All You Need to Know about Wire Benders

Posted on May 7, 2021

Wire Benders

Wire benders are a forming tool. The task of which is to create bends and/or curves on a workpiece. These machines are easy to use and do not require any special skills to operate. They are cost-effective since they don't need much power to operate with an electro-hydraulic system. A cable bender is used to bend the coiled wire into various forms, such as five-pointed ring, star, triangle, quadrilateral, polygon, and other irregular shapes.

Applications of Wire Benders

Wire benders feature high precision and high degree of automation. It is also easy to use which does not require a highly-skilled operator to use one. Coupled with powerful accessories such as precision ball screws or linear guides, wire bends can produce perfect bends and cuts.

In the automotive sector, wire bending machines have many applications such as manufacturing with tip forming units, headrest glasses, tank floats, child seat hooks, etc. Other applications include shop fittings, hydraulics, gym equipment, motorcycle and scooter accessories, office furniture, hospital furniture, bus and train window trims, prams, and pushchairs.

Capability of CNC Wire Bending Machines

These machines are also built with a CNC control system and AC servo motor, both of which are designed to improve production quality. CNC machines and wire bending machines are indispensable in most industries these days for this the ability to bend wires, give them a specific shape and still take care of their durability or high tensile strength. Stronger and high-quality products are manufactured using CNC machines and wire bending machines.

These machines save money by increasing efficiency and are used in a variety of applications, especially in a three-dimensional version. Typical wire bending machines may not be able to achieve remarkable finished products made on a CNC wire bending machine. 

The wire bending machine is usually fully automatic and can be precisely controlled during operation. The main purpose of the three-dimensional version is to offer different bending shapes. The process is done by feeding long wires to the machines and shapes are made according to pre-established requirements. 3D wire bending machines may differ from each other, but comply with general technical specifications.

High-speed Operation 

The machine is known to run at very high speed and the bending process is completed in seconds, approximately 1 to 1.5. These machines are capable of bending heavy materials such as wire with a diameter of approximately 10 millimeters. They have a built-in air compressor and a hydraulic pressure-driven motor to keep the machine running fast. The units are easy to open, clean, and maintain. The interface is usually user-friendly and can be easily programmed. With one press of a button and the operator will be able to command the machine to perform complex bending processes for remarkable end results.

Wire Bending Techniques 

Benders, simply put, are designed to bend into shaped parts of a product. It uses a variety of bending designs and styles. Standard bending is used in products that require strict or standard geometric lines. Machines that perform standard bending are equipped with electronic angular control, which ensures that every bend made is controlled by the machine. 

Edging is used if the product requires a parallel bending axis. A high finishing accuracy is required for this method. Offset bending is used when two materials have to be bent at the same time with a small distance between them. U-Bending, as the name suggests, is used on materials with a narrow geometry. These techniques apply to manufacture:
•    Kitchen baskets
•    Display stands
•    Springs
•    Fan guards
•    Home decoration
•    Bathroom accessories
•    Auto parts
•    Household appliances
•    Furniture for interior and exterior
•    Buildings
•    Supermarket and shop equipment
•    Wire wound resistors
•    Aircraft parts

Nowadays, CNC bending machines are more popular than ever because they require less time to set up and provide flexibility. These machines are also able to bend single pieces or small batches, but with the same efficiency and level of accuracy.

Wire Bending Varieties

CNC wire bending machines, which are generally automatic, can be single or double head and can be fully electric. They can also be equipped with integrated loading and unloading functions. They accept many kinds of wire such as aluminum and stainless steel to match the consumer's needs. The bends can be set to custom angles. They can be equipped with one or more reversible bending heads. They have a clockwise or counter-clockwise rotation and a variable radius.

Twin-head benders are perfect for machining operations on medium to long workpieces with multiple bends. Symmetrical and/or closed elements work just as well. They are widely used in the automotive, home appliances, interior, and exterior furnishings, shop and supermarket fittings, and the military industry.

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