Manual pneumatic wire bending press. Wire bending: manually and on wire bending machines

There are several known techniques for bending the wire. The most common option is to manually fold these parts. Within the framework of industrial production the manual method is not cost effective and has numerous costs. In production, various options for wire bending machines are used.

Types of wire bending machines

Depending on the technology, there are several types of wire machines:

• making parts from the coil;
• bending from a metal bar;
• bending in a rolling way;
• bending by the way of pushing;
• machines with cnc.

Coil wire machines

The specified type of unit is used for serial production. Such wire bending machines have high productivity and economy in comparison with others.

The wire manufacturing process goes through several stages:

• the unwinder is taken;
• a bay with a wire is fixed in it;
• two mechanisms act on the wire at once, one of which is flat, the other is roller;
• the wire becomes a straight rod;
• a straight wire rod is placed in the bending section of the machine;
• the output is a part that has the desired shape;
• the finished product is cut with special mechanical shears.

Similar is able to release only certain kind finished product... This is due to the presence in it of devices pre-configured for the manufacture of parts having a certain shape.

The units produce parts that are simple in shape and do not offer a wide variety of them. The number of bending operations on such machines is limited to five.

Metal bar wire bending machines

The specified device is considered more technological than the previous one. The machine carries out additional processing of the finished product, which is not done by the unit from the coil.

The device allows you to make punching and threading on wire products.

This type of machine has two main disadvantages:

• has a low performance;
• requires the installation of an auxiliary workpiece feeding device, which is characterized by a complex design.

Roll-in bending devices

Devices of this type are intended for the manufacture of round parts. The wire feed on the machine is carried out on a shaft with a predetermined radius. The feed is carried out by means of guide rollers. A rotational movement of the shaft is created, the result is the wire bending around the finger several times.

The device allows you to adjust the spring step and the angle of bending of the part. This is ensured by the position of the roll-in rollers in relation to the shaft.

The manual machine for bending makes only one type of product. To change the type and shape of the manufactured products, a preliminary replacement of the bending devices will be required. It will be necessary to carry out commissioning work.

Push-through units

The pushing method is used for a wire that needs to be shaped into a complex geometric shape.

The pushing procedure is based on the forward movement of the metal material through the roll forming device. The preset shape of the part is given by rolling rollers. A spring coiling device can be used instead of a roll forming machine.

The equipment on which it is possible to bend wire in this way is complex and requires special knowledge.

Numerical control devices

Progress in machine-tool construction allowed the introduction of CNC units, with the help of which it became possible to bend wire.

The machines produce 2D-shaped parts and 3D-shaped products. The machine tools are controlled by an industrial computer. Thanks to the computer, it is possible to rotate the bending arms in three-dimensional space in any sequence.

CNC units have high labor productivity. If it is necessary to change the form and type of products, you just need to change them on the computer.

DIY options for bending wire materials

For bending, it is sometimes enough to use the tools at hand. Much depends on the thickness of the material used.

For bending products with your own hands with a diameter of up to 3 mm, suitable:

• locksmith vice;
• pliers;
• round nose pliers.

The material is cut with side cutters or ordinary nippers.

Products with a large diameter will require the use of a hand-made device. The assembly of the machine is carried out in stages:

1. a 19 cm long steel corner is screwed to the table with bolts;
2. a frame is made of a metal plate, holes are drilled in it;
3. a frame with guide rollers and handles is screwed to the corner;
4. a metal bar is selected to the bed groove;
5. several through and blind holes are made in the bar;
6. a handle and a grooved roller are bolted to the bar;
7. plates are welded at the bottom of the bed;
8. the bar is inserted into the bed groove so that it slides in it and does not fall out;
9. guide rollers are screwed in;
10. bar construction is screwed to the corner.

A self-made mechanism will make it possible to make products of a more complex configuration.

Wire bending machinesIs the equipment that allows bending the wire in automatic mode. Such devices are equipped with three servo drives, which feed the wire, as well as carry out turns and are responsible for the bending process. All this leads to high efficiency rates, a decrease in operating noise and high bending accuracy rates, an error of ± 0.05 °. They can bend the wire using the push method. This method is relevant for the production of spirals.

Automatic wire bending machines model line CHR-3A are machines that work in automatic mode. They produce products with very high precision, the speed of the process is also at the appropriate level.

The unit is completed with a wire bending machine and a wire unwinder. The CNC is equipped with a simple and very intuitive interface. All tasks and parameters are displayed on a 15-inch display.

