Library Bending Technology

Technical information
Bending Technology
Technical information
Bending Technology
Edition: 05/2007
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for possible mistakes in this documentation. Any warranty for direct and
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documentation, is excluded, as far as this is in conformity with the law.
Before You proceed...
Contents This Technical information brochure "Bending Technology"

provides a quick overview of the essentials of bending.
After a brief outline of the TruBend Series 5000, the individual sub-
assemblies of the press brake are described in greater detail. This
is followed by explanations on the technology of bending (bending
methods and calculations) and of the TRUMPF tooling system;
attention is also paid to the ACB® angle sensor. Information
concerning materials and tips and tricks from daily practice round
off the topics discussed.
A list of key words provided at the end of this document makes it
easier to find specific information more quickly.
T488EN00.DOC Before You proceed... 0-5

Table of Contents
Chapter 1 Machine technology TruBend Series 5000
1. Machine concept............................................................ 1-3
2. Technical data................................................................ 1-4

2.1 Axes of the TruBend Series 5000.................................... 1-6
3. Sub-assemblies ............................................................. 1-7

3.1 Machine frame ................................................................. 1-8
3.2 Ram and downstroking drive ......................................... 1-10
3.3 Bed with crowning.......................................................... 1-11
3.4 Tool holder..................................................................... 1-13
Lower tool adjustment, I axis .................................... 1-14
Lower tool adjustment by example of
„Flattening“................................................................ 1-15
CNC-controlled lower tool adjustment (Option)........ 1-18
Bending aid (optional)............................................... 1-19
3.5 TASC 6000 control ........................................................ 1-22
Control panel ............................................................ 1-23
Operating station ...................................................... 1-24
Additional footswitch................................................. 1-25
4. Backgauge.................................................................... 1-26
4.1 Backgauge axis system ................................................. 1-29
4.2 Technical data: Backgauge ........................................... 1-31
4.3 Stop fingers and stop positions ..................................... 1-33
Micrometer stop fingers (Option) .............................. 1-35
5. TRUMPF BendGuard ................................................... 1-36
Chapter 2 Technology (Application technology)
1. Bending methods: Overview ........................................ 2-3

1.1 Air bending....................................................................... 2-3
1.2 Coining............................................................................. 2-5
0-6 Table of Contents T488EN00.DOC

1.3 Hemming.......................................................................... 2-7
1.4 Flattening ......................................................................... 2-8
1.5 Sensor bending................................................................ 2-9
Overview: Sensor bending ....................................... 2-13
Learned bend............................................................ 2-13
2. Calculations ................................................................. 2-14

2.1 Press tonnage................................................................ 2-14
2.2 Box height ...................................................................... 2-17
2.3 Inside radius .................................................................. 2-19
2.4 Selecting the die width................................................... 2-21
2.5 Shortest flange length.................................................... 2-23
2.6 Flat length ...................................................................... 2-26
Calculating the flat length in case of large bend
radii ........................................................................... 2-27
Calculating the flat length in case of small bend
radii ........................................................................... 2-29
Use of the compensation value in the machine
controller ................................................................... 2-33
2.7 Minimum distances and lengths .................................... 2-34
2.8 Different bending flange shapes.................................... 2-35
Chapter 3 Tool system
1. Terminology ................................................................... 3-2
2. Tools from TRUMPF ...................................................... 3-3

2.1 Tool identification............................................................. 3-3
2.2 Upper tools ...................................................................... 3-4
2.3 Lower tools ...................................................................... 3-6
Die width ..................................................................... 3-6
Opening angle ............................................................ 3-7
2.4 Tools for thin sheets ...................................................... 3-11
2.5 System segmentation of tools ....................................... 3-13
3. Laser hardening........................................................... 3-15
4. Imprint-free bending.................................................... 3-16
5. Special tools................................................................. 3-18
T488EN00.DOC Table of Contents 0-7

Chapter 4 Index
0-8 Table of Contents T488EN00.DOC

Chapter 1
Machine technology
TruBend Series 5000
1. Machine concept............................................................ 1-3
2. Technical data................................................................ 1-4

2.1 Axes of the TruBend Series 5000.................................... 1-6
3. Sub-assemblies ............................................................. 1-7

3.1 Machine frame ................................................................. 1-8
3.2 Ram and downstroking drive ......................................... 1-10
3.3 Bed with crowning.......................................................... 1-11
3.4 Tool holder..................................................................... 1-13
Lower tool adjustment, I axis .................................... 1-14
„Flattening“................................................................ 1-15
CNC-controlled lower tool adjustment (Option)........ 1-18
Bending aid (optional)............................................... 1-19
3.5 TASC 6000 control ........................................................ 1-22
Control panel ............................................................ 1-23
Operating station ...................................................... 1-24
Additional footswitch................................................. 1-25
T488EN01.DOC Machine technology TruBend Series 5000 1-1

4. Backgauge.................................................................... 1-26
4.1 Backgauge axis system ................................................. 1-29
4.2 Technical data: Backgauge ........................................... 1-31
4.3 Stop fingers and stop positions ..................................... 1-33
Micrometer stop fingers (Option) .............................. 1-35
5. TRUMPF BendGuard ................................................... 1-36
1-2 Machine technology TruBend Series 5000 T488EN01.DOC

1. Machine concept
Die TruBend Series 5000 comprises CNC-controlled press brakes

for bending flat metal workpieces.
The machines are designed for a great variety of bending tasks

and are distinguished by the following features:
• CNC backgauge system.
• Downstroking drive with two tandem cylinders.
• Lower tool adjustment (hemming without tool change).
• Self-centering tool holder.
• Quick and easy operation and programming.
• High level of work safety.
• Defined tilt of the ram.
• Automatic crowning.
T488EN01.DOC Machine concept 1-3

2. Technical data
C
D
Machine layout Fig. 44112
TruBend 5050 5085 5085 S 5130

Tonnage [kN] 500 850 850 1300
Machine dimensions Bending length (A) [mm] 1275 2210 2720 3230
Width between columns (B) [mm] 1040 1750 2260 2690
Throat (C) [mm] 420 420 420 420
Bed width [mm] 100 120 120 120
Open height (die space) (D) [mm] 385 385 (615) 385 (615) 385 (615)
Working height with 100 mm
[mm] 1050 1050 1050 1050
lower tool (E)
Speeds
Y rapid down speed [mm/s] 220 220 220 220
Y axis
Y press speed [mm/s] 0.1 - 10 0.1 - 10 0.1 - 10 0.1 - 10
Y rapid up speed [mm/s] 220 220 220 220
Y axis (ram) Stroke [mm] 215 215 (445) 215 (445) 215 (445)
Ram positioning
[mm] 0.005 0.005 0.005 0.005
accuracy
Ram tilt [mm] ±10 ±10 ±10 ±10
The values in brackets apply to enlarged versions (options) Tab. 1-1
1-4 Technical data T488EN01.DOC

TruBend 5170 5170 S 5230 5230 S 5320
Tonnage [kN] 1700 1700 2300 2300 3200
Machine dimensions Bending length (A) [mm] 3230 4250 3230 4250 4420
Width between columns (B) [mm] 2690 3680 3690 3680 3680
Throat (C) [mm] 420 420 420 420 420
Bed width [mm] 120 180 180 180 200
Open height (die space) (D) [mm] 615 615 615 615 615
Working height with 100 mm
[mm] 1050 1050 1050 1050 1050
lower tool (E)
Speeds
Y rapid down speed [mm/s] 220 220 220 220 220
Y axis
Y press speed [mm/s] 0.1 - 10 0.1 - 10 0.1 - 10 0.1 - 10 0.1 - 10
Y rapid up speed [mm/s] 220 220 220 220 220
Y axis (ram) Stroke [mm] 445 445 445 445 445
Ram positioning
[mm] 0.005 0.005 0.005 0.005 0.005
accuracy
Ram tilt [mm] ±10 ±10 ±10 ±10 ±10
Tab. 1-2
T488EN01.DOC Technical data 1-5

2.1 Axes of the TruBend Series 5000
Y2
Y1
X2
X1
R2 Z2
R1 Z1
V
I
Axes of the TruBend Series 5000 Fig. 38803
Axis Description TruBend 5050 TruBend 5085 – 5320

I axis Lower tool adjustment Pneumatic or Pneumatic or
(forward and back) CNC controlled* CNC controlled*
R axis Height adjustment of stop CNC controlled CNC controlled
fingers
V axis Crowning Not available Manual or
CNC controlled*
X axis Backgauge travel CNC controlled CNC controlled
and stop fingers forward
and back
Y axis Ram motion and ram tilt CNC controlled CNC controlled
Z axis Stop finger travel (left and Manual or Manual or
right) CNC controlled* CNC controlled*
Bending aid (BH1/BH2)* Workpiece support Not available CNC controlled
*Options Tab. 1-3
1-6 Technical data T488EN01.DOC

3. Sub-assemblies
5
2
6
3
4 7
8
10
1 Y drive and hydraulics 5 Hydraulic cylinder 9 Machine body

2 Control panel 6 Ram 10 Operating station
3 Upper tool clamp 7 TRUMPF BendGuard
4 Backgauge 8 Lower tool clamp
Sub-assemblies, TruBend Series 5000 machine Fig. 44068
T488EN01.DOC Sub-assemblies 1-7

3.1 Machine frame
The machine frame is a C-frame comprising two side frames

(housings), the bed and connection support.
The pressure cylinders and the ram are mounted on the upper part
of the C-frame. Due to this arrangement, the C-frame spreads
apart during the bending process (C-frame deflection).
This inevitable physical principle is compensated for by the control
(deflection compensation). There is therefore no negative impact
on the bending results.
Frame deflection
Y Ist > Y Soll
Reaktio Aktio
Y Ist
Soll
Y
Frame deflection Fig. 32203
• The press force acts upon the machine bed during the bending
process (action).
• This leads to a counter-force arising in the C-frame of the side
housings (reaction).
• Deflection occurs, despite the robust construction of the side
housings. This is the reason why the upper tool penetrates less
deeply into the lower tool than the hydraulic cylinders travel on
the stroke.
1-8 Sub-assemblies T488EN01.DOC

Deflection compensation On the TruBend 5050 – 5320, C-frame deflection is compensated
for by the machine control.
Two machine parameters are available for deflection
compensation:
• The compensation value [bar], with which the counter-pressure
is compensated.
• The deflection constant [µm/bar], with which the pressure-
dependent deflection is equalized.
These machine parameters can be checked or adapted at any time
using a service program.

