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4.
OPERATING THE BENDER
4.1
GENERAL OPERATING INFORMATION.
4.1.1
The bender can produce two basic types of bend. a) Smooth radiused bends using a
combination of the circular dies provided. b) Sharp bends using the sharp angle attachment.
4.1.2
Making a test piece. When producing parts from dimensioned drawings it is
advisable to make a test part first from scrap material of the same thickness to be
used in the final part. A certain amount of trial and error may be necessary in setting
up the bender to achieve an accurate part. To achieve a particular bend angle you will
need to make a trial bend first and then measure it.
4.1.3
Using the fixed or adjustable stop. Further adjustments may be necessary but once
you know the amount of rotation necessary to achieve a particular angle this can be
repeated by using the fixed or adjustable stops provided. (See figs.3&11)
4.1.4
Multiple bends. When doing more than one bend, similar trial and error may be
necessary to establish the correct relationship between bends. Mark the bend
positions on the trial workpiece. Make the bends and then measure the distance
between them. Make any necessary adjustments to the measurement to achieve the
desired result.
4.1.5
Bend sequence. Where a number of bends are to be made in the same piece of
metal attention should be paid to the order in which the bends are made to achieve
the finished part. You may need to re-orientate the workpiece in the bender by
reversing it or inverting its position. If necessary the bender can be disassembled to
remove or reposition a complex bend configuration.
4.1.6
Clamping the workpiece. Generally the workpiece is automatically clamped in place
by the action of the bender. In certain instances some slippage may occur e.g. when
forming material around a large die. This can be eliminated by clamping the end
of the material with locking pliers which then act against the stop block to prevent the material moving. (See fig.4)
4.2
MAKING RADIUSED BENDS. ( Do not try to bend material more than 1/4” thick around the centre pin. The 1” die must be used.)
fig.5
fig.6
4.2.1
Use of the ‘stop block’. The ‘stop block’ prevents the material from
rotating in the bender while a forming die mounted in the handle bends
the material either round the centre pin or around another die that has
been installed on the centre pin.
4.2.2
Orientation of the the ‘stop block’. The ‘stop block’ can be placed in
several orientations allowing additional flexibility in the positioning of the
workpiece in relation to the forming dies. Its relationship to the
workpiece is altered by rotating it on the hinge pin or by turning it
upside down on the pin and rotating it. However, only the four
orientations shown in fig.5 should be used for bending. No matter which
face is against the workpiece, the pin through the block should always
be positioned to the right of the block centre otherwise the block may
turn and the material will slip in the bender.
4.2.3
Position of the block support. The block support is used to position
the stop block vertically in the ring assembly loop as shown in fig.6.
Install the support in the appropriate loop hole where it will support the block but not interfere with the insertion of the hinge pin all the
way through the the hole in the block and into the hole in the lower part of the loop.
4.2.4
Installing the dies. Install in the centre of the bender the chosen die around which you are going to form the metal. Use a long
hinge pin to retain both the die and and the handle as shown in fig.7. Install the die which will do the forming into the handle loop and
retain it using the short hinge pin. The space between the two dies should be as small as possible whilst allowing the metal to pass
through.
4.2.5
Installing the stop block and block support. Rotate the handle anticlockwise to the approximate starting position as shown in fig.7.
Insert the metal to be formed in between the dies. Now install the stop block and block support at one of the five large holes in the ring
assembly’s loop.You will have to determine by trial and error which hole to use depending on the thickness of the material being bent,
the size of the centre pin die, and the orientation of the stop block. The block should be as close to the centre pin/die as the material
will allow. Retain the stop block with a long hinge pin.
WARNING! When making a bend or partial bend close to the end of a piece of material the bending force you are exerting on
the handle may suddenly be released as the bending die in the handle rolls off the end of the material. Watch the progress of
the die as it moves towards the end of the material and be prepared to release the pressure on the handle.
4.2.6
Making a bend. ( Before making a bend check that the bender is still firmly attached to the bench or floor. The floor should be clean
and dry and free from loose material. Wear non slip shoes and check that the area is clear of personnel and will remain clear whilst
you
are executing the bend.) If required, clamp the workpiece as shown in fig.4. Exert just enough pressure on the handle to hold the
material steady in the bender and check that the material is level. Make the bend with steady and even pressure until you reach the
desired finishing point as indicated in fig.8. ( As a rough guide to initially determine an angle when bending around a centrally
mounted die there are 16.36 degrees between the holes in the ring.) Measure the angle bent and make any necessary adjustments.
fig.4
fig.7
fig.3
fig.8
PBF04 & PBB04 - 1 - 161003
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