Wire bending machine parameters

1. CNC based on a computer with individual software developed specifically for Windows XP.
2. It is possible to save bending programs on a 160 GB hard drive. This amount of memory can accommodate up to 4 million bending programs, and if necessary, you can use an external hard drive for storage.
3. The presence of a touch screen, which greatly facilitates the work.
4. CNC provides several options for work. Thus, in manual mode, each machine drive operates independently by pressing a key. In the learning mode, all operations performed by the operator are memorized. In semi-automatic mode, all processes are carried out in stages. Automatic mode provides for continuous execution of operations according to the CNC.
5. It is possible to regulate the speed of all drives.
6. There is a self-diagnostic system capable of displaying the errors that have occurred on the monitor.

In our catalog you can choose the most the best option... You can buy a wire bending machine in Moscow by contacting representatives of our company. Our staff will quickly and efficiently select the option you need.

Flat wire bending machines find wide application from manufacturers shop equipment. The wire is fed from the coil, passes through the straightening block and is fed to the bending arm, where the product is bent according to a given CNC program. At the end of the bending process, the part is cut with a guillotine. All operations are performed fully automatically. The machines have ample opportunities for the manufacture of flat products of any complexity: rings, frames, various open and closed contours, flat spirals. To obtain a spatial product, many customers use a press, thus, having a high productivity in the production of flat products on a wire bending machine, the workpiece is placed under the press for spatial bending, which ensures high productivity and good repeatability of the resulting wire product.

have a patented non-flatness compensation system. It is relevant for domestic wire, which, when unwinding from the coil, retains internal stresses, the geometry of the product "twists" and it turns out not flat (which in 3D machines is usually compensated by turning the console). In UME bending machines, the mechanical ability to adjust the "reverse twisting" of the wire is realized, as a result of which an absolutely flat product can be obtained, without adjusting the bending tool or NC program.

UME series wire bending machines have a turntable, so the operator can adjust a convenient angle of the table (for example, more vertical or more horizontal), in accordance with the geometry of the product.

UME series wire bending machines very easy to operate and reliable. The CNC of the well-known company B&R (England) allows programming bending modes, there is the possibility of programming a batch of products, where several products are sequentially executed one after another. Both bending and pushing are programmable, with the transition from radius to radius.

Wire bending machine, model UME-40. Wire bending is made from a coil. The machines are most popular with manufacturers of shop equipment and POS products. Wire bending is carried out according to the CNC program. Distinctive feature- high productivity, as well as an inexpensive price of the machine and tool. Maximum standard size frames 600x600mm.

Wire bending machine, model UME-65. The wire is unwound from the coil, passes through the correct block and enters the bending and cutting unit. All operations are performed using the CNC program. The machines are most popular with manufacturers of shop equipment and POS products. A distinctive feature is high performance, as well as an inexpensive price for bending equipment and tools. The maximum standard frame size is 600x600mm.

Wire bending machine, model UME-80. The wire is unwound from the coil, passes through the correct block and goes to the bending and cutting unit. All operations are performed using the CNC program. The machines are used for the manufacture of flat wire products of various shapes, both with small radii and with large (variable) ones. A distinctive feature of the machine is its high productivity, as well as an inexpensive price for tools and equipment. The maximum standard frame size is 1000x1000mm.

Wire bending, carried out both manually and with the help of various tools and special equipment, allows you to give products from this material in various configurations. During the bending process, the inner layer of the wire is compressed, and the outer layer is stretched. Wire bending machines, which today are presented in a wide variety of models, are very popular, since bent wire products are actively used to solve various industrial and household tasks.

In order to carry out bending operations at home without any problems, it is best to choose a wire made of soft materials. It is possible to carry out simple bending of a more rigid wire, if necessary, using ordinary locksmith tools:

• pliers (with the help of such a tool that every home craftsman has, you can form a simple bend of the wire, and also reliably fix its segment for further processing);
• pliers (using this tool, which is one of the varieties of pliers, you can perform bending of varying degrees of difficulty);
• nippers, or needle-nose pliers (using such a tool, the wire can be cut into pieces of the required length).

If, using the bending method, it is necessary to make a product of a complex configuration from wire, it is better to first draw it on paper and periodically check the sketch. For the formation of the simplest shapes, such a sketch can be omitted. For example, if you need to create a bent rectangular product, you can do this as follows:

• The wire in the place of its future bend is clamped in a locksmith's vice.
• The upper (not clamped) part of the wire is bent with ordinary pliers or a hammer.

