在工业加工领域，异形铝条的折弯需求日益多样化，从复杂的建筑装饰线条到精密的机械配件，全自动铝条折弯机凭借精准控制能力成为实现异形折弯的核心设备。要让设备折出理想的异形铝条，需从工艺规划、设备调试到分步操作进行全流程把控，每个环节都藏着塑造异形轮廓的关键细节。

　　In the field of industrial processing, the bending demand for irregular aluminum bars is becoming increasingly diversified. From complex architectural decorative lines to precision mechanical components, fully automatic aluminum bar bending machines have become the core equipment for achieving irregular bending with precise control capabilities. To make the device fold into an ideal shaped aluminum strip, it is necessary to control the entire process from process planning, equipment debugging to step-by-step operation, and each link contains key details for shaping the shaped contour.

　　前期工艺规划与模型构建

　　Pre process planning and model construction

　　折异形铝条前，需先明确目标形状的技术参数。通过 CAD 软件绘制异形铝条的三维模型，标注出每个折弯角的度数、折弯半径、直线段长度等关键尺寸，尤其要注意非对称结构或复合曲线的拐点坐标。例如，折制带弧线段的门框铝条时，需将弧线分解为若干段微小直线折弯的组合，计算出每段的折弯角度与位移量。同时，根据铝条的材质（如 6063 或 5052 铝合金）和厚度（1-5mm 不等），查询材料的屈服强度与延伸率数据，以此确定折弯时的最小弯曲半径，避免因折弯半径过小导致材料开裂。

　　Before folding the irregular aluminum strip, it is necessary to first clarify the technical parameters of the target shape. Draw a 3D model of the irregular aluminum strip using CAD software, and mark key dimensions such as the degree of each bending angle, bending radius, and length of straight segments, paying special attention to the inflection point coordinates of asymmetric structures or composite curves. For example, when folding aluminum door frames with curved segments, the arc needs to be decomposed into several combinations of small straight line bends, and the bending angle and displacement of each segment need to be calculated. At the same time, based on the material (such as 6063 or 5052 aluminum alloy) and thickness (1-5mm) of the aluminum strip, the yield strength and elongation data of the material are queried to determine the minimum bending radius during bending, in order to avoid material cracking caused by too small a bending radius.

　　将三维模型导入折弯机的数控系统前，需进行工艺拆分。对于多折弯工序的异形件，要规划折弯顺序，遵循 “先小角度后大角度、先外侧后内侧” 的原则。如折制 “Z” 字形铝条时，应先完成底部折弯，再进行顶部折弯，避免后续折弯对已成型部分产生干涉。同时，在模型中标记出铝条在模具上的定位基准点，通常选择长度方向的端面或已加工的孔位作为定位参考，确保后续加工时位置精度。

　　Before importing the 3D model into the CNC system of the bending machine, process splitting is required. For irregular parts with multiple bending processes, it is necessary to plan the bending sequence and follow the principle of "small angle first, large angle second, outer side first, inner side second". When folding the "Z" shaped aluminum strip, the bottom bending should be completed first, and then the top bending should be carried out to avoid interference with the already formed part during subsequent bending. At the same time, mark the positioning reference points of the aluminum strip on the mold in the model, usually selecting the end face in the length direction or the processed hole position as the positioning reference to ensure the positional accuracy during subsequent processing.

　　设备调试与模具适配

　　Equipment debugging and mold adaptation

　　全自动折弯机的模具选择需匹配异形件的折弯需求。标准 V 型模具适用于直线折弯，而折制弧形或特殊截面时，需更换定制的成型模具。例如，折制圆弧铝条时，需使用带有圆弧凹槽的上模和相应弧度的下模，模具的弧度半径应比目标铝条的半径大 0.5-1mm，以补偿材料回弹。安装模具时，通过设备的模具定位系统校准上下模的对齐度，并用塞尺检查模具间隙，确保间隙值等于铝条厚度的 1.2 倍（如 3mm 厚铝条对应 3.6mm 间隙），避免间隙过小压溃材料或过大导致折弯角度偏差。

　　The selection of molds for fully automatic bending machines needs to match the bending requirements of irregular parts. Standard V-shaped molds are suitable for straight bending, but when bending curved or special sections, customized molding molds need to be replaced. For example, when folding curved aluminum bars, it is necessary to use an upper mold with curved grooves and a lower mold with corresponding curvature. The curvature radius of the mold should be 0.5-1mm larger than the radius of the target aluminum bar to compensate for material rebound. When installing the mold, calibrate the alignment of the upper and lower molds through the mold positioning system of the equipment, and check the gap between the molds with a feeler gauge to ensure that the gap value is equal to 1.2 times the thickness of the aluminum strip (such as a 3mm thick aluminum strip corresponding to a 3.6mm gap), to avoid material crushing due to too small a gap or bending angle deviation due to too large a gap.

　　调试设备的运动参数时，先设定折弯速度。对于复杂异形件，初始速度应控制在 5-10mm/s，待试折确认无误后再逐步提升至 15-25mm/s。压力参数的设定需参考材料力学数据，6063 铝合金在 2mm 厚度下，折弯压力通常为 8-12MPa，可通过设备的压力测试功能，在废料上进行压力梯度试验，找到既能保证折弯角度又不损伤表面的最佳压力值。同时，调整后挡料装置的定位精度，使用激光测距仪校准挡料块的位置，确保定位误差不超过 ±0.1mm，这对多段折弯的异形件尤为重要。

　　When debugging the motion parameters of the equipment, first set the bending speed. For complex shaped parts, the initial speed should be controlled at 5-10mm/s, and gradually increased to 15-25mm/s after confirmation of correctness through trial bending. The setting of pressure parameters should refer to material mechanics data. The bending pressure of 6063 aluminum alloy at a thickness of 2mm is usually 8-12 MPa. The pressure gradient test can be conducted on the waste material through the pressure testing function of the equipment to find the optimal pressure value that can ensure the bending angle without damaging the surface. At the same time, adjust the positioning accuracy of the material blocking device and calibrate the position of the blocking block using a laser rangefinder to ensure that the positioning error does not exceed ± 0.1mm, which is particularly important for multi segment bent shaped parts.