3.2 Ram and downstroking drive
The ram is guided by means of adjustable cam followers. The ram

is highly rigid and is spherically suspended, allowing it to be tilted.
The downstroking drive is an electro-hydraulic drive featuring two

tandem cylinders (left / right) each. The cylinders are controlled by
means of proportional valves.
Features:
• Exact synchronous motion of both cylinders pairs (Y1/Y2).
• Long service life of the guides and sealing elements.
• High positioning accuracy of the ram. The machine is equipped
with an incremental path measurement system.
1 2
1 Control block on cylinder pair Y1 3 Pump block

2 Control block on cylinder pair Y2
Ram and downstroking drive Fig. 43679
ACB busbar Embedded at the front of the ram is a busbar (CAN bus) for
connecting the modules of the ACB angle sensor.

3.3 Bed with crowning
Machine bed The bed, or press table, is parallel and at right angles to the
mounting surfaces of the hydraulic cylinders and the guideways of
the backgauge. It has a milled surface for the crowning motor.
A movable wedge plate and the lower tool holder are mounted
above the crowning motor.
Force distribution Under load, the ram, with the two hydraulic cylinder axes Y1 and
during bending Y2, acts like a beam on two supports. Despite the high moment of
resistance, the ram bows under load, i.e. during the bending
process.
Directly beneath the hydraulic cylinders, therefore, the upper tool
plunges deeper into the die than it does at ram center.
This effect varies with the length of the bend and the press
tonnage. As a result, ram deflection increases with higher
tonnages and longer bends.
Without crowning With crowning
Y1 Y2 Y1 Y2
1 Crowning --- Deformation

Fig. 32205, 32206

Purpose of crowning Crowning refers to the calculated and mechanically adjusted
curvature of the machine bed. Crowning provides for parallelism
between the ram and the bed (press table).
Since the press tonnage, the distance between cylinder pairs Y1
and Y2, the geometry and the material properties of the ram, and
thus the resistance moment, are known, the expected bowing can
be calculated.
Bowing is the vertical deviation from the horizontal bending line.
This deviation is compensated for by crowning (V axis).
90° 90°
> 90° 90°
90° 90°
Bending results with/without crowning Fig. 32207
Crowning The crowning mechanism consists of two wedge plates milled in a

wave pattern. The lower tool holder is mounted on the upper
wedge plate. The lower wedge plate is worked (milled) directly into
the bed.
The gradient angle of these wedge plates increases towards the
center.
The curvature (crowning value) in the bed needed to compensate
for the bowing of the ram is achieved by shifting the upper wedge
plate horizontally.
Adjustment takes place manually or CNC-controlled via the gear
motors integrated in the bed.
α1 α2 α3 α4 α4 α3 α2 α1
α1 < α2 < α3 < α4

X
X Bowing
Principle of crowning Fig. 51623

3.4 Tool holder
The tool holder is suitable for the use of head and shoulder-bearing
tools. The press force is evenly transferred through the tool to the
workpiece, even in case of large tool heights or lateral forces (e.g.
in hemming). Angle accuracy is not affected.
The upper and lower tool holders are machined and aligned in
such a way that the upper and lower tools are automatically
centered after clamping.
Head-bearing In the case of head-bearing tools, the punch butts against the
inside of the upper tool holder.
Shoulder-bearing In the case of shoulder-bearing tools, the punch butts against the
outside of the upper tool holder.
Shoulder-bearing tool Head-bearing tool
Tool types Fig. 35647, 35648
Upper tool holder Lower tool holder

Modufix clamping Clamping via short-stroke cylinder
Hydraulic clamping
Tools can be used in reverse
Clamping pressure: 50 bar
Tab. 1-4

Lower tool adjustment, I axis
The lower tool holder is mounted on the machine bed in such a

way that it can be shifted in X direction.
This adjustment is performed using pneumatic cylinders. The end
positions (fixed stops) are defined by means of various spacers
which are adapted to the widths of the lower tools.
The position of the adjustment path in front of or behind the lower
tool is set by means of the pivoting element.
Lower tool adjustment enables:
• Hemming (flattening) without tool change.
• Positioning of special dies.
• Station operation with tools of different heights.
• Work with lower tool adapters (e.g. two lower tools).
• Production of Z-bends with tool holder systems.
• Facilitates removal of complex parts.
1 2 3 1
1 Fixation of adjustment path, 3 Pivoting element for position

cannot be modified of the adjustment path
2 Spacer for the length of the
adjustment path
I axis Fig. 29259

„Flattening“
Program-controlled adjustment of the lower tool holder to fixed

stop.
Two positions:
Flattening in rear tool position: Flattening in rear tool position Flattening in front tool position:
(without punch support):
I axis is at the front. I axis is at the front. I axis is at the rear.

Flatting at front and rear Fig. 43700
The fixed stop depends on the tool width of a 30° lower tool. The
following spacers are available for this:
Die widths Spacers

W6, W8, W10 30 mm
W12 27.5 mm
W16 25 mm
W20 22.5 mm
W24 1 20 mm
Tab. 1-5
In addition to this, specially configured spacers are also available

for special dies.
1
The spacer for die width W24 is also suited for lower tool holder EV70 (holder
for Z inserts).

Flattening at the front Prerequisite
• The pivoting element butts against the rear fixed stop.
• Appropriate spacer for lower tool has been loaded at the front.
Fig. 29860
1. Bend to an angle of 30°.

I axis is located in the front position.
Fig. 29861
2. Flatten.
I axis is located in the rear position.

Flattening at the rear Prerequisite
• The pivoting element butts against the front fixed stop.
• Appropriate spacer for lower tool has been loaded at the rear.
Fig. 29858
1. Bend to an angle of 30°.

I axis is located in the rear position.
Fig. 29859
2. Flatten.
I axis is located in the front position.

CNC-controlled lower tool adjustment
(Option)
CNC-controlled adjustment of lower tools allows tool designs that

were previously impossible.
In CNC-controlled lower tool adjustment, a CNC-controlled
stepping motor is used for adjustment in X direction.
The lower tool can therefore be shifted to any position within the
entire travel range without having to interrupt production for
retooling (pivoting element/spacer).
Compressed air is therefore no longer required for press brake
operation. (Exception: Stop finger clamping at the 2-axes
backgauge).)
CNC-controlled lower tool adjustment Fig. 44066
Stepping motor unit Fig. 44065

Bending aid (optional)
Electromechanical bending aid for the TruBend 5085 - 5320.

The bending aid can be moved manually parallel to the bed, in
order to adjust it to the bending length and/or to bending stations. It
can also be adapted to different lower tool heights and widths by
means of 2 adjusting screws.
Maximum 2 bending aids can be used on a machine.
Advantages • Relieve the operator when working with large and heavy parts.
• No counter-bending effects when bending thin workpieces with
large flange lengths.
Technical data Capacities Max. swivel angle [°] 47

Max. working speed [°/s] 45
Max. support weight per arm [kg] 100
Max. Y speed [mm/s]
for die width 6 mm 2.5
Dimensions Weight per arm [kg] 330
Table width [mm] 275
Supported flange length [mm] 1000
Setting range for lower tool height [mm] 30 - 150
Setting range for die width [mm] 6 - 100
Max. workpiece weight in the table 10
extension area [kg]
Technical data for the bending aid Tab. 1-6
Note
The ram speed is automatically adapted for the chosen die width.

Reduced ram speed The smaller the die width of a lower tool, the less vertical travel by
the ram is needed to achieve a defined bending angle. Since the
swivel motion of the bending aid is synchronized with the vertical
travel of the ram and hence is also synchronized or parallel to the
motion of the bending flange, the press speed must be reduced for
small die widths.
Example Mild steel, bending angle 90°

Die width Reduced ram speed [mm/s] Travel in case of sheet deformation (from clamping
point to Y-nominal) [mm]
s = 1 mm s = 2 mm
6 2.5 2.407 -
8 3.5 3.541 3.173
10 4 4.432 3.972
12 5 5.539 4.807
Tab. 1-7
Options for the bending aid The following options are available for the bending aid:
• Table extension.
• Table widening.
• Support table for table length extension.
Bending aid with two table widening sections and two Fig. 29651
table extensions.

Support brackets The support brackets assist the operator when processing heavy
and unwieldy workpieces. The support brackets are mounted on
the same guide system as the bending aid. They can however be
detached as required.
The support brackets can be used in combination with the bending
aid.
Support brackets Fig. 38539

3.5 TASC 6000 control
The TASC 6000 control is distinguished by the following features:

• Bend sequence calculation.
• Tonnage calculation.
• Y parallelism calculation (station bending).
• Setup plan.
• Automatic crowning.
• Automatic stop finger positioning.
• Pre-selection, number of workpieces.
• Axes positioning from the operating station.
• Access to bending factors.
• 3D visualization.
• 2D programming.
• Teach function for all axes.
• Collision check with visualization.

Control panel
5
6
1 User interface / Touch screen 6 STOP button

2 E-STOP impact switch 7 Height adjustment lock
3 Numeric keyboard 8 USB ports
4 Cursor key 9 Keyboard and mouse
5 START button
Control panel Fig. 42581
The TruBend Series 5000 can be operated per Touch screen as

well as per keyboard/mouse combinations and numerical input
fields. In addition to this, two USB ports located on the right side of
the panel can be used for data transfer (bending programs /
software updates).
The operating panel has a large pivot and swing area and can also
be adjusted in height.
Consequently, the bending space is not obstructed by the panel,
allowing the operator to assume an ergonomically correct work
position at all times.

Operating station
1 LCD key pad 5 Control lamp

2 EMERGENCY UP foot switch 6 E-STOP release
3 Storage tray 7 RAM DOWN foot switch with
4 E-STOP impact switch E-STOP function
Operating station Fig. 40676

Additional footswitch
1 Connector 4 Indicator lamp

2 EMERGENCY UP foot switch 5 E-STOP impact switch
3 RAM DOWN foot switch with 6 E-STOP release
E-STOP function
Additional footswitch Fig. 42390

4. Backgauge
The backgauge defines the flange size of a bend. The available

backgauge systems are described in brief below.
2-axis backgauge Only parts with bending lines that are parallel to the indexing edge
can be bent with the 2-axis backgauge.
2-axis backgauge Fig. 45301
• X drive (forward/back) by means of racks and pinions:

high precision and dynamics.
• R drive (up/down) by means of ball screws.
• No Z drive (left/right): Stop fingers can only be offset manually.
The stop fingers are pneumatically clamped.
4-axis backgauge Only parts with bending lines that are parallel to the indexing edge
can be bent with the 4-axis backgauge.
4 -axis backgauge Fig. 45302

1-26 Backgauge T488EN01.DOC

• Z drive (left/right), Z1 and Z2 stop fingers by means of toothed
belt drive: high dynamics when positioning light-weight parts.
5-axis backgauge With the 5-axis backgauge, it is also possible to bend parts which
have no bending lines parallel to the indexing edge.
Backgauge with relative X axis Fig. 45303

• Z drive (left/right), Z1 and Z2 stop fingers by means of toothed
belt drive: high dynamics when positioning light-weight
parts.
Z2 stop finger can be moved ±75 mm in X direction via CNC
control.
T488EN01.DOC Backgauge 1-27

6-axis backgauge With the 6-axis backgauge, it is also possible to bend parts which
have no bending lines parallel to the indexing edge.
6-axis backgauge Fig. 45304
• X drives (forward/back), X1 and X2 by means of racks and

pinions: high precision and dynamics.
• R-drives (up/down), R1 and R2 by means of ball screws.
• Z-drives (left/right), Z1 and Z2 by means of racks and pinions:
The 6-axis backgauge is not available for the TruBend 5050.
Technological aspects 2-axis backgauge Bending lines run parallel to the indexing edge.
4-axis backgauge Bending lines run parallel to the indexing edge.
5-axis backgauge Bending lines need not run parallel to the
indexing edge in X-direction (horizontal).
6-axis backgauge Bending lines need not run parallel to indexing
edge in X and R-direction (horizontal / vertical).
Tab. 1-8

4.1 Backgauge axis system
X axis and R axis Dimension R0 refers to the top of the lower tool clamp. In normal
bending (Manual mode, Production, Programming), however, the
stop finger is always 0.2 – 0.3 mm above R0 (top of lower tool).
This means that both the lower tool height and the calculated or
adjusted crowning value is taken into account by means of an
appropriate zero point offset.
This zero offset is not displayed.
X0 X+
R+
R0
R-
X axis, R axis Fig. 23738

Z axis
1 2
Z+
Z0
Z2 Z1
1 Sheet 2 Machine bed

Z axis Fig. 51624
The reference edges for the stop finger positions are at the outside
left and right.
Clamping (5 and 6 axis In the "Clamping" indexing method, the workpiece is aligned
backgauge) exactly against the backgauge in both X and Z directions.
The following clamping possibilities are supported:
• Clamping on one side
• Clamping on both sides
Clamping on both sides Clamping on one side

Clamping functions Fig. 35065

4.2 Technical data: Backgauge
X2
X1
R2
R1 Z2
Z1
Axes: Backgauge Fig. 44111
TruBend 5050 5085 5850 S 5130 5170

Travel range X1/X2 axis [mm] 600 600 600 600 600
2
R1/R2 axis [mm] -50 -50 -50 -50 -50
+200 +200 +200 +200 +200
Z1/Z2 axis 4 axis [mm] 753 1463 1973 2403 2403
5 axis [mm] 670 1380 1890 2320 2320
6 axis [mm] - 1340 1850 2280 2280
Max. stop range In X direction [mm] 860 860 860 860 860
In 4 /5 axis [mm] 929.5 1640 2150 2580 2580
Z direction
6 axis [mm] - 1530 2040 2470 2470
Speeds X1/X2 axis [mm/s] 0 - 1000 0 - 1000 0 - 1000 0 - 1000 0 - 1000
R1/R2 axis [mm/s] 0 - 330 0 - 330 0 - 330 0 - 330 0 - 330
Z1/Z2 axis [mm/s] 0 - 1000 0 - 1000 0 - 1000 0 - 1000 0 - 1000
Positioning accuracy X1/X2 axis [mm] 0.04 0.04 0.04 0.04 0.04
R1/R2 axis [mm] 0.08 0.08 0.08 0.08 0.08
Z1/Z2 axis [mm] 0.06 0.06 0.06 0.06 0.06
Distance Finger – 4/5 axis [mm] 25 25 25 25 25
Finger
6 axis [mm] 10 10 10 10 10
Finger – Side 4 axis [mm] 60 60 60 60 60
element
5 axis [mm] 25 25 25 25 25
6 axis [mm] 115 115 115 115 115
Technical data: Backgauge 5050 – 5170 Tab. 1-9
2
Reference edge R0

TruBend 5170 S 5230 5230 S 5320
Travel range X1/X2 axis [mm] 600 600 600 600
3
R1/R2 axis [mm] -50 -50 -50 -50
+200 +200 +200 +200
Z1/Z2 axis 4 axis [mm] 3393 2403 3393 3393
5 axis [mm] 3310 2320 3310 3310
6 axis [mm] 3270 2280 3270 3270
Max. stop range In X direction [mm] 860 860 860 860
In 4/5 axis [mm] 3570 2580 3570 3570

Z direction
6 axis [mm] 3460 2470 3460 3460
Speeds X1/X2 axis [mm/s] 0 - 1000 0 - 1000 0 - 1000 0 - 1000
R1/R2 axis [mm/s] 0 - 330 0 - 330 0 - 330 0 - 330

Z1/Z2 axis [mm/s] 0 - 1000 0 - 1000 0 - 1000 0 - 1000
Positioning accuracy X1/X2 axis [mm] 0.04 0.04 0.04 0.04
R1/R2 axis [mm] 0.08 0.08 0.08 0.08

Z1/Z2 axis [mm] 0.06 0.06 0.06 0.06
Distance Finger – 4-/5 axis [mm] 25 25 25 25
Finger
6 axis [mm] 10 10 10 10
Finger – Side 4 axis [mm] 60 60 60 60

element
5 axis [mm] 25 25 25 25
6 axis [mm] 115 115 115 115
Technical data: Backgauge 5170 S – 5320 Tab. 1-10
3
Reference edge R0

4.3 Stop fingers and stop positions
Stop positions for standard stop fingers Fig. 32228
Standard The stop fingers of all backgauge systems have three different stop
positions:
• Stop position 0: Workpiece is indexed at the stop finger. At
the max. X position (X = 600), flanges 600 mm long can be
indexed.
• Stop position 30: Workpiece is placed on the lower support of
the stop finger and indexed. At the max. X position (X = 600),
flanges 630 mm long can be indexed.
• Stop position 260: Workpiece is placed on the upper support
of the gauge finger and indexed. At the max. X position (X =
600), flanges 860 mm long can be indexed.
Option • Stop position 400: The workpiece is placed on the upper

support of the gauge finger and indexed. At the max. X position
(X = 600), flanges 1000 mm long can be indexed
1 1
1 Stop position 1000 mm

Fig. 32301

0
30
260
400
Stop positions Fig. 44110

Micrometer stop fingers (Option)
Micrometer stop fingers are available in 3 different versions:

• Micrometer stop fingers for 2-axis backgauge.
• Micrometer stop fingers for 4-axis backgauge.
• Detachable micrometer stop fingers for 4-axis backgauge.
Fig. 45307 Fig. 45305 Fig. 45306

Micrometer stop finger for Detachable Micrometer stop finger for
2 axis backgauge. micrometer stop finger 4 axis backgauge.
for 4-axis backgauge.
Tab. 1-11
It is possible to use several stop fingers simultaneously.

Micrometer stop fingers are ideal when processing workpieces with
steps.
Travel paths are limited to ±15 mm.

5. TRUMPF BendGuard
Note
Work at a rapid speed higher than 10 mm/s is permitted only if an
opto-electronic safety device is used. The TRUMPF BendGuard is
such an opto-electronic safety device.
Background In practice, TruBend press brakes are normally loaded by hand. In

accordance with the valid safety regulations, the following concepts
of operation exist to avoid accidents
• Two-hand operation at working speed. Disadvantage: the part
must be put down before approaching the bending position;
longer cycle times
• Foot operation at working speed. Disadvantage: longer cycle
times.
• Operation with light curtain at rapid speed. Disadvantage: can
only be used with certain part geometries.
TRUMPF BendGuard TRUMPF BendGuard enables you to work at rapid speed without
jeopardizing the safety of the operating personnel and without
restrictions in parts handling. TRUMPF BendGuard monitors the
area under the upper tool by means of two laser light bands. The
rapid downward motion of the ram is halted if the light beams are
interrupted.
TRUMPF BendGuard is a non-contact safety protection device
(BWS) Type 4 according to EN954 with integrated tracking control
unit. A safety level in accordance with EN12622 (2001) 5.3.2(f) is
achieved.
1-36 TRUMPF BendGuard T488EN01.DOC

Principle Located at a distance of 4 mm (beam array A) and 14 mm (beam
array B) beneath the upper tool tip, two parallel beams of laser light
shine in front of the upper tool and provide protection for hands
and fingers. The effective overall width of the laser lights is 40 mm,
i.e. 20 mm in front of and 20 mm behind the upper tool tip.
14 mm
4 mm
A
1 2 3
B
20 mm 20 mm
1A Monitoring range 1A 2B Monitoring range 2B

(in front of the upper tool tip, (with circular cross-section,
laser light A) laser light B)
1B Monitoring range 1B 3A Monitoring range 3A
(in front of the upper tool tip, (behind the upper tool tip,
(laser light B) laser light A)
2A Monitoring range 2A 3B Monitoring range 3B
(with circular cross-section, (behind the upper tool tip,
laser light A) (laser light B)
Laser beam and tools Fig. 31003
With the two 40 mm wide bands of laser light, three areas are
monitored at a distance of 4 and 14 mm beneath the upper tool tip:
Monitoring range 1 20 mm in front of the upper tool tip.

Monitoring range 2 Exactly under the upper tool tip (circular cross-
section).
Monitoring range 3 20 mm behind the upper tool tip.
Tab. 1-12
T488EN01.DOC TRUMPF BendGuard 1-37

BendGuard modes There are 6 different BendGuard modes:
• BendGuard Mode 1:
Both laser bands as well as the point-shaped laser beam
directly under the tool tip are active during rapid downward ram
motion. If either of the two laser lines or the point-shaped beam
is interrupted, ram motion stops.
Initially, all laser bands are active. The machine stops at the
first interruption of laser band B (e.g. by the side wall of a box).
The two laser bands front and rear of the tool tip are no longer
monitored from here on. The two laser beams with circular
cross-section directly under the upper tool tip may not,
however, be interrupted.
Like BendGuard mode 1, except that the ram stops at the mute
point and has to be restarted using the foot switch.
• BendGuard Mode 5: (BendGuard not active) Downward ram
motion only at working speed.
• BendGuard Mode 6: (BendGuard not active with stop at mute
point)
1-38 TRUMPF BendGuard T488EN01.DOC

Chapter 2
Technology
(Application technology)
1. Bending methods: Overview ........................................ 2-3
1.1 Air bending....................................................................... 2-3
1.2 Coining............................................................................. 2-5
1.3 Hemming.......................................................................... 2-7
1.4 Flattening ......................................................................... 2-8
1.5 Sensor bending................................................................ 2-9
Overview: Sensor bending ....................................... 2-13
Learned bend............................................................ 2-13
2. Calculations ................................................................. 2-14

2.1 Press tonnage................................................................ 2-14
2.2 Box height...................................................................... 2-17
2.3 Inside radius .................................................................. 2-19
2.4 Selecting the die width................................................... 2-21
2.5 Shortest flange length.................................................... 2-23
2.6 Flat length ...................................................................... 2-26
Calculating the flat length in case of large bend
radii ........................................................................... 2-27
T488EN02.DOC Technology (Application technology) 2-1

Calculating the flat length in case of small bend
radii ........................................................................... 2-29
Use of the compensation value in the machine
controller ................................................................... 2-33
2.7 Minimum distances and lengths .................................... 2-34
2.8 Different bending flange shapes.................................... 2-35
2-2 Technology (Application technology) T488EN02.DOC

1. Bending methods: Overview
The following bending methods can be used on machines of the

TruBend Series 5000:
• Air bending
• Coining
• Hemming
• Flattening
• Air bending + ACB
1.1 Air bending
Air bending Fig. 34902
Air bending is a frequently used, flexible bending method. In air

bending, the workpiece is in contact with the upper and lower tools
at three different points:
• At the tip of the upper tool.
• At both working radii of the lower tool.
In air bending, the bent angle is achieved "in air", or "freely". The
bending angle is dependent on the material data (material, sheet
thickness) and tool data (die widths, working radii). It is determined
by the position of the upper tool (depth by which the upper tool
plunges into the lower tool).
No uniform bend radius is formed in air bending, but rather a
curvature line with the smallest curvature in the bending apex.
T488EN02.DOC Bending methods: Overview 2-3

Advantages of air bending • Any angle between approx. 32° and 180° can be produced
without changing tools.
• Low bending tonnage.
Air bending Air bending is a path-dependent bending method

on the TruBend
The ram travels to the programmed Y axis position at the
calculated pressure.
If the pressure is insufficient, the ram does not reach the lowest
nominal Y axis position and stops at the point where the opposing
forces are in equilibrium. This is usually the case when the tensile
strength and thickness of the material being bent differs
considerably from the data used by the control system in its
calculations.
2-4 Bending methods: Overview T488EN02.DOC

1.2 Coining
Coining Fig. 34903
In coining, the bend angle is produced in a form locking manner,

i.e. by pressing the workpiece into a defined form (lower tool, or
die). The angles of the upper and lower tools must be identical,
they determine the workpiece angle.
Important notes on • Coining is used:

coining – If the required inside radius of the workpiece is less than
the sheet thickness
– If holes, cutouts or angled edges are located near or on the
bending line.
– Extreme contour accuracy (radius RI).
• Each specific angle and inside radius requires a dedicated tool
set (upper and lower tool).
• Coining requires at least 3 times more tonnage than does air
bending, depending on the material and sheet thickness.
• The cost-efficiency of coining (tool costs/tool set-up time) is
often attained only in large-series production.
• Springback can be influenced only by changing the press
tonnage.

• The decisive parameters for coining are:
– Material.
– Sheet thickness.
– Inside radius.
– Shortest flange length.
– Bending angle.
– Angle accuracy.
– Sheet thickness tolerance.
– Max. tensile strength.
Coining on the TruBend Coining is the pressure-dependent bending method.

The ram descends at a pre-determined pressure until this pressure
has been present for at least 0.3 s. This pressure equilibrium
should not be achieved until positive contact between upper tool,
material and lower tool has been established.
For this reason, the nominal Y axis position in coining is approx.
2 mm beneath the bottom of the die (positive locking).
If pressure equilibrium sets in before the positive lock is achieved,
then the press tonnage has to be increased manually.
This is usually the case when the tensile strength and the
thickness of the material being bent differs considerably from the
data used by the control system in its calculations.

1.3 Hemming
Hemming Fig. 34901
In hemming, a seam is produced along a sheet edge using special

tools (e.g. upper tool OW 210/S and hemming tool FWZ).
Important notes on • As in air bending, hemming is a path-dependent bending

hemming method.
• Hemming is used:
– If a seam does not need to be pressed completely flat.
– To minimize the counter-bend effect in long seam flanges.
– If a defined dimension needs to be produced between the
flanges.
X Defined dimension between the seam flanges

Fig. 35066

1.4 Flattening
Flattening Fig. 34900
In flattening, a seam is produced along a sheet edge using special

tools (e.g. upper tool OW 210/S and hemming tool FWZ).
Important notes on • Analog to coining, flattening is a pressure-dependent bending

flattening method.
• Flattening is used when a seam is to be pressed completely
flat:
1 Teardrop
Completely flattened seam Fig. 51627
Counter-bend effect in hemming Fig. 35067

1.5 Sensor bending
Sensor bending with the ACB® angle sensor is based on air

bending.
To obtain an accurate bend angle in air bending, the workpiece is
over-bent by an amount equal to the elastic springback. Several
trial bends are usually necessary to determine the exact bending
parameters. This can waste time in small lot sizes and does not
guarantee that larger lot sizes will stay within the production
tolerances.
In sensor bending, it is not only the actual value of a bend angle
that is measured; different springback angles and varying material
properties are also recorded. The nominal value of the bend angle
is controlled with the aid of this information.
The advantages:
• High-precision bend angles through automatic measurement
and control, regardless of the …
– Grain
– Tensile strength
– Sheet thickness deviations
• Complicated trial runs are no longer necessary.
• Less material is used as there are no rejects.
• Shorter machining times. The workpieces, having accurate
angles, do not need to be refinished or measured for quality
assurance.
The ACB® angle sensor includes the following:

• Sensor module
• Sensor tool.
• Various accessories (not illustrated).

1
1 Sensor module 2 Sensor tool

Angle sensor ACB Fig. 36824
Angle sensing in the The angle sensing system is integrated in the upper tool and is
upper tool loaded with the conventional upper tools in the respective bending
stations.
Sensor tool Fig. 14869

Four-point measurement with Located in the sensor tool are two measuring or sensor disks of
sensor disks different diameters which center themselves in the bending
flanges. 4 contact points on the inside of the bend are measured
by the disks during the bending process at working speed. The
distance between the center points of the disks changes with the
penetration depth of the disks. The system continuously calculates
the actual angle based on this distance.
Four-point measurement by means of sensor disks Fig. 14755
Two-dimensional angle Disk displacement is evaluated two-dimensionally by means of

sensing intelligent signal processing. This means that the bending angle as
well as a possible tilt angle of the workpiece in X direction are
measured. The tilt angle is eliminated as a possible source of error
when the actual angle is calculated.

