2 Best Ways to Learn Safety Protection Analysis of Bending Process

The sheet metal bending process is not only directly related to the smooth progress of the company’s production plan, but also has a very important impact on the economic benefits of the company. Therefore, the safety issues of the sheet metal bending process have received more and more attention from enterprises and society. For the management personnel of enterprise production, in the whole production process, not only should pay attention to the safety of the operator of the bending machine, but also conduct a comprehensive inspection of the hazard sources affecting the bending machine, and propose corresponding safety protections. Measures to escort the safety of front-line workers in the workshop.

Hazard Analysis of Bending Process

Analysis of Bending Process In the entire production process of an enterprise, a qualified production manager must pay attention to the personal safety of employees, because the most important thing in the production process is safety. Generally speaking, the hazards during the operation of the bending machine mainly include mechanical damage and electrical damage.

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1. Mechanical injury problem

Mechanical injury refers to a mechanical accident that occurs when mechanical energy is accidentally released. There are many sources of danger, and it is also the most vulnerable injury to bending operators during the production process. The main hazards of mechanical injury are as follows:

• The operator of the bending machine should not stretch a certain part of his body between the upper and lower molds under any circumstances, such as when he stretches his hand between the upper and lower molds to adjust the positioning. Because when the operator stretches his hand between the upper and lower molds, the upper mold or the rear positioning of the bending machine may collide with their hands, thereby posing a threat to personal safety.

• Due to the wide variety of parts for bending operations, when the processing size of the parts is large or heavy, two people need to cooperate to complete the bending operation of the product. At the same time, two operators are required to simultaneously push the product to the designated position. When pushing the parts, two people must complete it at the same time. There are great requirements for the cooperation ability of the operators between people and people and machines. The probability of accidents increases, and the parts are very likely to collide with their heads during the process of falling. Threat to life safety. Analysis of Bending Process

• When the bending machine is in use, the foot control switch is used to push the parts by hand, and the upper and lower molds are moved under the action of hydraulic pressure, so as to achieve the requirements for the bending of the parts. When bending small parts or the size of the parts is smaller than the upper die of the bending machine, due to the incorrect bending gesture, the operator’s hand will be clamped between the upper die and the part inadvertently. Analysis of Bending Process

• During the entire operation of the bending machine, it is also necessary to avoid excessively high stacking of materials on the bending machine, which may cause parts to fall and hurt legs or feet. In addition, when placing materials, it should not be too close to the bending machine to prevent the parts from scratching the workers when they turn around.
• When the two-person operation of the bending machine, if the dual foot switch is not turned on, it may happen that one person has started to step on the foot switch while the other is still adjusting the position of the part, causing the part to scratch the operator and the part to hit the operator’s chin. Condition. In addition, in the process of pushing parts, because the edges of some parts may be relatively sharp, the hand of the inspector may be scratched.
• Bending, as an intermediate process, is the upper bearing shearing and punching process, followed by the glue, welding and assembly processes. After the previous process is completed, it needs to be hoisted to the bending process for bending operations, or the product is placed on a pallet or trolley after the bending of the product is completed, and is sent to the next process for production, and the hoisting and transportation are placed In the process, the parts fall and hurt or crush people.

2. Electrical damage

Among the operating accidents of the bending machine, the accident with the highest mortality rate is caused by electrical injury, which is the most direct harm to the human body, and the hazards of this kind of injury are mainly manifested in the following aspects. Analysis of Bending Process

• In the process of operating the bending machine, due to the poor quality of the tools and instruments used by the personnel, it is very likely to cause an electric shock accident. In addition, the motors and lighting facilities emit a large amount of heat energy after being energized, and operators may get burned if they are not paying attention.
• Some wires on the bending machine may be damaged due to the use of too long. In the case where the wire is partially exposed, the operator of the bending machine or equipment maintenance personnel is very likely to get an electric shock due to the damage of the wire. Analysis of Bending Process
• Operators of the bending machine will receive electric shocks when they illegally operate electrical equipment. In addition, in the process of continuous air movement around electrical equipment, a large amount of static electricity may cause the appearance of electric sparks, which may lead to fires.

Analysis of Safety Protection

Analysis of protection against mechanical damage

• From the perspective of prior protection work, the operator of the bending machine must first do a series of protection work before proceeding, such as wearing non-slip shoes, gloves, and safety helmets. In addition, the operators in the previous process must deburr the large burrs on the bending parts. Analysis of Bending Process
• Standardization of the safe production process of the bending machine, formulate relevant procedures in the production of the bending process and the transportation of its parts, such as safe operation procedures for mechanical handling and lifting operations, safe operation procedures for the use of parts transportation and storage, and formulate bending operations in the operation of the machine Guidance documents, such as instructions, enable operators to use tools and machines correctly and ensure their own safety. Analysis of Bending Process
• Ensure the safety and protection of the placement of the parts to be bent and finished parts, the operator must focus on keeping the man-machine synchronization, and the bending work area is separated by guardrails.
• During the entire operation of the bending machine, it is also necessary to avoid excessively high stacking of materials on the bending machine, which may cause parts to fall and hurt legs or feet. In addition, when placing materials, it should not be too close to the bending machine to prevent the parts from scratching the workers when they turn around.

