Alu 0,5 Alu 0,5 V= Matrizenffnung die opening t= Blechstrke material thickness
innerer Radius approx. inner radius
kleinste Schenkellnge fr 90 Bge smallest flange for 90 bends

Empirische Regel:

Beim Freibiegen entspricht der Innenradius Ri ca. 16% der Matrizenffnung V. Werte Ri und B gltig fr 90 Bge.

Empirical rule:

For air bendings the inner radius Ri is approx. 16% of die opening V. The values Ri and B are valid for 90 bends.
Berechnung der Hydrokissenkraft Calculation of the hydrocushion-force
Die Hydrokissenkraft, die auf ein Stempelteil von L=100 mm wirkt, berechnet sich wie folgt: Calculation of the cushion-force for 1 top tool section of a length of 100 mm: A1ST (cm2) x PK (bar) 100
B = Hydrokissenbreite 50 mm B = width of the hydrocushion 50 mm L = Standard Stempellnge 100 mm L = 100 mm length of a standard top tool section FK A1ST PK B
Hydrokissenkraft capacity of the cushion beaufschlagte Hydrokissenflche (B x L) subjected surface of the hydrocushion Hydrokissendruck hydrocushion-force
Beispiel: FK pro Stempelteil mit 100 mm Lnge und einem Hydrokissendruck von 50 bar. Sample calculation: Capacity of cushion FK for 1 top tool section of 100 mm length by a cushion pressure of 50 bar. B (cm) x L (cm) x PK (bar) cm2 x 50 bar 100

= 2,5 t

Hydrokissenkraft bei PK = 50 bar Kissendruck Capacity of the hydrocushion PK at a pressure of 50 bar

FK (t) (kN)

50 47.42.37.32.27.22.17.12.7.2.110 120
Biegelnge L (cm) / Bending length (cm) Maximale Kapazitt des Hydrokissens 1000 kN/m (100 t/m) Maximum capacity of the hydrocushion 1000 kN/m (100 t/m)
Arbeitsraumverhltnisse an der Hmmerle 3-Punkt-Biegemaschine Working space on the Hmmerle 3-point-bending machine
SH Hub Stroke 265 21.004.00 21.004.00 21.005.21.002.00 21.003.00 21.004.00 21.004.00 21.004.00 21.005.00 21.005.00 21.005.00 21.005.00 21.010.00 * 21.010.00 * 11.003.00 11.007.00 12.015.00 11.001.00 12.015.00 11.001.00 22.006.00 11.010.01 12.015.450 11.003.22.006.00 11.010.11.003.915 21.002.00 11.001.11.007.129 22.006.00 11.010.82 11.003.21.002.00 11.001.255 Open height Punch holder Punch Top tool height Free space max. box height Einbauhhe Stempelhalter Stempel Oberwerkzeughhe Freiraum max. Bordhhe DL Typ Typ PH FS (M = 86) BH Operation Flachdrcken Hemming ja / yes nein / no nein / no nein / no ja / yes nein / no nein / no nein / no nein / no nein / no ja / yes nein / no nein / no nein / no ja / yes nein / no

max. Kapazitt des Hydrokissens 1000 kN/m (100 t/m) max. capacity of the hydrocushion 1000 kN/m (100 t/m)

SH 3P-Biegen 3P-Bending

Flachdrcken Hemming

M = 86 / 120

Matrizenhhe Bottom tool height
* Diese Stempelkombinationen sind fr Blechdicken bis max. 3 mm zugelassen * This top tool combinations are limited for sheet thickness up to max. of 3 mm.
Zusatzplatte fr: Supporting plate:

Formel / Formula

Fr die Berechnung der Bordhhe: For the calculation of the max. box height: BH (mm) = PH (mm) 90 2
31.060.00 or 31.090.00 or 31.110.00
Fr die Berechnung der Stempelhhe: For the calculation of the top tool height:

PH (mm) = BH (mm) 2 + 90

Standard Werkzeuge Standard tools

Matrizen Bottom tools

Alle Materialdicken- und Winkelbereiche beziehen sich auf Stahlblech mit einer Zugfestigkeit von Rm = 450 N/mm2. Indications with regards of material thickness and angle range refer to mild steel plates with a tensil strength of Rm = 450 N/mm2.
Standardmatrize L = 100 mm mit Halteschiene L = 100 mm. Standard bottom tool piece L = 100 mm with holding rail L = 100 mm.
5 Standardmatrizen 100 mm auf einer Halteschiene 500 mm montiert. 5 standard bottom tool pieces of L=100 mm each assembled on a holding rail of 500 mm length.
Eine Matrize besteht immer aus einem Grundkrper, einer Halteschiene und den Matrizenbolzen. A bottom tool always consists of the basic bottom tool body, a holding rail and the bottom tool pins.
Matrizen - Zwischenstcke Bottom tool intermediate pieces
Fr die Matrizen bis 60 mm Nutenffnung sind auch Zwischenstcke lieferbar. 1 Satz Zwischenstcke besteht immer aus 10 Stck. For bottom tools up to 60 mm w-opening intermediate pieces are also available. 1 set always consists of 10 intermediate pieces.

