Metal needs. We ensure that you get access to the best tools and machines at affordable prices, so buying them from us is more advantageous than anyone else.
Each component plays a vital role in the bending tooling successful operation. Yet there are some essential components like bend die, clamp die, pressure die, wiper dies, and mandrel.
So, before diving into each bending tooling component, let us understand what tube and pipe bending is.
What is Tube and Pipe Bending
Tube and pipe bending is a manufacturing process. In this process we use a machine for bending pipes, tubes. And try to get a perfect bending shape. It allows the production of shapes that are not achievable by other processes such as roll forming, plate rolling, press brakes, or tube cutting.
We use Tube and pipe bending processes in several applications in almost every industry, such as exhaust systems, headrests, etc.
Each component plays a vital role in perfect bending in the bending tooling process, which we will discuss later in the same article.
How Tube and Pipe get bent
Bending tubes and pipes can be a daunting process for someone unfamiliar with the equipment, techniques, and safety requirements. The process requires specialized machinery, a trained, experienced operator, plenty of time, and attention to detail.
Either manually or with automated machines you can finish Tube and pipe bending process. It depends upon the type of manufacturing product. Tube bending machines are best suited for short-radius turns, while more sophisticated pipe benders make longer radius bends. With tube bender you can make fittings such as tees and crosses, but you’ll need a pipe bender for elbows and other complicated shapes.
Calculations often determine the success or failure of any bending tooling, which needs to be done before the tooling is set. Some of these calculations decide things like the ideal bend radius and others whether or not your specific equipment can even complete the bend.
Moreover, the material you are using must not be bent cold in the bending tooling process. Cold bend dies only work for materials like iron and aluminum. If your material exceeds a hardness of 101 BHN, it cannot be produced with a cold die on a press brake. The more complex your material is, the more likely you will need an induction heater to heat the bar to make a bend.
Perishable and Non-Perishable Components Of Bending Tooling sets
Tube bending components consist of both perishable and non-perishable components. Perishable components will eventually have to replace, and non-perishable components are those you won’t have to replace.
The two big pieces of perishable tooling are the wipers and the mandrel (Shank, body, nose, and ball mandrels all included). The non-perishable components include:
It is a quick, cheap and easy way to produce extreme bends in thin-walled, low conductivity metals. From the reverse side of the bend die, a blank is pushed through a groove. And then the metal’s composition is rolled into a thin sheet over the die surface and compressed. The blank is then made through the die with enough pressure to bend it and finally falls off upon reaching the exit hole of the die.
Clamp Dies
It is one of the most common hydraulic tools. There are various types and sizes of clamp dies available.
In CNC machines it is the common tool. A clamp die can create pressure and hold stationary any part that goes through the machine when machining it.
Ratcheting dies, snap-action dies, and clamping dies are synonyms of clamp die. The clamp die is essential in your bending tool kit, no matter what name it goes by. A clamp die can clamp together two die flanges to accommodate various sheet metal thicknesses without you having to resize the dies for each new material thickness.
Pressure Dies
We use pressure dies in high volume, tight tolerances, or highly high output production applications. Only High-pressure machines can create these dies. They only work if they are at the correct pressure level. Otherwise, they could cause damage to the products.
There are many pressure dies in bending tooling, each designed for a particular application or material type. Pressure dies are usually the last step in this process after a forming operation. And finally it imparts the final bend profile on the formed metal blank or part.
Wiper Die
Wiper dies are bending die inserts and mainly use for bending and forming operations. These dies most commonly used in standard shapes and sizes, and made from high-quality tool steel. While their usage can vary within the industry, their function is consistent — to remove the smaller amount of material found on the top side of a sheet. Because wiper dies to remove only the excess sheeting that presents an issue during bending, they act as a sacrificial die and will wear out quickly.
Mandrels
The mandrels in bending tooling allow a continuous bend of the pipe or tube to any desired radius. A hydraulic system operates it. In this process, you put a stack of mandrels inside the machine. Mandrel rotation arrangement work with the stack of mandrels according to the diameter and length of the products.
Final Note
This is certainly not a comprehensive guide to bending tooling, but it should help you determine if it’s the right option for your business. And as mentioned above, there are many more considerations than what we discussed here. Whether you end up opting for these tools or going with a different approach, keep in mind that the best decision is often the one that suits your specific business needs and budget.