As a result of this simple procedure, a right-angle bend is formed on the surface of the wire.

Manual bending rules

If you are going to bend the wire by hand, there are a number of guidelines you must follow that will allow you to perform this procedure without harm to your own health.

1. All bending procedures should be carried out only with gloves made of dense fabric.
2. The wire that is being bent must be fixed in a vice as securely as possible so that it does not jump out during operation.
3. All tools and equipment that you are going to use for work must be serviceable and efficiently perform the functions assigned to them.
4. Heavy tools and fixtures that you use when bending should not be placed on the edge of the worktable, so as not to accidentally hit them and do not drop them on your feet.
5. Carrying out all the manipulations with the wire bending tool with one hand, the other should be kept as far as possible from the place of the future bend. Pliers and any other tool can break off and injure a hand close to the bending site.

It is possible to bend the wire using available tools only in small volumes, since such a procedure is quite laborious. In addition, this operation can only be used to create products of the simplest configuration.

A specialized wire bending machine allows to produce in large volumes various products, including those with complex shapes.

Working with a wire bending machine

For the manufacture of wire from a large number of bent products can be used various techniques, for the implementation of each of which special equipment is used. The most common and economical method is coiled bending.

Bending using this technology takes place in several stages.

1. The wire, which is wound on coils, is fed to a two-plane roller machine, which performs its alignment.
2. After alignment, the wire is fed to the wire bending machine, on which the product of the required configuration is formed.
3. The formed product is cut off, and the entire bending cycle is repeated anew.

The use of this technology makes it possible to fully automate the bending process and thereby achieve its high productivity.

A wire bending machine can also look like a stationary template around which the wire is rolled using movable pressure rollers. Using such devices, bends of even the smallest radius, the size of which is comparable to the outer diameter of the workpiece, can be formed on the surface of the wire. In this case, the configuration of the product formed on such a machine can be quite complex.

The wire bending machine can also work on the principle of pushing the workpiece through the roller system. When using such equipment, the end of the wire is connected to a special wire, which pulls the product through the working bodies of the machine. A wire bending machine of this type, due to the peculiarities of its design, makes it possible to manufacture products that differ even in a very complex shape.

When aligning the wire, a wire bending machine is also used, which in this case used for straightening. The working bodies of such equipment can be correct frames or two-plane correct blocks. At the same time, rotating regular frames are distinguished by a higher efficiency, which is why they are used in cases when the leveling of the wire surface must be performed as smoothly and efficiently as possible.

Types of professional equipment

Most simple type professional equipment, on which wire bending is performed, are machines with one console. Meanwhile, such devices can only produce products of simple geometrical shape, the sweep length of which does not exceed 1000 mm.

Items of various configurations and purposes can be made from wire. During work, it is important to bend the material correctly, therefore, if the diameter of the metal thread is more than 1 mm, it is advisable to use special devices.

The main types of this type of tools, as well as how to make a do-it-yourself wire bending machine, will be discussed in this article.

If it is necessary to perform a small amount of work, then manual devices are used to bend the wire. For bending soft metal material or when the wire diameter does not exceed 3 mm, pliers or round nose pliers are used. These tools allow you to reliably clamp a part of the product in one tool, and with the help of another, bend the wire to the desired angle.

In this way, you can bend the material with the help of a joiner's vise. In this case, the wire is fixed in a vertical position, and the change of direction is also carried out using pliers or any other clamping device or mechanism.

If it is necessary to perform a round bend, then for this purpose any rod of suitable diameter is used, which is also clamped in a vice. A round bend will need to be made when self-production springs made of elastic wire.

To do this, it is enough to clamp a rod or pipe of a suitable diameter in a vice, fix the end of the wire on one side, and use the pliers to wind the wire for the required number of turns.

If the wire has to be bent too often, then the most correct solution would be to purchase special devices or machines.

Tools for bending this material are a design in which the wire is clamped and bent by human muscle strength. In machine tools, as a rule, it is used electric drives, and for the manufacture of complex products, such machines are equipped with electronic control.

Rules for work

Wire bending is not a complicated process, but for effective work with this material, you must adhere to the following rules:

1. For work it is necessary to use gloves made of thick fabric.
2. Use only serviceable tools and automatic machines.
3. If a vice is used to perform this operation, then before starting the process, you must make sure that the workpiece is securely fixed.
4. Align the workpiece before making a bend.

