Incorrect Mandrel Position: Adjust The Mandrel’s Extension Into The Tube To Ensure It Supports The Bending Area.
Mismatched Tooling: Check If The Bend Die, Clamp Die, And Pressure Die Match The Tube Dimensions.
Excessive Speed: Reduce The Bending Speed, Especially For Thin-Walled Tubes.
Material Issues: Inspect Tube Quality To Ensure Uniform Wall Thickness.
Material Springback: Use The CNC System’s Springback Compensation function to overbend the tube by a calculated amount based on the material’s properties (hardness/thickness).
Hydraulic Instability: Check The Hydraulic System pressure for fluctuations, ensure the oil temperature is stable, and inspect seals for leaks or aging.
Tooling Alignment: Verify the alignment of all tooling components (bend die, clamp die, etc.) and ensure all fasteners are properly tightened.
Tooling Cleanliness: Clean the dies (especially the bend die groove) thoroughly to remove any metal chips or debris that can cause scoring.
Lubrication: Apply an appropriate bending lubricant to the tube surface or the die before bending to reduce friction.
Die Surface Quality: Inspect the working surfaces of the dies for wear, nicks, or excessive roughness; polish or replace if necessary.
Power Supply: Check the input voltage to the servo drive for stability and correct phase sequence.
Mechanical Overload: Check if the axis is physically stuck or encountering excessive resistance, which could trigger a high-current or over-torque alarm.
Encoder Feedback: Verify the connection and functionality of the encoder cable, as corrupted feedback can lead to positioning errors and alarms.
Calibration: Periodically perform a Machine Zero Point Calibration to ensure the machine’s absolute reference point is accurate.
Data Correction: Use the machine’s software to implement YBC Data Correction or Total Length Correction after measuring a sample part to compensate for cumulative error.
Processing Order: Optimize the bending sequence to minimize the effect of earlier bends on later positioning.
Hydraulic Pump Noise: Check the hydraulic oil level and cleanliness; low oil level or contaminated oil can cause the pump to cavitate and generate noise.
Mechanical Play: Inspect for loose bolts, worn bearings, or excessive clearance (play) in the transmission components (gearbox, chains) which can cause rattling or knocking sounds.
Servo Motor Vibrations: Check the servo tuning parameters; improper tuning can cause the motors to oscillate or vibrate excessively during movement.
Material Selection: Ensure the tooling material (e.g., high-carbon steel, heat-treated alloy) is appropriate for the tube material being bent (e.g., high-strength steel requires higher grade tooling).
Optimal Lubrication: Implement a consistent, high-quality lubrication schedule to minimize friction and wear.
Tooling Alignment: Maintain precise alignment of all tooling to prevent uneven wear or point loading on die surfaces.
Parameter Recall: Utilize the CNC system’s memory function to quickly recall and load previously saved bending programs and settings for the new tube size.
Tooling Changeover: Standardize tooling change procedures using quick-change mechanisms and a documented setup sheet to minimize downtime.
Trial Bends: Perform a minimum number of trial bends, using the stored compensation values to confirm accuracy before starting mass production.
Mandrel Support: For thin-walled tubes, use a Ball Mandrel and ensure it provides adequate internal support to the entire bending area.
Pressure Die Assistance: Increase the Boosting Force applied by the pressure die to assist in tube feeding and reduce drawing stress on the outside bend radius.
Bending Speed: Further reduce the bending speed to allow the material more time to flow and form around the die.
Regular Backup: Establish a mandatory routine for backing up all system files and part programs (including parameters, offsets, and tooling data) to an external storage device (USB, network drive).
Restore Procedure: Have a documented procedure for restoring the system from the latest reliable backup file.
Contact Support: Immediately contact the machine manufacturer’s technical support for official assistance and potential remote diagnostics/fixes.