Delahenty Machinery
At Delahenty Machinery, we make the highest quality bending tooling. Our bending tooling creates a better product faster, lowering your manufacturing costs without sacrificing quality. We’ve made it easy to find what you’re looking for with a simple call or click with a wide range of products and an exclusive package design philosophy. Contact us for more details.
Steel plates are used in numerous ways around the world. But did you know steel plates can be bent into intricate shapes? Yes, they can.
Though bending steel plates can seem like a daunting prospect, it is not as difficult as it may appear and is easier to learn than you may imagine.
Here we have five tips to bend steel plates ideally. With these solutions, you will get good help in the steel plate bending process.
Bend the sheet beyond the desired angle
Sheet metal contains a high-bending ability to spring back to its original position. The material should be turned beyond its required angle when bending a sheet.
Is the sheet metal workable enough?
Bending into a sharp corner can break the sheet metal. For that reason, you should avoid this process. Using the steel metal gauge would be best, as not every material would be feasible enough to resist bends into sharp corners.
Always use a press brake.
Press brake provides support and guarantees cleaner sheet metal bending. It continuous pattern across bent sheets. So, always use a press brake where you can.
Do not forget the process position holes.
It would help if you processed position holes on bending parts to guarantee the sheet metal’s precise positioning in the die. This way, you will eliminate the sheet metal moving during the bending process. And make sure actual results across multiple sheet metals.
Bend Allowance
Accounting for bend allowance is vital in knowing how to bend sheet metal. It would guarantee more error-free numbers ensuring perfection in finished products.
Final Note
Steel Plate Bending is one of the most lucrative projects in the construction industry. It has changed the way of measuring success in this business. By bending steel, you have the potential to make a lot of money — provided you know how to do it right.
Before bending steel plates and pipes to your will, it’s essential to understand the basics. First, understand the concept of impact bending, then start the process. This process allows for various tools and techniques and is relatively simple to start working on.
The key to successful Bending is the eliminate tension and increase speed. Through years of hands-on experience and interpretation of the industry’s leading experts, we have learned that these five tips to bending steel plates with different techniques always work in all circumstances.
If you have any questions or concerns regarding steel plate bending, don’t hesitate to contact us directly, and we’ll get you taken care of!
Sheet metal bending is one of the most common operations. You can call it as folding, braking, flanging, die bending, and edging.
Sheet metal bending is when a single flat piece of metal is deformed through force. This force must be applied evenly across the workpiece to achieve a bend. The final result is a permanent change in the shape of the piece. Metal bracelets are just one example of what can be achieved with a simple sheet metal bending process.
But do you know? What are the most common bending methods? How to calculate bend allowance?
We will discuss all these questions in this blog and some bending tips. We would unfold every aspect of sheet metal bending.
Sheet Metal Bending Methods
Whether you have your own company that does lots of bending, or you’re a hobbyist who does it just for fun, you should always be looking for ways to improve the overall quality of your bending projects. It might not have occurred to you before, but there are multiple methods for bending sheet metal. And Each has its advantages. The problem is usually between accuracy or simplicity, while the latter gets more usage.
V-bending method
The V-Bending method is the most common sheet metal bending method. This is because it is the most accessible workable sheet metal that can be usually completed in 2 or 3 steps. In this method, an instrument is a punch, and v-die gets bend sheet metals to a required angle. The bending punch presses on the sheet metal placed over the V-die. After that, The angle formed by the sheet metal depends upon the pressure point of the punch.
V-bending is used for most bending projects. Bending stock material to fit a contour of a pre-existing component is what a v-bend does. This method you can use in automotive fenders, grills, vans, trucks, and RVs.
The V-bending method can be classified into three:
Bottoming
Coining
Air Bending
Roll Bending Process
To bend sheet metals into rolls or curved shapes, you can use roll bending. The method employs a hydraulic press, a press brake, and three rollers to make different bends or a big round bend. This process forms cones, tubes, and hollow shapes.
U-Bending Process
The U-bending process is similar to the V-bending process. It uses the same instrument and method. The only difference is that the result in terms of the shape is U-shaped. U-bending is very famous. Moreover, other methods produce the form flexibly.
Wipe Bending Process
Wipe bending is a sheet metal working process used to create almost flawless bends. It is free of the double scarring found in taper dies. Wipe bending allows the metal shape using just one piece of metal. The wiping dies is possible. It enables the metal to shape and when in operation.
Rotary Bending Process
In the process of bending, scratching is produced by the tool. The rotary Bending Process does not lead to scratching the material’s surface. It is also ideal because it can bend materials into sharp corners. Therefore, it has become a must-know skill in sheet metal work workshops.