L S R H-S H-FLD P EL

= = = = = = = = = = =
Lnge / length (mm) Segmentiert / segmented (mm) Radius / radius (mm) Standard Halteschiene / standard holding rail Halteschiene fr Flachdrcken / holding rail for hemming Matrizenbolzen / Pin for bottom tool Einlageleiste / insert rail Winkelbereich / angle range Materialdickenbereich / range of material thickness (mm) Gewicht / weight (kg/100 mm) max. zulssige Belastung / max. permitted load (kN/m)

L S R = = = 100 / 95 0.6

L S R = = = 100 / 95 2

R 0.5x45 P 31.006.H-FLD

t G F H-S H-FLD P

= = = =

30180 0.1.61.100.01 61.100.08 61.200.27

P 31.005.H-FLD

H-S EL 1 EL 2 EL 3 EL 4 P

31.110.00

75 R 4. 3. 2. 1. 120
61.400.02 61.400.01 31.110.00 EL 4 EL 3 EL 2 EL 1 P H-S
9.61.100.07 61.500.04 61.500.05 61.500.06 61.500.07 61.200.31

Oberwerkzeuge Top tools

1 Satz Standard Oberwerkzeuge 1 set standard top tools Ein Oberwerkzeug besteht immer aus dem Stempel und dem Stempelhalter. Der Stempelhalter kann eine Lnge von L = 100 mm oder 200 mm haben. A top tool always consists of the punch and the punch holder. The punch holder is available in the length of L = 100 mm or 200 mm.
Oberwerkzeuge Zwischenstcke Zwischenstcke mit Horn Top tools Intermediate pieces Intermediate pieces with horn
1 Satz Oberwerkzeuge Zwischenstcke ohne Horn besteht aus 10 Stck. 1 set of intermediate top tool sections without horn consists of 10 pieces.
1 Satz Oberwerkzeuge Zwischenstcke mit Horn besteht aus 8 Stck. 1 set of intermediate top tool sections with horn consists of 8 pieces.
Standardhhen der 3P-Oberwerkzeugkombinationen Standard heights of 3-point top tool combinations
Stempelhalter Punch holder 21.004.00 21.010.00 * 21.005.00 21.005.00 21.010.00 *

21.002.00

Stempel Punch 12.015.00 11.001.00 12.015.00 11.001.00

11.001.00

12.015.00
Die max. Belastung der Werkzeugkombination entspricht der max. Belastung des jeweiligen Stempels. The max. permitted load of the tool combination is equal to the max. permitted load of the punch.
* Werkzeugkombinationen mit dem Stempelhalter 21.010.00 sind fr Blechdicken bis max. 3 mm zugelassen. * Top tool combinations with the punch holders 21.010.00 are limited for steel thickness up to max. 3 mm.

L S R G F SH

Lnge / length (mm) Segmentiert / segmented (mm) Radius / radius (mm) Gewicht / weight (kg/100 mm) max. zulssige Belastung / max. permitted load (kN/m) Segmente mit Horn / segments with horn

Stempel Punches

L S SH = = = 95 75,80 / 75 115

11.028.00

1 0.397 1000

11.003.00

11.006.00

1 0.627 1000

2 0.448 1000

11.007.00

11.008.00

1 0.257 1000

1 0.438 1000

11.010.00

11.033.10

1 0.165 600

3 0.451 1000

11.034.00

11.035.00

4 0.620 1000

5 0.628 1000

11.036.00

12.014.00

6 0.733 1000

1 3.358 975

12.017.00

12.025.00

12.052.00

L S SH

95 75,80 / 75 115

1 2.62 975

1 2.755 750

1 1.354 250

2 2.622 975

12.053.00
12.065.00 L S SH = = = 95 75,80 / 75 115

3 2.644 975

1 1.360 1000

L S R t G F SH

= = = = = = =
Lnge / length (mm) Segmentiert / segmented (mm) Radius / radius (mm) Materialdickenbereich / range of material thickness (mm) Gewicht / weight (kg/100 mm) max. zulssige Belastung / max. permitted load (kN/m) Segmente mit Horn / segments with horn

61.200.24

61.200.23.01

61.200.24.01

61.200.23.02

61.200.24.02

61.200.25

61.200.26

61.200.25.01
Pos. Masse (mm) Gewicht (kg) pos. size (mm) weight (kg).01.x x 77 0.06 0.05

61.200.26.01

61.200.25.02

61.200.26.02

61.200.27
Pos. Masse (mm) Gewicht (kg) pos. size (mm) weight (kg).01.x x 87 0.02 0.01

61.200.27.01

61.200.28.01

61.200.27.02

61.200.28.02

61.200.29

Pos. Masse (mm) Gewicht (kg) pos. size (mm) weight (kg).01.x x 62 0.06 0.05 61.200.29.01

