Solution: One-Hit Rib Bending for 1.2 mm Steel Sheet Using Amada Press Brake

Customer Requirement

The customer approached us with a specific bending challenge involving a thin steel sheet with rib structure, requiring both efficiency and dimensional consistency.

Customer's main requirements included:

Material: Steel sheet, 1.2 mm thickness

Machine: Amada press brake

Lower die opening: V = 60 mm

Forming method: One-hit forming (single-step bending)

Part feature: Multi-angle profile with reinforcement rib (stiffening structure)

Quality expectation:

Stable bending angles

Clean forming without distortion

Consistent rib shape

High repeatability for batch production

 

Because the workpiece includes rib geometry and multiple bending angles, standard straight punches were not suitable for achieving the required shape in a single operation.

Challenge Analysis

After reviewing the drawing, our engineering team identified several key challenges:

1. Rib Structure Requires Controlled Material Flow

The presence of a rib (reinforcement feature) increases forming resistance and changes how material flows during bending. Without proper tooling support:

• The rib may collapse or deform
• Material stress may cause angle deviation
• Multiple forming steps may be required

This would reduce production efficiency and increase cycle time.

2. One-Hit Forming Requires Precision Tool Matching

The customer specifically required one-hit forming, meaning:

• All angles must be formed in a single stroke
• Tool geometry must match the part profile precisely
• Springback must be properly compensated

This requires custom-profile tooling, not standard punches.

3. Thin Material Needs Stable Support

With 1.2 mm steel, incorrect tooling selection may cause:

• Wrinkling
• Uneven angles
• Surface deformation
• Reduced rib accuracy

Proper support from the die shoulders is essential.

Our Solution: Rib Bending Tooling Recommendation

After technical evaluation, our engineers recommended using custom Rib Bending Tooling, specifically designed to match the profile shown in the drawing.

Recommended tooling configuration:

Tool Type: Rib Bending Punch & Die Set

Machine Compatibility: Amada system

Lower Die Opening: V = 60 mm

Forming Method: One-hit profile forming

Material Support: Optimized for thin sheet forming

Profile Matching: Custom geometry following part rib shape

This tooling design allows the rib and angles to be formed simultaneously in one press stroke.

 

Why Rib Bending Tooling Was Selected

The rib structure shown in the drawing includes:

• Multiple bending angles (155° + 110°)
• Reinforcement rib geometry
• Controlled dimensional spacing

Standard punches cannot accurately control deformation in such structures. Rib bending tooling provides:

Accurate Rib Formation

The specially designed punch nose supports the rib geometry and prevents collapse during forming.

One-Step Production Efficiency

With matched tooling geometry:

• No secondary forming required
• Reduced cycle time
• Higher production efficiency

Improved Dimensional Consistency

Custom rib tooling ensures:

• Stable angle accuracy
• Uniform rib height
• Reduced springback variation

Result Achieved

After implementing the recommended rib bending tooling, the customer successfully achieved:

• One-hit forming operation completed successfully
• Stable rib structure without deformation
• Accurate bending angles
• Improved production efficiency
• Consistent batch production quality

The final formed parts met the customer's dimensional and functional requirements.

Engineering Insight

This case demonstrates that when bending parts with rib or stiffening structures, selecting the correct tooling profile is critical.

For components requiring:

• Reinforced rib features
• Multi-angle forming
• Thin sheet precision bending
• Single-hit forming efficiency

Custom rib bending tooling is often the most reliable solution.