Following these recommendations will prevent marriage and injury in the event of a sudden release of material from the holding device. You should also take care of the serviceability of the wiring and proper grounding when using machines that run on electricity.

Equipment use

If the amount of work is large enough, then perform a large number of operations will be allowed by equipment equipped with an electric motor. The use of machine tools will significantly increase labor productivity, but by initial stage it will take some effort to learn how the wire bending machine works.

The most economical wire bending machine is considered to be coiled equipment, in which material is fed from bulk coils.

The process of wire bending on such equipment is carried out in the following order:

1. The wire from the coil is fed to the roller mechanism, which realizes the leveling of the material.
2. The aligned wire is fed to the bending mechanism.
3. The next stage is the bending and separation of the wire products.
4. After cutting the finished product, the process is repeated.

To make the work of bending the wire as comfortable as possible, CNC machines are used.

Despite the significant cost of such equipment, the return on investment in a business is made within a few months. Machines equipped with a microprocessor allow not only fully automating the process, but also welding curved products.

DIY adaptation

If the wire bending device will be used only for homework, then you can make a manual machine yourself. Self-made equipment will not be distinguished by high productivity, but such a product will be quite enough for performing daily operations in a small volume.

For a homemade machine, you will need to prepare the following materials:

1. Sheet steel 4 mm.
2. Steel bar 20 mm.
3. Profile pipe 20 * 20 mm and 30 * 30 mm.
4. Two nuts 12 mm.
5. Steel pipe ¾.
6. Bolt 12 * 70 mm.
7. Bushing with jet thrust of the car VAZ 2106.

Also, to complete this work, you will need to prepare tools:

• drill and 20 mm.

A do-it-yourself device for bending wire is made in the following sequence:

1. A rectangle with a size of 150 * 80 mm is cut from a steel sheet with a grinder.
2. Having stepped back from the side of shorter length about 30 mm, it is necessary to make a hole with a diameter of 20 mm exactly in the middle.
3. Cut a piece 45 mm long from the metal bar.
4. Install a piece of bar in the hole made earlier and weld it on the back.
5. Cut a 70 * 30 mm rectangle out of a metal sheet.
6. Make two holes with a diameter of 16 mm in the 70 * 30 mm plate. The holes should be equidistant from the edges of the plate, and the distance between them should be equal to 20 mm.
7. Weld 70 * 30 mm M12 nuts to the plate so that they align with the previously made holes. In order to perfectly center the nuts before welding, it is recommended to press on the bolt, which should be threaded into the hole.
8. From steel pipe¾ cut off a piece with a length of 45 mm.
9. Weld a 70 * 30 mm plate to the resulting cylinder from a metal pipe, so that the pipe hole is in the same row with the previously drilled 16 mm holes. When doing this work, the plate should be placed exactly in the middle of the height of the steel cylinder.
10. Cut a piece with a length of 400 mm from the profile pipe 30 * 30 mm.
11. Weld a section of a shaped pipe to a steel plate 70 * 30 mm. The metal is joined from the side opposite to the welded cylinder. This will create a lever with a cylinder and 2 holes at the end.
12. A piece with a length of 100 mm is cut from a profile pipe 20 * 20 mm.
13. A section of a profile pipe is welded to the edge of the plate 150 * 80 mm. It is necessary to position this element from one of the corners to the level of the previously welded metal bar.
14. Cut a 70 * 40 mm plate from a metal sheet. This part will be designed to stop the workpiece, so it must also be welded to the section of the shaped pipe.
15. The tie rod bushing is put on a 12 mm bolt, which must then be screwed into a nut welded to the lever.
16. The lever with the sleeve is put on by the cylinder on a piece of metal rod welded to the bed.
17. To securely fix the machine during operation, it is recommended to fix the bed on a flat horizontal surface using threaded connections or welding.

Wire bending is carried out as follows:

1. The workpiece is placed on the side platform in such a way that the front part is inserted into the gap between the central cylinder and the sleeve fixed to the lever.
2. The lever is rotated to the required angle.
3. The workpiece is removed from the machine, cut off and used for its intended purpose.

If homemade machine was made of quality materials and welds are made at a professional level, the device can be used not only for processing wire. In this case, it is possible to use the product for bending pipes, including profile ones, with a diameter of up to 10 mm.

Useful video

Watch a video where a person shows how to assemble a simple reinforcing bender structure for bending bars and a square: