Occasionally a design may call for a large radius on a part, a radius which may be difficult to tool conventionally. The simplest method would be to use a pyramid roller to achieve the desired roll. However this can be difficult if the roll doesn’t continue throughout the entire part or if there are flanges which would interfere with the roller.  Grooves can be cut into rollers to allow for flanges, and secondary flanges can be added after the rolling, though you will have to accept that the secondary flange will still have the rolled radius.  Eventually there is a limit to how complex a part can be designed if a pyramid roller is to be used.

For more complicated and accurate parts step bending can be employed. Step bending sequences a large number of highly open bend angles closely with one another to achieve an almost smooth roll. The more bends the smoother the roll, however the more time consuming the process. This process requires some extra programming of presses to properly compensate and offset tooling, but can provide highly accurate and acceptably smooth rolls precisely where they are needed. Check out the video below to see an automated panel bender step bending a large radius piece.

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Filed under: Category Metal Fabrication | Tags: bending,Large,Radii,Step by Admin