61.200.30

Pos. Masse (mm) Gewicht (kg) pos. size (mm) weight (kg).01.02

61.200.30.01

61.200.29.02

20 x x 67

0.06 0.05

61.200.30.02

61.200.31

61.200.31.01

61.200.31.02

www.bystronic.com

Copyright Bystronic 2009/Hmmerle Werkzeuge Tools/0910d-e/Printed in Switzerland

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unique in bending

Hmmerle bending machines

Unmatched 3-point bending technology
Intelligent concept, optimal bending processes
The highly precise Hmmerle 3-point bending machines enable the forming of simple and complex parts and they ensure cost-effective and time-saving production. Tool systems, programming, and peripherals are conceived for easy application and easy operation. With a very large stroke of the upper beam and generous clear space to the front and rear of the machine, the system provides optimal bending capacities with the highest flexibility. Thus the most advanced and efficient processing can be achieved.
Most important performance features Tonnage 8002250 kN Bending lengths21004100 mm Stroke265/400 mm Backgauge system 6 axes Entire type series overfloor construction Safety: CE and EMC certified

3-point technology

The innovative Hmmerle machines offer flexible tools and unique technology. In contrast to free bending or air bending, with the 3-point bending process, the bending angle of the workpiece is determined by three precisely defined points in the lower tool. Thus the desired angles are achieved by a CNCcontrolled depth setting of the bottom tool groove. Because there is compensation for machine-related, external, and material-dependent influences, a consistent bending angle is achieved across the entire bending length. Variable bending angle The most important components of the Hmmerle 3-point bending system are the hydraulic cushion and the bottom tool holder with an integrated CNCcontrolled wedge system. While the top tools are supported in the hydraulic cushion, the bottom tool holder with the wedge system enables a variable, precisely-repeatable setting of the groove depth of the bottom tools. Constant bending pressure The hydraulic cushion compensates for the machines deflection and assures consistent bending pressure along the entire bending length. At the same time, the cushion protects the tools and the entire system against overload. Precisely defined bending points The lower tools with variably adjustable groove depth achieve a forming similar to coining. When the bending process is completed, the sheet metal not only contacts the two edges of the V opening, but also the adjustable bottom point of the lower tool. Thus the three points that determine the bending angle are all on the same side of the workpiece. The necessary data for angle settings and cut lengths are thus calculated on the basis of empirical values.
The top tools supported by the hydraulic cushion follow the bending line of the lower beam.
The working principle of 3-point bending a Hydraulic cushion in unloaded condition b Hydraulic cushion in loaded condition c Bottom tool with height-adjustable groove depth
The bottom tool holder is equipped with an integrated sliding tool unit controlled by the CNC so that four different positions can be approached. This way, hemming operations can be performed without changing tooling within a bending sequence.

Important components

Tool clamping Thanks to the hydraulically operated top and bottom tool clamping system, the segmented tool system can be changed out in a very short time. At the same time, the length can be adjusted so flexibly that even multi-sided parts can be bent at different stations. The tools no longer need to be aligned, for the individual segments are centered automatically.
Safety systems The Hmmerle 3-point bending machines have contact-free safety systems on the operating side that are integrated into the safety doors. These not only have a distancing effect; they can also be switched on as a control unit with the touch of a button. The back side of the machine is also secured against entry by a light curtain.
Operator terminal Programming, control, and visualization of the processes occur via a comfortable operator terminal with a 15-inch active TFT LCD color screen. The modern, clearly arranged touch pad keyboard with graphic operator guidance makes work easy. In addition, an input keyboard is available.
User software Bybend supports process control through simple dialog control in a professional W indows interface. The software is suitable for graphical and numeric programming. It enables automatic calculation of the cut lengths and calculates the bending sequence with collision control. In addition, Bybend offers numerous other important functionalities that significantly help the user. For example, there is a tool setup plan, input control, and program administration. Extensive databases contain the parameters for parts and tools as well as

