Michigan Shop Crushing Press Brake Productivity with CI Software

In a previous post, we outlined how Accurate Engineering & Manufacturing boosted their business to new heights by adding a 175-ton BASEFORM press brake with CI Software to their shop floor (see Total Game Changer: Michigan Shop Installs CI Press Brake). In this article, we revisit the Holland, Michigan-based metal fab job shop to focus in on the Bend Sim and Unfolder apps, and the effect they have had in streamlining operations.

Recap

Accurate has been in business since 1995, serving clientele primarily in western Michigan, producing anywhere from one piece to 2,000 pieces, with most runs in the sub-ten-piece range. They’ll reverse engineer parts for their clients, and they don’t shy away from challenging projects or materials. Parts consist of control boxes, control units, stainless steel table tops, etc. “You name it, we make it,” said Owner & President Randy VanderPloeg.

Like everyone, Accurate experienced a downturn during the pandemic. But business has come back so strongly, they recently bought a used 90-ton, 8-foot CI press brake to run smaller parts.

The company has carved out a niche for themselves in short run, high precision work, which means a lot of setup and changeovers. That is precisely the environment where the CI software shines.

“The Bend Sim and Unfolder software really have made our life easier,” said Shop Manager Chad Hill. “Now, I wouldn’t want to work without them.” For example, Hill says that with a limited amount of data input into Bend Sim, he can answer the three basic questions that need to be answered before beginning any job: Can we do it, what tooling do we need to do it, and do we have the tooling in-house? “Plus, the whole process takes little or no data entry at the machine level,” he said.

Creating a Flat File

Ninety-five percent of the work Accurate gets from their clients comes in the form of some kind of 3D file. “From there we have the option of putting it into our version of SolidWorks for some adjustments, or we can go right into the Unfolder app,” Hill said.

Once the file is in Unfolder, the end goal is to create a flat pattern of the final 3D image. “Unfolder comes with a bank of tooling that you can select to use for the bend profiles of the part,” said VanderPloeg. “Based on the tooling you select, it outputs the correct flat pattern while maintaining overall dimensions of the model.

“Unfolder and Bend Sim work great hand-in-hand.  Our clients benefit because the software combination can suggest alternate ways a part can be fabricated. That might save them money.”

Simulation and Program Files

While the flat pattern is saved as a DXF file on the server, there’s also a link in the program to export the file to Bend Sim. All the flange dimensions, bend links and data regarding tooling selected are transferred over. Bend Sim can then generate multiple simulations of the bend sequence. It can do this automatically, or you can program it manually, based on your technical expertise,” said Hill. “The simulations notify you of any interference errors like hitting the ram, your  tooling or bed rails.” Backgauge motion is also calculated. A  set up sheet is then generated that shows the sequence of operation.

“Once you select a simulation you like, Bend Sim will create a program file which is saved on our server along with any setup notes that I create for the operator,” said Hill. “These might include any known issues or screenshots of the simulation sequence that might prove helpful for running the job.”

This is useful when the file goes out on the floor to the machine. The operator will grab the saved program file and notes from the server at the machine. If there’s any question, the operator can run the simulation at the machine level and resolve issues before bending material.

With skilled operators hard to come by, VanderPloeg really sees this as a big plus. “It eliminates guesswork and allows less-experienced people to run more complex jobs,” he said.

Countless Benefits for All

For any fab shop, Bend Sim and Unfolder are tremendous time savers. Our setup times have been reduced from 30 minutes down to as low as five,” said Hill. “That’s why we use them for so much of our work.”

“Our clients love it because we can prove a process without going to the trouble of creating a prototype or test part. You can imagine how much time that saves in an environment where there are many different types of short run parts.”

“Having the ability to save screenshots of the simulation is helpful when trying to explain something to the customer as well,” Hill added.

“With all these advantages, the question isn’t why would a shop consider adding Bend Sim and Unfolder to their press brake,” said VanderPloeg. “The question is why wouldn’t they?”

Would you like to gain a competitive edge for your business?

Learn more about our press brakes, software offerings and more!