On the top of the bending machine, a hazard source information board was posted on the bending production site. The board clearly pointed out the hidden safety hazards in the bending work area and pointed out that improper operation of the bending machine could easily bring harm to the operators themselves and the parts handling process. Injuries to other people passing by; analysis of hazard sources in the bending operation area, pointed out that the door panels and other parts are longer and heavier, the parts are raised and lowered too fast during bending, and the operator is not paying attention to the bending machine Whether there is someone behind it is the main reason. Analysis of Bending Process

Analysis of protection against electrical damage

• The operator of the bending machine must wear insulation equipment when conducting electrical inspections. During the inspection, illegal operations are strictly prohibited. When checking the electrical insulation and equipment grounding, you must carefully check in advance whether the wire is damaged or leaking. Once you find such a situation, you need to stop the inspection immediately. Analysis of Bending Process

• When checking the circuit and the instrument, make sure that the power supply is in a disconnected state. In order to reduce the risk of inspection, red warning signs must be posted on the surrounding guardrails. During the inspection, try not to use temporary power and circuits to prevent leakage and fire. Analysis of Bending Process

• It is necessary to post comics and text descriptions of the safety precautions for bending operations on the top of the bending machine, and to indicate the switch status of the photoelectric device of the bending machine to increase the effect of information board management. Analysis of Bending Process

In short, there are many hidden safety hazards in the production process of the bending process. We must have full knowledge and understanding of the existing hazards and take the initiative to protect ourselves. Only in this way can production and work be carried out on the basis of ensuring their own safety. Analysis of Bending Process

When the operator completes sheet metal processing or produces sheet metal parts, he must have a comprehensive study and understanding of the functions of the machinery and machine tools that need to be used, such as the functions, standards, precision of the machine tools, etc., and understand the buttons, The purpose of handles and switches and how to operate, etc. Sheet metal processing should pay great attention to safe operation during the bending operation. The safe operation has detailed specifications. It is not just that there is no risk of operation. Analysis of Bending Process

It is necessary to cultivate understanding in the mind and cultivate the plan in the actual operation, especially For those who are engaged in the operation of sheet metal machine tools, in addition to complying with the basic process operating rules, they must also comply with some other auxiliary tool process rules; usually, one person operates one machine if it appears that multiple people operate one machine Attention should be paid to the division of labor, and the irregular and idle operation of the machine cannot be carried out at will. Analysis of Bending Process

Because the sheet metal process itself is a relatively complex metal processing process; Shenzhen sheet metal processing manufacturers remind you that it is easy to operate by unskilled personnel There are many problems, so if you need more than one person to operate, you should pay attention to the safety of the operators, and then inform them of some problems that need to be paid attention to prevent some confusion and troubles due to unskilledness. Analysis of Bending Process

The bending process is a manufacturing operation used to deform or reshape materials, typically metal sheets or tubes, into specific shapes or angles. This process is commonly used in various industries, including aerospace, automotive, construction, and metal fabrication. Analyzing the bending process involves understanding its key components, methods, equipment, and important considerations. Analysis of Bending Process

Key Components of the Bending Process:

Material Selection: The choice of material plays a critical role in the bending process. Different materials, such as steel, aluminum, or copper, have varying properties and require specific bending techniques and equipment. Analysis of Bending Process

Bending Methods:
a. Press Brake Bending: This is one of the most common methods, where a press brake machine exerts force on the workpiece, causing it to bend around a die or tool.
b. Roll Bending: In roll bending, a set of rolls is used to gradually bend a workpiece into a curve or a circular shape.
c. Tube Bending: Specialized equipment is used to bend tubes or pipes into various angles or shapes, commonly used in plumbing and HVAC systems.

Tooling and Dies: Specific tooling and dies are required for each bending operation. The selection of the die’s shape and size determines the final bent shape.

Equipment: Machines like press brakes, roll benders, or tube bending machines are used to apply force and reshape the material. Analysis of Bending Process

Material Properties: Understanding the material’s mechanical properties, such as yield strength, tensile strength, and elasticity, is crucial in predicting how it will behave during the bending process.

Bend Radius and Angle: The desired bend radius and angle must be precisely defined, as they dictate the tooling and setup required. Analysis of Bending Process

Analysis of the Bending Process: Analysis of Bending Process

Springback: When a material is bent, it tends to partially return to its original shape due to its elastic properties. Calculating and compensating for springback is essential to achieve the desired final shape accurately.

Material Thickness: The thickness of the material affects the bending process, as thicker materials may require higher forces and specialized equipment.

Stress and Strain: Analyzing stress and strain in the material helps ensure that it doesn’t exceed its elastic limits, which could lead to cracks or permanent deformations.

Tool Wear: Over time, tooling and dies can wear out, affecting the quality of the bends. Regular maintenance and replacement are necessary to maintain precision. Analysis of Bending Process

Tolerance and Quality Control: Maintaining tight tolerances and conducting quality checks throughout the bending process are essential to ensure the final product meets specifications.

Material Fracture: Excessive bending force or incorrect tooling can lead to material fracture or cracks. Analyzing and minimizing the risk of fracture is critical.

Cost Analysis: Assessing the cost-effectiveness of the bending process, including equipment, labor, and material costs, is crucial in manufacturing decisions.

Environmental Impact: Understanding the environmental impact of the bending process, including energy consumption and waste generation, is becoming increasingly important in modern manufacturing.

In summary, the analysis of the bending process involves a comprehensive understanding of material properties, equipment selection, tooling, quality control, and cost considerations. Proper analysis and optimization of these factors are essential for producing high-quality bent components while minimizing waste and cost.

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