Technical data Current sensor tools All common
standard upper tools.
(Special radii on request)
Tool width [mm] 25
Max. number of sensor tools per 1

sensor electronic unit
Max. number of electronic sensor units 8
per press brake
Max. number of sensors per bend 3
Measurement range [°] 42 - 135

(dependent on type of sensor, material
and sensor disks)
Angle accuracy [°] ±0.3
Tab. 2-1
α1
α3
α5 ±0,3°
α2
α4
A B C D E
t
0
A Pre-bending C Finish bend (required angle + E Measure final angle

B Measure springback + monitor springback angle) t Time
the tilt angle D Pressure relief + monitor the tilt
angle
Schematic sequence of a complete sensor bend Fig. 32785

Overview: Sensor bending
TASC 6000 settings and Function

programming
For each bend…
• the springback is calculated
• the nominal angle regulated
• tilting is checked.
For the first bend in an active program…

• the springback is calculated
• the nominal angle regulated
• tilting is checked.
Each further identical bend (with referral to a reference bend) is bent with angle
regulation.
The established Y-position for an ACB bend is adopted for each further identical
bend (position regulation)
For each bend…

• the nominal angle is approached with angle regulation,
• springback and tilting are not measured.
Tab. 2-2
Learned bend
In learned bends, bending is accomplished using the Y axis data of

a previously completed sensor bend. In this case, the sensor tool
has neither a measuring nor a controlling function, i.e. it is not
active. It can however remain loaded in the workstation during the
bending process.
If the sensor bend was performed with 2 sensors, the Y-parallelism
correction is also applied.
If sensor bending was performed with 3 sensors, the crowning
correction will also be applied.
Application Taught bending is implemented whenever the same angles in the

same grain of the material are required in one single product. This
allows for more economical production.
A detailed description of learned bends is found in the ACB® angle

sensor manual.

2. Calculations
2.1 Press tonnage
The press tonnage for air bending can be calculated using a

formula determined empirically by TRUMPF:
Press tonnage calculation for air bending Fig. 2857
1.33 × l × Rm × s 2
F=
W − (2 × cos 45° × rOW )
1.33 Frictional resistance between material and lower tool (determined
empirically)
F Press tonnage [N]
l Bend length [mm]
Rm Maximum tensile strength of the material [N/mm2]
s Sheet thickness [mm]
W Die width [mm]
rOW Radius of upper tool [mm]
cos 45° ≈ 0.7
The formula value (2*cos45°*rOW) has a decisive impact only for large
upper tool radii; it can be ignored for TRUMPF standard tools where
rOW = 1 mm.
2-14 Calculations T488EN02.DOC

The tonnage can also be determined using the TRUMPF bending
slide rule or with the press tonnage table:
Example: Length of bend 1 m - Sheet thickness 3 mm - Die width 24 mm - Material tensile strength 400 N/mm2
Result: Press tonnage 200 kN
TRUMPF Bending slide rule - Front Fig. 35615
T488EN02.DOC Calculations 2-15

Press tonnage table (Material tensile strength 400 N/mm2)
s W 6 8 10 12 16 20 24 30 40 50 60 70 80 90 100 120
b 4.5 6 7.5 9 12 15 18 22.5 30 37.5 45 52.5 60 67.5 75 90
Ri 1 1.3 1.6 1.9 2.6 3.2 3.8 4.8 6.4 8 9.6 11 13 14 16 19
0.75 52 39 31 26
1 93 70 56 47 35
1.25 145 109 87 73 55 44
1.5 209 157 126 105 79 63
1.75 214 171 143 107 86 71
2 223 186 140 112 93
2.5 291 218 175 145 116
3 314 251 209 168 126
3.5 428 342 285 228 171 137
4 447 372 298 223 179 149
4.5 566 471 377 283 226 189 162
5 466 349 279 233 200 175
6 670 503 402 335 287 251 223
7 684 547 456 391 342 304 274
8 715 596 511 447 397 358 298
10 798 698 621 559 466
12 1005 894 804 670
Tab. 2-3
W Die width [mm]
b Shortest flange length [mm]
Ri Inside radius [mm]
Tonnage [kN/m] at optimal die width W
Example: Sheet thickness s = 3 mm - Die width W = 24 mm
Result: Press tonnage F = 209 kN/m

2.2 Box height
The maximum box height for a bend angle of 90° can be calculated
using the following formula:
SHi
OWH
Calculating the maximum box height Fig. 33329
OWH − B
SH i = × 0.95
1.414
SH i
OWH = × 1.414 + B
0.95
SHi Box height (inside) [mm]

OWH Upper tool height [mm]
B Ram center to outside edge of Modufix = 24 mm

The following rounded, maximum box heights result for the
standard tool heights:
Upper tool height [mm] Maximum box height [mm]

120 65
140 78
220 131
240 145
Tab. 2-4

2.3 Inside radius
The inside radius Ri is primarily dependent on the die width W.

Given an upper tool radius of 1 mm and a 90° bend angle, this will
result in the following inside radius Ri:
Ri ≈ 0.16 x W

W Die width [mm]
The inside radius can also be determined using the TRUMPF

bending slide rule:
Example: Sheet thickness 3 mm - Die width 24 mm

Result: Inside radius (bend radius) 3.8 mm
TRUMPF Bending slide rule - Rear Fig. 34663

s W 6 8 10 12 16 20 24 30 40 50 60 70 80 90 100 120
b 4.5 6 7.5 9 12 15 18 22.5 30 37.5 45 52.5 60 67.5 75 90
Ri 1 1.3 1.6 1.9 2.6 3.2 3.8 4.8 6.4 8 9.6 11 13 14 16 19
0.75 52 39 31 26
1 93 70 56 47 35
1.25 145 109 87 73 55 44
1.5 209 157 126 105 79 63
1.75 214 171 143 107 86 71
2 223 186 140 112 93
2.5 291 218 175 145 116
3 314 251 209 168 126
3.5 428 342 285 228 171 137
4 447 372 298 223 179 149
4.5 566 471 377 283 226 189 162
5 466 349 279 233 200 175
6 670 503 402 335 287 251 223
7 684 547 456 391 342 304 274
8 715 596 511 447 397 358 298
10 798 698 621 559 466
12 1005 894 804 670
Tab. 2-5
W Die width [mm]
b Shortest flange length[mm]
Tonnage [kN/m] with optimal die width W
Result: Inside radius Ri = 3.8 mm

2.4 Selecting the die width
The die width of a lower tool depends on the type of material, sheet
thickness, upper tool radius, the tool load and on the tonnage
required.
In practice, die width W is calculated according to the following rule
of thumb:
W = (6 to 10) x s
Sheet thickness s [mm] Die width W [mm]

0.5 - 2.5 6*s
3.0 - 6.0 8*s
≥8.0 10*s
Tab. 2-6
The optimum die width can also be determined using the TRUMPF
bending slide rule or the tonnage table:
Example: Sheet thickness 3 mm

Result: Possible die widths (the ones behind which a bending radius is indicated): 16 mm, 20 mm, 24 mm, 30 mm,
40 mm
The middle value is the ideal die width (in this case: W = 24 mm).

s W 6 8 10 12 16 20 24 30 40 50 60 70 80 90 100 120
b 4.5 6 7.5 9 12 15 18 22.5 30 37.5 45 52.5 60 67.5 75 90
Ri 1 1.3 1.6 1.9 2.6 3.2 3.8 4.8 6.4 8 9.6 11 13 14 16 19
0.75 52 39 31 26
1 93 70 56 47 35
1.25 145 109 87 73 55 44
1.5 209 157 126 105 79 63
1.75 214 171 143 107 86 71
2 223 186 140 112 93
2.5 291 218 175 145 116
3 314 251 209 168 126
3.5 428 342 285 228 171 137
4 447 372 298 223 179 149
4.5 566 471 377 283 226 189 162
5 466 349 279 233 200 175
6 670 503 402 335 287 251 223
7 684 547 456 391 342 304 274
8 715 596 511 447 397 358 298
10 798 698 621 559 466
12 1005 894 804 670
Tab. 2-7
W Die width [mm]
Tonnage [kN/m] with optimal die width W
Example: Sheet thickness s = 3 mm
Result: Possible die widths (those for which a tonnage is listed):

W = 16 mm, 20 mm, 24 mm, 30 mm, 40 mm.
The middle value is the ideal die width (in this case W = 24 mm).

2.5 Shortest flange length
Determining the shortest flange length Fig. 3856
The following equation can be used to determine the shortest

flange length b for a 90° lower tool:
2
b= ×W
2

W Die width [mm]
The shortest flange length can also be determined using the

TRUMPF bending slide rule or the tonnage table:

Example: Sheet thickness 3 mm - Die width 24 mm
Result: Shortest flange length 18 mm

s W 6 8 10 12 16 20 24 30 40 50 60 70 80 90 100 120
b 4.5 6 7.5 9 12 15 18 22.5 30 37.5 45 52.5 60 67.5 75 90
Ri 1 1.3 1.6 1.9 2.6 3.2 3.8 4.8 6.4 8 9.6 11 13 14 16 19
0.75 52 39 31 26
1 93 70 56 47 35
1.25 145 109 87 73 55 44
1.5 209 157 126 105 79 63
1.75 214 171 143 107 86 71
2 223 186 140 112 93
2.5 291 218 175 145 116
3 314 251 209 168 126
3.5 428 342 285 228 171 137
4 447 372 298 223 179 149
4.5 566 471 377 283 226 189 162
5 466 349 279 233 200 175
6 670 503 402 335 287 251 223
7 684 547 456 391 342 304 274
8 715 596 511 447 397 358 298
10 798 698 621 559 466
12 1005 894 804 670
Tab. 2-8
W Die width [mm]
Tonnage [kN/m] with optimum die width W
Result: Shortest flange length b = 18 mm

2.6 Flat length
The outside surface of the bend is subjected to tension, i.e. it is

stretched during bending, while the inside surface (facing the upper
tool) is compressed (inside radius Ri).
1 Tension (stretching) 2 Compression

Fig. 51629
Located between these two areas is the so-called "neutral axis". In

a part with small bend radii (R < 20 mm), the neutral axis migrates
towards the inside radius (Ri).
The run of the "neutral axis" corresponds to the length of a bend
part when it is unfolded (flat length).
Inside radius The inside radius is decisive for the flat length (length of the flat
blank) of a bending part. The inside radius is dependent on the
following variables:
• Tool parameters
– Die width of lower tool
– Radius of upper tool
• Material parameters
– Sheet thickness s
– Tensile strength Rm
– Grain
• Workpiece parameters
– Bend angle

Example 120 (A)
110 (B)
35 (B)
40 (A)
0 34.75 144.26 179.01
A Outside dimension B Inside dimension

S = 5 mm Fig. 51628
Calculating the flat length in case of large

bend radii
When calculating the flat length for parts with a bend radius 20 mm
and greater, one can assume that the "neutral axis" runs through
the middle of the sheet cross-section.
The flat length L can be calculated with the following formula:
L = L1 + L2 + L3 + ...
L Flat length [mm]

Lx Length of individual segments [mm]

Example
45°
=1
L2
R4
2
L3
L1
Sheet thickness s = 4 mm
Calculating the flat length in case of large bend radii Fig. 38662
L1 = 30 mm
s
π × d ×α π × 2( R + ) × α π × 2(42)mm × (145°)
L2 = = 2 =
360° 360° 360°
L2 = 113.62 mm
L3 = 80 mm
L = L 1 + L2 + L3
= (30 + 113.62 + 80) mm
= 223.62 mm

Calculating the flat length in case of small
bend radii
If the part has a bend radius of ≤20 mm, the "neutral axis" no
longer runs precisely through the middle of the sheet cross-section.
A compensation value therefore needs to be taken into account
when calculating the flat length.
b a
Fig. 38663
The flat length L can be calculated with the following formula:
L=a+b-v
L Flat length [mm]

a Flange length 1 [mm]
b Flange length 2 [mm]
v Compensation value [mm]

Calculating the compensation value v
Compensation value for

opening angle 0° - 90°
β
r
s.k
s
2
a
Fig. 50534
180° − β s
v = 2(r + s ) − π × × (r + × k )
180° 2

r Bend radius [mm]
ß Bend angle [°]
k Correction factor
The correction factor k, a variable of the bend factor v, is calculated

using the following formula:
r
k = 0.65 + 0.5 × log
s
k Correction factor
r Bend radius [mm]

Compensation value for β
r
b
s
a
s
2
Fig. 50535
180° − β 180° − β s
v = 2(r + s ) × tan −π × × (r + × k )
2 180° 2

r Bend radius [mm]
ß Bend angle [°]
k Correction factor
Correction factor k indicates the deviation of the location of the

neutral axis s/2 and is calculated as follows:
r
k = 0.65 + 0.5 × log
s
k Correction factor
r Bend radius [mm]
Note
The bend factor v can also be obtained from Supplement 2 of
DIN 6935.

Compensation value for β
s
b
a
Fig. 50536
v=0
Note
The values here for v are minimal, the accuracy suffices in
practice.

Use of the compensation value in the
machine controller
The TASC 6000 control accesses the TruToPsBend database for

technology data. This database contains the compensation values
for all conventional material-tool combinations.
These values can be called up in both manual and programming

modes.
Icons Icon Function / Significance

Compensation value, can be overwritten.
Compensation value from TRUMPF database.
No compensation values present in the database.
Tab. 2-9
Retrieving a correction ¾ Double click the icon to the left of the X-correction input field.
value Bend allowance / Correction value will be displayed.
Note
Another double click re-enables the X correction input field.
When working with the TruToPsBend Profile Editor, the flat length
is calculated on the basis of the tool, material and product angle,
and then displayed on the screen.

2.7 Minimum distances and lengths
When bending parts which in their flat state have a hole or a notch
close to the bending line, a minimum distance must be observed
between the edge of the hole or notch and the bend itself to avoid
deforming the shape of the hole or notch.
Workpieces with holes or notches Fig. 1411
The minimum distance x1 (for holes) or x2 (for notches) is

calculated as follows:
x1 = 0.75 xW x 2 = 0.75 xW
x1, x2 Minimum distance of bend from hole or notch [mm]

W Die width
A quick method for determining the minimum distance in the

workshop is to calculate the shortest flange length (see Page 2-23,
slide rule, tonnage table). Notches and holes can be produced
without deformation if the distance between them and the bending
line is greater than the shortest flange length.

2.8 Different bending flange shapes
Deformation and compression in the bending zone occur during

the bending process and need to be taken into account in the
workpiece design.
Especially in air bending, such deformation and compression can
have a negative impact on the workpiece shape.
Correct and incorrect

Incorrect design: Correct design:
workpiece design
Fig. 51630

Number Description Remedy
1. The bending lines should not form any Notches measuring
shared points of intersection in the x = 1.5 x s
material. This would otherwise hinder
tension and compression in the
bending zone, resulting in cracks.
2. Avoid edges at an angle to the bending • Vertical distance to
line. the bending line,
measuring
lmin = 0.75 x W
• Notch the angled

edge.
3. Instead of a short bending flange y, • xmin = (1 to 1.5) x s
move the edge of the other flange back
by an amount equal to x. • Notch the angled
edge.
4. Instead of the short bending flange y, xmin = (1 to 1.5) x s
make the cutout around the bending
line.
Significance:
• s Sheet thickness [mm]
• W Die width [mm]
Tab. 2-10
Note
If flange shapes such as those in Nos. 2, 3 and 4 cannot be
avoided because of design considerations, then a different bending
method should be used – change from air bending to coining.

Chapter 3
Tool system
1. Terminology ................................................................... 3-2
2. Tools from TRUMPF ...................................................... 3-3

2.1 Tool identification............................................................. 3-3
2.2 Upper tools ...................................................................... 3-4
2.3 Lower tools ...................................................................... 3-6
Die width ..................................................................... 3-6
Opening angle ............................................................ 3-7
2.4 Tools for thin sheets ...................................................... 3-11
2.5 System segmentation of tools ....................................... 3-13
3. Laser hardening........................................................... 3-15
4. Imprint-free bending.................................................... 3-16
5. Special tools................................................................. 3-18
T488EN03.DOC Tool system 3-1

1. Terminology
2
6
3
4
7
1 Upper tool (punch) 5 Die width (W)

2 Workpiece 6 Lower tool radius
3 Inside workpiece radius (Ri) 7 Upper tool radius
4 Outside workpiece radius (Ra) 8 Lower tool (die)
Fig. 12763
3-2 Terminology T488EN03.DOC

2. Tools from TRUMPF
2.1 Tool identification
Identification codes provide information about the tools. The letters

identify a certain type of tool or a important tool characteristic.
Code Upper tool (punch) Lower tool (die)

OW Upper tool
UW Lower tool
EV Single V die
KEV Plastic single-Vee die

S Shoulder-bearing tool Narrow die (30° dies are narrow on
one side whereas 84° dies are narrow
on both sides).
K Head-bearing tool
H Upper tool height Height of lower tool (die)
If the letter H is missing, the lower tool
height is 100 mm. If only Clamp …/H
is specified, then the lower tool height
is 150 mm. Code H+number refers to
tools with defined special heights.
R Radius (punch tip) Working radius
W Die width
ZM Any high (>140 mm) special tool with
tension spring and Multi-LEDs
MF/S Modufix adapter, shoulder-bearing
ZE Insert for Z bends Insert for Z bends
FWZ Hemming tool
MST Torque support
ZDL Flattening bar
FEV Hemming bar and single-V die
Combination lower tool for hemming
without I-axis adjustment.
Tab. 3-1

2.2 Upper tools
OW200/S OW200/K
Upper tools Type OW200 Fig. 23589; 23588
Note
Both head and shoulder bearing upper tools can be used on the
TruBend Series 5000.
Upper tool heights Standard upper tools are available in two different heights. Lower
upper tools (working height ≤120 mm) are head-bearing, high
upper tools (working height ≥220 mm) are shoulder-bearing.
In the case of special upper tools, it is not the tool height alone that
determines whether the upper tool is head-bearing or shoulder-
bearing. The press tonnage exerted on the tool is also a decisive
factor, in addition to the geometric shape, which might lead to off-
center loads during the bending process.
3-4 Tools from TRUMPF T488EN03.DOC

Shoulder-bearing tool Head-bearing tool
Tool types Fig. 35647, 35648
Note
In upper tool type OW210/S, both punches, the higher and the
lower one, are shoulder-bearing.
OW 210/S H240 OW 210/S H140

Upper tools OW 210/S Fig. 22942; 22882
Load-bearing capacity of • When using head-bearing upper tools, the tool clamping can
upper tool clamp be loaded with maximum 1350 kN/m.
• In the case of shoulder-bearing upper tools, the tool clamping
can be loaded with maximum 1870 kN/m.
• Higher loads apply for tool lengths greater than 500 mm:
– head-bearing upper tools: max. 1800 kN/m.
– shoulder-bearing upper tools max. 2500 kN/m.