　　数控编程与分步折弯操作

　　Numerical Control Programming and Step by Step Bending Operation

　　在折弯机的人机交互界面中，导入前期构建的三维模型后，系统会自动生成 G 代码程序。对于异形件，需手动优化程序中的折弯顺序和补偿参数。例如，在程序中加入 “折弯 - 停顿 - 检测” 的循环步骤，每完成一次折弯后，设备暂停 2-3 秒，让铝条释放内部应力，减少连续折弯时的累积误差。针对材料回弹现象，在程序中设置回弹补偿值，通常 6063 铝合金在 90° 折弯时回弹角为 2-3°，可将目标角度设为 92-93°，通过回弹补偿确保最终角度准确。

　　In the human-computer interaction interface of the bending machine, after importing the 3D model constructed in the early stage, the system will automatically generate a G-code program. For irregular parts, it is necessary to manually optimize the bending sequence and compensation parameters in the program. For example, adding a loop step of "bending pause detection" in the program, the equipment pauses for 2-3 seconds after each bending is completed, allowing the aluminum strip to release internal stress and reduce cumulative errors during continuous bending. To address the phenomenon of material rebound, a rebound compensation value is set in the program. Typically, the rebound angle of 6063 aluminum alloy during 90 ° bending is 2-3 °, and the target angle can be set to 92-93 ° to ensure accurate final angle through rebound compensation.

　　开始折弯操作时，先将铝条放置在工作台上，利用定位挡块和夹具固定，确保铝条的折弯线与模具的中心线重合。对于长尺寸异形铝条，需在悬空端加装辅助支撑装置，防止折弯时因重力下垂导致角度偏差。启动设备后，密切观察折弯过程，首件加工完成后，使用三坐标测量仪或角度尺全面检测尺寸精度，重点检查折弯角度（误差应≤±0.5°）、直线度（每米≤0.3mm）和表面质量（无划痕、裂纹）。若检测到某段折弯角度超差，可在程序中调整该步骤的压力值或增加二次折弯修正工序。

　　When starting the bending operation, first place the aluminum strip on the workbench, use positioning blocks and fixtures to fix it, and ensure that the bending line of the aluminum strip coincides with the centerline of the mold. For large-sized irregular aluminum bars, auxiliary support devices need to be installed at the suspended end to prevent angle deviation caused by gravity sagging during bending. After starting the equipment, closely observe the bending process. After the first piece is processed, use a coordinate measuring instrument or angle ruler to comprehensively check the dimensional accuracy, with a focus on checking the bending angle (error should be ≤± 0.5 °), straightness (≤ 0.3mm per meter), and surface quality (no scratches or cracks). If the bending angle of a section is detected to be out of tolerance, the pressure value of this step can be adjusted in the program or the secondary bending correction process can be added.

　　误差修正与量产优化

　　Error correction and mass production optimization

　　当异形铝条的折弯误差超出允许范围时，需从多方面分析原因。若整体角度偏大，可能是压力不足或回弹补偿值设置偏小，可将压力提高 1-2MPa 或增加回弹补偿角 1°；若局部出现扭曲，可能是铝条固定不牢或模具磨损，需检查夹具压力并更换磨损的模具部件。对于复杂的异形件，可采用 “分段试折 - 逐步修正” 的方法，先完成关键部位的折弯并检测，再根据结果调整后续步骤的参数，避免一次性加工导致不可挽回的误差。

　　When the bending error of the irregular aluminum strip exceeds the allowable range, it is necessary to analyze the reasons from multiple aspects. If the overall angle is too large, it may be due to insufficient pressure or a set rebound compensation value that is too small. The pressure can be increased by 1-2 MPa or the rebound compensation angle can be increased by 1 °; If there is local distortion, it may be due to the aluminum strip not being firmly fixed or the mold being worn. It is necessary to check the fixture pressure and replace the worn mold components. For complex shaped parts, the method of "segmented trial bending and gradual correction" can be used. First, the key parts are bent and tested, and then the parameters of subsequent steps are adjusted based on the results to avoid irreversible errors caused by one-time processing.

　　进入量产阶段前，需进行连续 5-10 件的试生产，统计尺寸波动范围。若发现某段折弯的角度一致性差，可启用设备的自动补偿功能，通过传感器实时监测折弯力和角度，动态调整压力参数。同时，定期（每 50-100 件）检查模具的磨损情况，对圆角部位进行抛光处理，确保模具精度稳定。对于批量生产的异形铝条，可在设备上加装视觉检测系统，每完成一件后自动扫描轮廓，与三维模型比对，对超差产品实时标记并剔除，保证批量产品的一致性。

　　Before entering the mass production stage, continuous trial production of 5-10 pieces is required to calculate the size fluctuation range. If the consistency of the bending angle of a certain section is found to be poor, the automatic compensation function of the equipment can be enabled, and the bending force and angle can be monitored in real time through sensors to dynamically adjust the pressure parameters. At the same time, regularly (every 50-100 pieces) check the wear of the mold, polish the rounded corners to ensure stable mold accuracy. For mass-produced irregular aluminum bars, a visual inspection system can be installed on the equipment to automatically scan the contour after each piece is completed, compare it with the 3D model, mark and remove out of tolerance products in real time, and ensure the consistency of the batch products.

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