bending-technical data for example, empirical values for the bending allowance and angle setting enabling efficient production planning. The Bybendpart user software complements Bybend. It enables the import and export of data for processing by cutting and bending programs. The display of the bending programs occurs in 3D.
Backgauge system The highly dynamic backgauge system provides simultaneous movement of all six axes. The system is robustly built and has a vertically movable beam in the R-axis; individually mounted stop arms with integrated, brushless asynchronous servo drive; and digital axis control. The backstop arms in the X and Z directions can be positioned and corrected independently. Optionally available are straight, tiltable, quick-change or multifunctional stop fingers with four stop positions and two side stops.
Workpiece support The front workpiece supports move on linear guides and spherical guide carriages; they can be parked next to the table. Adjustment in the X, Y or Z directions occurs manually. A special apparatus prevents crushing points. For machines with a capacity greater than 130 tons, reinforced support consoles are available.
Bending aids The bending aids can, if desired, be built in on the operator side or on the backgauge side. Every one has three CNC-controlled axes. The rear bending aids offer an additional W-axis for side adjustment. The front bending aids can be lengthened if necessary or broadened with additional elements. The supports are equipped with synthetic brushes for scratch-free handling of the material. If heavy parts are being processed, supports with spherical rollers are available. The stepless hydraulic drive of the pivoting axes occurs in angles between 0 and 75.

Advantages

Robust machine frame design using stress-free steel construction Side frames, set beyond the length of the bed, allow full utilization of the maximal bending and backgauge length Newly developed, modular block hydraulics with proportional valve t echnology for highly dynamic upper beam control with optimal efficiency Standard built-in partial flow filter that increases the lifespan of valves, cylinders, and the hydraulic oil Constant bending forces and repeat able settings ensure even angle and side piece lengths

Expansion possibilities

Front and rear bending aids Table extension for front bending aids Reinforced front support consoles Additional stop arm X3, Z3 Complex stop fingers Side stops Table extension (parking place) Additional foot switch Workspace lighting Large, segmented tool selection Tool cabinet Bybend (2D) user software Bybendpart (3D) user software Robot interface

Service & Support

Bystronics proven technology and extensive expertise produce systems that are extremely reliable. With its global network of specialized service and training experts and comprehensive spare parts inventories in the local markets, Bystronic guarantees that it will support what it sells. In addition to maintenance, spare parts delivery, and repair services, customers are also offered training programs as well as hardware, software, and operational support so that they are in a position to get the most from their machine investment.

Areas of application

3-point bending machines are used everywhere where sheet metal parts must be produced quickly and flexibly, yet with the highest repetition and precision. Production of components for kitchen and office furniture Lift and transport equipment in medical and ventilation technology Machine and apparatus construction, etc. With its slim tool system, even complex hemming can be produced in one sequence. Therefore, the procedure is suitable for the widest variety of applications.
Sheet metal thicknesses Mild steel Stainless steel Aluminum
0.512 mm 0.510 mm 0.512 mm

Finished parts

Relay frame for electrical distribution unit 2 mm, mild steel
Frame part for gas distribution unit 5 mm, mild steel
Cable holder for tool machines 2 mm, mild steel

Results of comparison

Hmmerle Conventional
Due to the hemming unit and the slim tool system, complex parts can be produced in one sequence from a single blank.
This shaped part was hemmed in the conventional manner. The disadvantage of this production method is the separate point welding and polishing.

Hmmerle

Conventional
The 3-point process allows the forming of large parts in one sequence from a single blank. High-precision hemming of the long sides with a double bend afterward eliminates subsequent drilling, welding, and polishing.

Conventional parts hemmed as welded construction without hemming require subsequent processing. Here the long sides were reinforced after the fact with angle irons, drilled, and the part was then polished.

Customer benefits

G reater utilization and bending lengths since the distance between the side frames exceeds the maximum tool length by 100 mm M inimal setup and programming times thanks to precise, repeatable settings and optimal user guidance E asy calculation of cut lengths and bending programs using empirical values based on database-supported control S harply reduced production and h andling times thanks to optimized bending sequences S equential production of profiles and complex, multi-sided parts Q uick, time-saving tool change U se of normal and extra-high tools due to an extra-large upper beam stroke and large open height
This brochure may show parts that are not included in the standard equipment, but rather are available as options. For better identification of machine details, some safety equipment has been opened or removed for the pictures. Changes to dimensions, construction and equipment are reserved. For technical data, see separate data sheet. Certified in accordance with ISO 9001
Bystronic is a worldwide active supplier of application-oriented systems and services for the laser and waterjet cutting processes, as well as bending: economical, high-performance, reliable.
Laser cutting Laser cutting systems for the innovative processing of a wide variety of materials and geometries
Bending 3-point and air bending machines for high-precision working of sheet metals
Waterjet cutting Waterjet cutting systems for cutting metals, glass, synthetics, ceramic, and many other materials
Automation High-performance handling and automation solutions from simple loading systems to fully automated laser production cell with integrated storage system
Software & Control User-friendly programming and operation with requirementoriented applications programs and interfaces to CAD and ERP systems
Service & Support Competence and customer proximity with after-sales support available worldwide: local contact per-sons, prompt delivery of spare parts, and professional training courses

Your contact

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Hmmerle/0808e/Printed in Switzerland Copyright Bystronic 2008