2.3 Lower tools
Overview of lower tools
EV 001 EV 001/H EV001/S KEV ...

Lower tools Fig. 31183; 31182;
33330; 33331
Die width
Where the die width is concerned, a distinction is made between

the nominal width and the width which is relevant for calculating
the penetration depth.
Nominal width The nominal width is specified on the lower tool, e.g. W = 6 for
EV001. The nominal width is measured at the point where the
radius of the lower tool becomes the straight line of the V-opening.
Technically important width This width Wt is measured at the intersecting point of the tangents.
for penetration depth The difference between the nominal width and the technical die
width becomes more obvious the larger the working radii are.
Note
The Wt value is calculated by the control based on the lower tool
data and factored in for bend sequence calculation.
⎛α ⎞ ⎛ ⎛ α ⎞⎞
Wt = W + 2 × tan⎜ ⎟ × R × ⎜⎜1 − sin ⎜ ⎟ ⎟⎟
⎝2⎠ ⎝ ⎝ 2 ⎠⎠

Wt
W
R
α
W Specified die width Wt Technically important width for

= nominal width calculating the penetration depth
Die width Fig. 33333
Opening angle
TRUMPF lower tools come with 5 different opening angles:

• 30°
• 80°
• 84°
• 86°
• 90°
The question of which opening angle needs to be used depends on

the application in question.
30° lower tool In air bending, a lower tool with an opening angle of 30° is usually
utilized. Maximum bending flexibility is achieved with this kind of
tool because (providing the corresponding upper tool is available)
any angle between 180° and almost 30° can be bent.
30° lower tools are available in widths W = 4 mm to 24 mm. The
tools with die widths W = 4 mm and 5 mm are thin sheet tools
designed for sheet thickness s ≤1 mm, see page 3-11.

Lower tool Die width W [mm]
EV/S-W4/30° 4
EV/S-W5/30° 5
EV001 6
EV002 8
EV003 10
EV004 12
EV005 16
EV006 20
EV007 24
Tab. 3-2
80° lower tool Lower tools with an opening angle of 80° are used for thick sheets,
allowing angles ≥90° to be bent. When bending thick material, the
springback can be so great that coining would result if a 84° lower
tool were used for producing 90° angles.
This can cause two problems:
• The required Y axis position is not attained after an angle
correction is made while air bending.
• The ACB® angle sensor cannot be used.
80° lower tools are available in die widths W = 24 mm to 100 mm.

EV W24/80° 24
EV W30/80° 30
EV W40/80° 40
EV W50/80° 50
EV W60/80° 60
EV W70/80° 70
EV W80/80° 80
EV W90/80° 90
EV W100/80° 100
Tab. 3-3

84° lower tool Lower tools with an opening angle of 84° are used to bend
workpieces containing holes or cutouts near the bending line,
(distance ≤ shortest flange length). The holes/cutouts are not
deformed in the process (see Chapter 2).
Only ≥90° angles can be bent with 84° lower tools.
The 84° lower tool is suitable for use with the ACB® sensor in all
conventional materials (mild steel, stainless steel, aluminum).
The lower tools with die widths W = 4 mm and 5 mm are thin sheet
tools for sheet thicknesses s ≤1 mm, see page 3-11.

EV/S-W4/84° 4
EV/S-W5/84° 5
EV W8/84° 8
EV W10/84° 10
EV W12/84° 12
EV W16/84° 16
EV W20/84° 20
Tab. 3-4
86° lower tool Lower tools with an opening angle of 86° are the predecessors of
the 84° lower tools.
However, as the springback is so great when bending stainless
steel and various aluminum alloys, coining is performed with an
86° lower tool to produce a 90° angle. The ACB® angle sensor
cannot be utilized in such cases.
86° lower tools are available in die widths of W = 6 mm to 50 mm.
Note:
A coining effect is achieved when 80°, 84° and 86° lower tools are
used for bending 90° angles.

EV020 6
EV021 8
EV022 10
EV023 12
EV024 16
EV025 20
EV026 24
EV027 30
EV028 40
EV029 50
Tab. 3-5
Note
86° lower tools should now be purchased only in order to
supplement an existing set of tools. When purchasing new tools,
preference should instead be given to 84° lower tools.
90° lower tool Lower tools with an opening angle of 90° are used for coining.
The lower tools with die widths W = 4 mm and 5 mm are thin sheet
tools for sheet thickness s ≤1 mm, see page 3-11.

EV/S-W4/90° 4
EV/S-W5/90° 5
EV040 6
EV041 8
EV042 10
EV043 12
EV044 16
Tab. 3-6

2.4 Tools for thin sheets
Tools for thin sheets offer the highest precision in conjunction with
narrow die widths in sheet thickness ≤1 mm.
Advantages • The small upper tool radii and small die widths make the
smallest bending radii possible.
• Thanks to the slim tool geometry, short flange lengths can also
be achieved.
Bending with thin sheet tools Fig. 31178

Upper tool There are 3 upper tools for thin sheets, 2 of which are upper tool
inserts for tool holders OW/K 80 and OW/K 130:
• OW280/K (complete tool).
• OW390 (upper tool insert).
• OW391 (upper tool insert).
All thin sheet tools are head-bearing, regardless of the working

height.
Upper tool Working height [mm]

OW280/K 140
OW390 170 (with OW/K 80)
220 (with OW/K130)
OW391 170 (with OW/K 80)
220 (with OW/K130)
Tab. 3-7
Lower tool For thin materials, lower tools are offered with die widths of W =
4 mm and 5 mm and opening angles of 30°, 84° and 90°.
These lower tools come only in a narrow version (see Page 3-6) in
order to produce narrow Z bends.

2.5 System segmentation of tools
Tools are available in different segmentations and lengths.

With the system segmentations A and B offered, any bending
length, from 25 mm all the way to the bending length of the
machine, can be produced in 5 mm increments.
In addition to this, upper tools are also available in left gooseneck
and right gooseneck versions. Gooseneck tools are 100 mm long.
Tool sets: Segment, standard dimension:

Length [mm], Length [mm]
variant
25 30 35 40 45 50 100 H100L 1 H100R 200 2 3002 5002
Basic division 2 1 1 1 1 1 1 - - - - -
250
1250, A 2 1 1 1 1 1 8 1 1 - - -
1250, B 2 1 1 1 1 1 1 1 1 2 1 -
2050, A 2 1 1 1 1 1 16 1 1 - - -
2050, B 2 1 1 1 1 1 1 1 1 1 1 2
2550, A 2 1 1 1 1 1 21 1 1 - - -
2550, B 2 1 1 1 1 1 1 1 1 1 1 3
3050, A 2 1 1 1 1 1 26 1 1 - - -
3050, B 2 1 1 1 1 1 1 1 1 1 1 4
4050, A 2 1 1 1 1 1 36 1 1 - - -
4050, B 2 1 1 1 1 1 1 1 1 1 1 6
Tab. 3-8
1
Gooseneck tools (H100L, H100R) are available only in upper tool sets. In
lower tool sets, gooseneck tools are substituted by 2 lower tools, each
100 mm in length.
2
The max. weight of the segments is limited to 25 kg. If this weight is
exceeded, the respective tools are replaced by shorter (=lighter) segments.

System segmentation All tools can be ordered either as complete tool sets or as single
versions tools.
The following tool set versions are possible:
• Basic segmentation 250 mm.
• Tool sets 1250 mm, 2050 mm, 2550 mm, 3050 mm or
4050 mm:
– System segmentation version A:
Longest tool 100 mm (see Tab. 3-8, Page 3-13).
– System segmentation B:
Longest tool max. 500 mm (see Tab. 3-8, Page 3-13).
Locking element All upper tools up to 100 mm in length are equipped with "Safety-
"Safety-Click" Click". "Safety-Click" is a safety locking mechanism integrated in
the tool to prevent it from falling out of the tool holder. The lock can
be released by pressing a button.
• The upper tool can be exchanged vertically - quickly but still
safely.
• Shorter tool set-up times as the tools no longer have to be
removed sideways out of the upper tool holder.

3. Laser hardening
TRUMPF tools are laser-hardened. Thanks to the use of a

TRUMPF TruFlow high-powered laser with innovative special
hardening optics, a greater hardening depth and a wider hardened
zone are achieved as compared to earlier laser hardening
methods:
• Degree of hardness 63-64 HRC.
• Hardening depth 3-4 mm.
Hardened work zones Fig. 33334
Safety of laser-hardened Only the surface of the tool is hardened in laser hardening; the
tools interior of the tool remains "soft".
The tool does not splinter under excessive load; instead, either the
tool splits or the hard layer is pressed into the soft core.

