Sheet metal folding, also known as metal bending or metal forming, is a manufacturing process that involves bending or folding a sheet of metal to create desired shapes, angles, or geometries. This process is typically performed using a machine called a press brake.

Here is an overview of the sheet metal folding process:

1.Set-up: The operator prepares the press brake machine by selecting the appropriate tooling, such as a "V" shaped die and a matching punch. The tooling determines the angle and shape of the bend.

2.Material positioning: The sheet metal is positioned on the press brake, typically resting on a bed with adjustable back gauges that ensure accurate placement and alignment.

3.Clamping: Clamps or other holding devices secure the sheet metal in place, preventing it from moving during the bending process.

4.Bending: The press brake applies downward force to the sheet metal, forcing it to bend. The bending occurs at the point where the punch and die meet, creating a desired angle or fold. The angle and depth of the bend are determined by the shape of the punch and die, as well as the amount of pressure applied.

5.Repeat steps: If multiple bends or folds are required in the sheet metal, the operator follows the same process for each bend, repositioning and reclamping as necessary.

6.Inspection: The operator checks the accuracy and quality of the folded metal, ensuring it meets the specified dimensions and tolerances.

Sheet metal folding offers design flexibility and versatility, allowing for the creation of various shapes, angles, and geometries. It is commonly used in industries such as automotive, aerospace, construction, and electronics to manufacture components and products such as brackets, enclosures, panels, and frames.​​​​​​​

The sheet metal folding process involves several stages, including preparation, programming, machine set-up, folding, and inspection. Here is a general overview of the process:

1.Design and Programming: The design team examines the requirements of the product and determines the best method for folding the sheet metal. They take into account factors such as the desired shape, dimensions, material thickness, and bend angles. They then create a program using computer-aided design (CAD) or computer-aided manufacturing (CAM) software to guide the folding machine.

2.Material Preparation: The sheet metal, typically in the form of flat sheets or blanks, is prepared by cutting it to the required size and shape. Any necessary punching, drilling, or other operations may also be performed at this stage.

3.Machine Set-up: The folding machine, such as a press brake, is prepared for the folding process. This involves selecting the appropriate tooling, such as the die and punch, based on the desired bend angles, sheet metal thickness, and material type. The machine's back gauges and other positioning mechanisms are set up to ensure accurate placement of the sheet metal.

4.Folding Process: The programmed instructions are loaded into the folding machine's control system. The operator positions the sheet metal onto the machine's bed and aligns it according to the programmed specifications. The machine clamps the sheet metal securely in place to prevent movement during the folding process. The machine's ram then applies downward force onto the sheet metal, pressing it against the die to create the desired bends or folds.

5.Inspection and Quality Control: Once the folding process is complete, the folded product is inspected for accuracy, quality, and adherence to specifications. Measurements may be taken to ensure that the bend angles, dimensions, and overall shape of the product meet the required standards. Any necessary adjustments or corrections can be made at this stage.

6.Post-processing: Depending on the specific requirements of the product, additional processes such as welding, deburring, or surface finishing may be performed after the sheet metal folding process.

The above steps may vary depending on the complexity of the product, the type of folding machine used, and the specific requirements of the project. Throughout the process, experienced operators and quality control measures are employed to ensure precise and consistent results.​​​​​​​

Materials that can be CNC folded include:

1.Mild Steel: This is a common type of steel with low carbon content, making it relatively easy to bend and form.

2.Coated Steels: These are steels that have been coated with protective layers such as galvanized or powder coating. The folding process can be performed without damaging the coating.

3.Stainless Steel: This is a corrosion-resistant steel that is commonly used in industries requiring high durability and hygiene. It can be folded, but the process may require higher pressure and specialized tooling.

4.Aluminium: Known for its lightweight and corrosion-resistant properties, aluminium is commonly used in various applications and can be readily CNC folded.

5.Alloys: Various alloy materials, such as brass, copper, and bronze, can also be CNC folded. The folding process for alloys may require specific tooling and parameters according to the properties of the specific alloy.

It's worth noting that the thickness and dimensions of the material can vary depending on the specific capabilities of the CNC folding equipment. It is always recommended to consult with the manufacturer or service provider to ensure that the desired material and dimensions can be accommodated in the CNC folding process.​​​​​​​