Sheet Metal Bending Allowance
So, what is bend allowance? Bend allowance is a manufacturing term that refers to the allocation given to accommodate sheet metal’s stretch and bending.
When sheet metal is bent from its original flat shape, its physical dimensions will change. The force employed to bend the material causes the material to compress and stretch on the inside and outside.
This deformation changes the sheet metal due to the exerted force of compression and stretching on the bend. The length calculated from the bend’s thickness between the inner surface and the exterior remains the same. And we called this a “neutral axis.”
Bend allowance examines the thickness of the bending angle, the method employed, and the K-factor. Bend allowance measures the compression ratio on the inside line of a bend to the tension on the outside of the bend.
Questions you may ask before bending a sheet metal
What is the best sheet metal bending method?
All sheet metal bending modes serves various purposes and produces multiple shapes. So, the best bending method depends on the material’s goal as per shape.
Is sheet metal easy to bend?
Bending steel plates is not that easy. But, with an understanding of the process, it can become manageable. Firstly, you need to understand the methods to use and the tools available. You can go over the article to get familiar with the process.
Conclusion
So that wraps up our discussion of different methods for bending sheet metal. Remember, though, that the correct solution to your particular problem will depend on the type of material you are using and the shape and size of your finished piece. If you have specific questions about these topics, don’t hesitate to contact us or another professional in your area!
We are Delahenty Machinery. We build the machines that build the world!
Kudos to the Team !! Delahenty Machinery are proud of their achievements and time spent in winning the award after being nominated Australian Industrial Businesses Magazine.
We are pleased to announce Delahenty Machinery have been awarded a silver award in the sixth edition of Australian Industrial Businesses Magazine for Bringing the most innovative industrial and manufacturing solutions to valued customers.
This award demonstrates our hard work and dedication to provide top quality customer service, product knowledge and outstanding machinery products. This is another reason why Delahenty Machinery has been growing as a business since 1964.
Moreover, The team from Delahenty machinery are pleased to have been awarded the silver award by Industry inMotion. And thankful too for this great article in Australian Industrial Businesses magazine.
CNC machining is a great way to create parts without relying too much on the workforce. And aluminum is a popular choice of materials for CNC machining due to its density and flexibility. Its popularity has led to various aluminum alloys. It’s always interesting to learn more about the different options available in today’s market.
This article will explain the five most popular aluminum alloys for CNC machining in addition to some details about each alloy and its properties.
Aluminum 6061-T6
At this point, it’s easy to see why 6061-T6 is one of the most popular aluminum alloys on the market and one of the standard grades for CNC machining. It offers a good balance between strength and machinability and tolerances that are typically quite close.
Referred to as an extruded alloy, it is very versatile and easy to machine in the CNC machining industry. Engineers can use this alloy in many applications like chassis, bicycle frames, valves, computer parts, etc.
Aluminum 7075-T6
7075-T6 aluminum, manufacturer uses this alloy in all applications with high-stress or high-performance requirements. This grade is considerably stronger and offers excellent corrosion resistance if appropriately treated. Manufacturers use this alloy in aerospace, military industries, and typical applications include aircraft fittings, missile parts, and fuse parts.
However, there are trade-offs to using aluminum 7075-T6. It is more expensive and less flexible than many other grades of aluminum alloys. And this grade of aluminum is more prone to cracking than different grades and has a lower elasticity.
Aluminum 2024-T4
2024-T4 aluminum is a standard aluminum alloy used in sheet, plate, and extrusions for various applications. This alloy is commonly found in welding electrodes and applications where components must have high purity and strength at elevated temperatures. The primary use for 2024-T4 is as an aerospace material.
Generally, you can use this type of alloy to include aircraft fuselage, transport vehicle parts, and wing tension members. However, it can be attacked by acids, alkalis, or seawater. It also has high thermal conductivity, which means it can be heat treated to form extremely brittle material.
Aluminum MIC 6
It is the best alloy to use to produce Stable and high-tolerance plates. Aluminum MIC 6 has a specific combination of alloy and casting methods, which is why it comes in a unique category.
This metal has higher strength-to-weight ratios, excellent accuracy, good elasticity, and excellent thermal stability while remaining relatively easy to the machine compared with other aluminum alloys.
There is one drawback also of this alloy. MIC 6 threads aren’t as strong, leading to early thread failure. Engineers should keep this limitation in mind during the material selection phase as a manufacturer.