4. Imprint-free bending
During bending, imprints and abrasion result on the workpiece at

the support points of the lower tool.
In order to avoid marks and abrasion on high-quality or painted
sheets and on visible parts, one can choose among the following
standardized technologies:
• Use a KEV die.
• Use bending foil.
• Use lower tools with radius R = 3 mm (e.g. with foil-coated
sheets).
KEV die Bending foil

Fig. 33340; 33338
KEV die In the case of KEV dies, a plastic strip is inserted in the area of the
radius so that the workpiece lies on the plastic strip and not on
metal. This prevents marks on the workpiece due to friction
between metal (die) and metal (workpiece).
Die Die width W [mm]

KEV W8/30° 8
KEV W10/30° 10
KEV W12/30° 12
KEV W16/30° 16
KEV W20/30° 20
KEV W24/30° 24
Tab. 3-9
Note
As a general rule, the service life of the plastic strips is
considerably greater if calculations are made with the formula W =
≥8*s when selecting the die width.
3-16 Imprint-free bending T488EN03.DOC

Bending foil The bending foil is made of plastic, 0.4 mm thick and 100 mm
wide. It is laid loosely over the lower tool and for that reason is able
to prevent marks on the workpiece which could arise from the
rubbing of metal against metal.
Bending with bending foil Fig. 33339
Note
As a rule, the bending foil lasts much longer if calculations are
made with the formula W = ≥8*s when selecting the die width.
Lower tool with Lower tools with standard radii are of limited suitability for bending
Radius R = 3 mm film-coated sheets without bending marks being visible on the
workpiece surface after the foil has been removed. The danger
when using lower tools with standard radii is that the foil may be
cut through, leaving imprints on the workpiece.
A lower tool with a radius of R = 3 mm can be used in such cases.

Thanks to the large radius, the foil on the workpiece will not be
destroyed.
Note
The shortest flange length that can be bent increases if a lower tool
with a larger radius is used (see Chapter 2).

5. Special tools
Customized special tools can be designed in collaboration with

TRUMPF at any time. A wide array of special tool solutions are
listed and illustrated in the "TruBend - Working examples for
bending tools" technical information brochure.
3-18 Special tools T488EN03.DOC

Index
2 A
2-axis backgauge ...................................... 1-26 Air bending................................................... 2-3
• Press tonnage ..................................... 2-14
3
30°lower tool................................................ 3-7
B
Backgauge ................................................. 1-26
• 2-axis backgauge ................................ 1-26
• 4-axis backgauge ................................ 1-26
• 5-axis backgauge ................................ 1-27
• 6-axis backgauge ................................ 1-28
4 BendGuard................................................. 1-36
4-axis backgauge ...................................... 1-26 • Mode.................................................... 1-38
• Safety concept..................................... 1-36
Bending
• imprint-free .......................................... 3-16
Bending aid ................................................ 1-19
• Options ................................................ 1-20
5 Bending flange shapes .............................. 2-35
5-axis backgauge ...................................... 1-27 Bending foil ................................................ 3-17
Bending method
• 0............................................................. 2-3
• 1............................................................. 2-5
• 11........................................................... 2-8
• 3............................................................. 2-9
6 • 4........................................................... 2-13
• Air bending ............................................ 2-3
6-axis backgauge ...................................... 1-28
• Coining .................................................. 2-5
• Flattening with coining........................... 2-8
• Learned bend ...................................... 2-13
• Sensor bending ..................................... 2-9
Bending slide rule .......... 2-15, 2-19, 2-21, 2-24
8 Box height .................................................. 2-17
• maximum ............................................. 2-17
80°lower tool................................................ 3-8
84°lower tool................................................ 3-9
86°lower tool................................................ 3-9
C
Coining......................................................... 2-5
9 • Press tonnage ....................................... 2-5
Crowning.................................................... 1-12
90° lower tool............................................. 3-10
T488EN04.DOC Index 0-1

D L
Die ............................................................... 3-2 Laser hardening ......................................... 3-15
Die width ...................................... 2-23, 3-2, 3-6 • Degree of hardness............................. 3-15
• Selection ............................................. 2-21 • Hardening depth.................................. 3-15
Downstroking drive .................................... 1-10 Learned bend............................................. 2-13
Load-bearing capacity.................................. 3-5
Lower tool .............................................3-2, 3-6
• Coining ................................................ 3-10
• Designation............................................ 3-6
• Die width................................................ 3-6
F • Opening angle ....................................... 3-7
Flange length.................................... 2-23, 3-17 • Radius ................................................... 3-2
Flat length .................................................. 2-26 • Radius 3 .............................................. 3-17
• Calculation by the control.................... 2-33 • Thick sheet ............................................ 3-8
• Large bend radii .................................. 2-27 • Thin sheet............................................ 3-12
• Small bend radii .................................. 2-29 Lower tool adjustment................................ 1-14
Flattening
• Flattening front .................................... 1-16
• Flattening rear ..................................... 1-17
Flattening with coining ................................. 2-8
M
Machine
• Speeds ...........................................1-4, 1-5
Machine bed .............................................. 1-12
G Machine dimensions .............................1-4, 1-5
Gooseneck tools........................................ 3-13 Machine frame ............................................. 1-8
H O
Height Operating station........................................ 1-24
• Upper tool.............................................. 3-4
P
I Press tonnage............................................ 2-14
I axis .......................................................... 1-14 Press tonnage table ....... 2-16, 2-20, 2-22, 2-25
Identification ................................................ 2-9 Punch ........................................................... 3-2
Imprint-free bending .................................. 3-16
Inside radius .............................................. 2-19
R
R axis ......................................................... 1-29
K Ram............................................................ 1-10
KEV die...................................................... 3-16 Regulation.................................................... 2-9
0-2 T488EN04.DOC
S U
Safety concept........................................... 1-36 Upper tool .............................................3-2, 3-4
Safety element "Safety-Click".................... 3-14 • Height .................................................... 3-4
Sensor bending ........................................... 2-9 • Load-bearing capacity ........................... 3-5
Sensor tool................................................... 2-9 • Radius ................................................... 3-2
Special tools .............................................. 3-18 • Thin sheet............................................ 3-12
Speeds.................................................. 1-4, 1-5 Upper tool height........................................ 2-17
• Press speed ................................... 1-4, 1-5
• Rapid speed ................................... 1-4, 1-5
• Rapid up speed .............................. 1-4, 1-5
Support brackets ....................................... 1-21
W
Working height ......................................1-4, 1-5
Workpiece .................................................... 3-2
T • Minimum distance ............................... 2-34
• Minimum length ................................... 2-34
Technical data Workpiece radius ......................................... 3-2
• Bending aid ......................................... 1-19
Thin sheet tool
• Lower tool............................................ 3-12
• Upper tool............................................ 3-12
Tool.............................................................. 3-2
• Length ................................................. 3-13
X
• Locking element .................................. 3-14 X axis ......................................................... 1-29
• Lower tool....................................... 3-2, 3-6
• System segmentation ......................... 3-13
• Tools for thin sheets............................ 3-11
• Upper .................................................... 3-4
• Upper tool.............................................. 3-2
Tool holder................................................. 1-13 Z
Tool lengths ............................................... 3-13 Z axis.......................................................... 1-30
Tool:........................................................... 3-13
Tools for thin sheets .................................. 3-11
T488EN04.DOC 0-3

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Technical information

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Contents This Technical information brochure "Bending Technology"

T488EN00.DOC Before You proceed... 0-5

Chapter 1 Machine technology TruBend Series 5000

1. Machine concept............................................................ 1-3

2. Technical data................................................................ 1-4

3. Sub-assemblies ............................................................. 1-7

5. TRUMPF BendGuard ................................................... 1-36

Chapter 2 Technology (Application technology)

1. Bending methods: Overview ........................................ 2-3

0-6 Table of Contents T488EN00.DOC

2. Calculations ................................................................. 2-14

Chapter 3 Tool system

1. Terminology ................................................................... 3-2

2. Tools from TRUMPF ...................................................... 3-3

3. Laser hardening........................................................... 3-15

4. Imprint-free bending.................................................... 3-16

5. Special tools................................................................. 3-18

T488EN00.DOC Table of Contents 0-7

0-8 Table of Contents T488EN00.DOC

2. Technical data................................................................ 1-4

3. Sub-assemblies ............................................................. 1-7

T488EN01.DOC Machine technology TruBend Series 5000 1-1

5. TRUMPF BendGuard ................................................... 1-36

1-2 Machine technology TruBend Series 5000 T488EN01.DOC

Die TruBend Series 5000 comprises CNC-controlled press brakes

The machines are designed for a great variety of bending tasks

T488EN01.DOC Machine concept 1-3

Machine layout Fig. 44112

TruBend 5050 5085 5085 S 5130

1-4 Technical data T488EN01.DOC

T488EN01.DOC Technical data 1-5

Axes of the TruBend Series 5000 Fig. 38803

Axis Description TruBend 5050 TruBend 5085 – 5320

1-6 Technical data T488EN01.DOC

1 Y drive and hydraulics 5 Hydraulic cylinder 9 Machine body

T488EN01.DOC Sub-assemblies 1-7

The machine frame is a C-frame comprising two side frames

Frame deflection Fig. 32203

1-8 Sub-assemblies T488EN01.DOC

T488EN01.DOC Sub-assemblies 1-9

The ram is guided by means of adjustable cam followers. The ram

The downstroking drive is an electro-hydraulic drive featuring two

1 Control block on cylinder pair Y1 3 Pump block

1-10 Sub-assemblies T488EN01.DOC

Without crowning With crowning

1 Crowning --- Deformation

T488EN01.DOC Sub-assemblies 1-11

Bending results with/without crowning Fig. 32207

Crowning The crowning mechanism consists of two wedge plates milled in a

α1 < α2 < α3 < α4

1-12 Sub-assemblies T488EN01.DOC

Shoulder-bearing tool Head-bearing tool

Tool types Fig. 35647, 35648

Upper tool holder Lower tool holder

T488EN01.DOC Sub-assemblies 1-13

The lower tool holder is mounted on the machine bed in such a

1 Fixation of adjustment path, 3 Pivoting element for position

1-14 Sub-assemblies T488EN01.DOC