Aluminum 6082
Aluminum 6082 has a higher tensile strength. Further, it’s exceptionally corrosion-resistant. 6082 aluminum alloy is a good option for manufacturers who want more power at an affordable price.
Aluminum 6082 is promising for general-purpose applications that require an added degree of toughness. Aluminum 6082 material is popular in construction and preferable in bridges, towers, and trusses. However, product designers should remember that it’s daunting to get thin walls using aluminum 6082.
Wrapping Up
Aluminum alloys 2024-T4, 7075-T6, and 6082 are best for high-performance applications, while 6061 and MIC 6 can be used in most cases where an all-purpose aluminum will suffice.
If you’re in the market for a CNC machining vendor, we hope that this guide will help you better understand what alloys suit for which applications. These analyses can be helpful to engineers across several industries and regions, helping them make educated decisions on what materials to choose when it comes time to purchase materials for their projects.
Delahenty Machinery
CNC machinery by Delahenty Machinery is the place to go for robust machines that can help your business flourish. Our machines are high-quality, and customer service is our top priority. If it’s time to buy a new CNC machine, check out our latest listings.
Among CNC machining parts, Aluminum is the most common material due to its robustness. However, other materials like steel and brass can also be used for high-quality machining parts. With the heat treatment process, these materials can give excellent results. This blog will explain the merits of different alternatives to Aluminium in CNC machining.
Substitutes of Aluminium Metal
Steel
Pros
Strength
Temperature resistance
Cons
Machinability
Weight
Steel is a carbon- and iron-based alloy used as the primary material in most CNC parts. Steels are a high-strength, low-cost choice for high-stress applications and strong welds. Using CNC machining processes such as turning and milling, it is possible to create parts with exceptional strength.
However, compared with Aluminium, steel is heavier and not as malleable. If temperature resistance is an important consideration and weight is not, steel may be the best alternative to Aluminium.
Titanium
Pros
Strength-to-weight ratio
Cons
Cost
Titanium alloys are used primarily in aerospace reach a high level of resistance, high thermal stability, and strength. This type of metal has an exceptional strength-to-weight ratio. It has twice strong as Aluminium and four times more potent than stainless steel.
Due to its high strength-to-weight ratio, titanium is used in various industries, from aerospace and medical devices to sports equipment. However, the material is so costly if you look at the advantages mentioned above.
Titanium, like Aluminium, is a lightweight metal. It has roughly one-third the density of Aluminium. This makes titanium easier to work with and ideal in situations where strength is not an issue (such as a biaxial orthopedic joint prosthesis), but minimal weight is paramount.
Magnesium
Pros
Machinability
Weight
Cons
Machining safety
Corrosion resistance
Magnesium is a lightweight metal alloy that is also non-ferrous. As with aluminum alloys, magnesium is light, easily cast, and machined. It makes it useful for many purposes, including marine hardware, intake manifolds, and engine casings.
Brass
Pros
Some aesthetic applications
Cons
Cost
Brass is an alloy of copper and zinc which have a golden appearance when polished. It is popular in applications where machining time is an essential factor. Its machinability rate makes it suitable for high-volume orders. As a result, it is prevalent in applications like valves and nozzles.
Copper
Pros
Electrical conductivity
Cons
Machinability
Copper is a malleable, ductile, and highly conductive metal with excellent thermal properties. These copper alloys have been used for more than two centuries in structural applications where both low weight and high strength are required.
Copper is often considered a poor choice for many applications due to challenges in forming and machining. However, several copper alloys offer similar machinability to popular aluminum grades.
POM
Pros
Electrical insulation
Low friction
Cons
Strength
Heat resistance
POM is one of the most exciting materials used in the manufacturing industry. It has a low melting point but has good strength.
POM is an electrical insulator suitable for parts like electronic enclosures. It is also ideal for mechanical parts in high consistency, wear, and abrasive-resistant applications.
However, you can use POM as a like-for-like replacement with Aluminium, where thermal and electrical conductivity has negligible importance.
PTFE
Pros
Electrical insulation
Very low friction
Cons
Strength
PTFE is a widely used engineering plastic. PTFE has excellent chemical resistance and is an electrical insulator. Which makes it a perfect choice for use in industrial processes where exposure to chemicals and high temperatures are common.
During manufacturing, the performance of PTFE is enhanced by adding optional additives throughout the polymer matrix. PTFE is also resistant to high temperatures up to 260°C, making it a viable aluminum alternative for high-temperature applications.
PEEK
Pros
Medical use
Cons
Machinability
Cost
PEEK is more difficult to machine than aluminum alloys. But its thermal stability (up to 260°C) makes it a genuine alternative to Aluminium, with similar mechanical properties and temperature resistance. As a result, it is popular in parts like valves, bearings, pumps, and nozzles testify.
Final Note
We hope you enjoyed reading the above article and that it has helped expand your knowledge of the alternatives to Aluminium when it comes to CNC machining. Whichever material you choose for your CNC machined parts, rest assured that you will have an experienced point of contact to help you prepare, machine, and finish your work.
A press brake tooling is used for bending sheet and plate material that is already formed through pre-punched materials. In the past, engineers needed to operate it manually, but now we have automated specific models. This device is widely used in various industries such as the automobile, aircraft manufacturing, light industry, shipbuilding, containers, elevators, railway vehicles, etc.
The structure of the Press Brake Machine
The press brake machine is a free-standing CNC press with an integral welding processing structure. The working range of the machine is as extensive as it can be. The maximum length of the mainframe can go up to 6000mm or so.
The mechanical outline structure of the Press Brake Machine mainly refers to its upper and lower parts and working mechanism. But also, it relates to its movable slider, which has become a “focus” in recent years. Because of its importance in the production process and functional performance.
The press brake machine’s hydraulic system has a super simple configuration. In this way, you can reduce the pre-installation of the pipeline process to one-fifth. And the maintenance work will become mobile. It is reliable, safe and beautiful.
Types of Press Brake Tooling
There are essentially two categories of press brakes.
Electronic Press Brakes
An electric press brake has a motor directly linked to the bending mechanism, rather than an operator having to switch it on and off. This allows for greater efficiency, mainly when operating a press brake that can make many bends in a single round.
Hydraulic Press Brakes
Hydraulic press brakes rely on oil-filled hydraulic cylinders to operate. They are the most potent mechanical press brakes and are often preferred for more extensive jobs. Because they can quickly cycle even large pieces of material. However, it is worth noting that this machine also tends to use more electricity and oil. And it is less energy efficient.
How Press Brake Tooling Works
Press brake systems are a great way to cut metal. They use rollers and a series of rollers to generate a horizontal force that is about the same as the sheet metal or plate material during manufacture.
The press brake system uses a vacuum to pull on the sheet metal to create multiple points of contact with the metal stock. It helps prevent warping.
A press brake system has a frame supporting the roller, moving side to side as the roller rotates.
A power source drives the rollers and causes them to turn. The material to be bent is fed through the machine.
The pressure on the fuselage is released, causing it to flatten out. And as a result, the material automatically turns into the desired shape.
How to choose a Press Brake Tooling Machine
A small metal-bending machine will do just fine if you’re a beginner. However, if you are looking for a metal press that can handle medium-sized and even high-end metal bending jobs, then you’re going to want to look at more giant metal bending machines. But before you start, keep the below points in your mind.
Base size
The base size of your press brake is essential to consider. For example, the bed length between the two arms is known as the “base length.” Typically, a smaller base is better for working with thinner sheet metal up to 22 gauge (0.036 inches).
Choose a specific model
The primary purpose of purchasing a specific model of sheet metal press is to meet your demand in terms of sheet dimensions, thickness, and material grade. Moreover, you need to pay attention to the material you are using the press brake tool and buy accordingly.
Affordability and Quality check
Press brake tooling price is essential. Because it may decide how long your press brakes will be functional before requiring maintenance or a complete overhaul. Sometimes, old tooling may also cause more damage to the structure of your press brake. So it’s good to go with newly manufactured tooling, which can reduce your maintenance costs in the future.
Strength and Power of Machinery
The press brake tool’s strength is essential to check before buying. Because when a master would say something like “the quality does not match the price”, it will hurt your market presence. Moreover, it is a matter of decisive factor in this product, and Different quality tools have different price tags!
Final Note
Ultimately, purchasing press brake tooling for your business is an investment in your company’s future. There are other bending sheet and plate materials options, but very few of them have the speed and power of a press brake. Therefore, having the proper press brake tooling for your manufacturing business will allow you to achieve its maximum potential.
Delahenty Machinery – Get robust Press Brake Tooling
Delahenty Machinery is the leading provider of press brake tooling in Australia by offering the highest quality, durable and reliable products on the market. When you need high precision, entry-level machining, and material handling at a cost-effective price, there’s no better place to go. Contact us for more details.
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