Brake Applications Catalog

Catalog for application examples
TRUMPF LASERdur bending tools for your products
https://www.mytrumpf.com
Catalog for
application examples
Edition:
05/2007
Mat. no.:
1439870
Language: English
This document was created by the Technical Documentation of TRUMPF

Maschinen Austria GesmbH & Co. KG.
All rights to this documentation, in particular the rights of reproduction,
distribution, and translation, are retained by TRUMPF Maschinen Austria
GesmbH & Co. KG, even in the case of notifications of protective privilege. No
part of this documentation may be reproduced, processed, duplicated, or
distributed by means of electronic systems in any form whatsoever without the
prior written consent of TRUMPF Maschinen Austria GesmbH & Co. KG. We
reserve the right to make technical changes and to amend errors/omissions.
TRUMPF Maschinen Austria GesmbH & Co. KG
TRUMPF Maschinen Austria GesmbH & Co. KG cannot be made responsible
for possible mistakes in this documentation. No liability is accepted for direct or
indirect damage or injury resulting from the delivery or use of this
documentation, in so far as this is legally permissible.
Before you read on...

On the contents
In this catalog, we present to you the application examples and

their tool solutions. You can see for yourself the options that
TRUMPF offers to you.
The key to success is combining Know How with quality and
technology. We believe in technical consultation so that we can do
justice to your requirements.
The TRUMPF bending tools develop just the right tool solution for
you to optimize the production of your tools. The tools are tested
on your special material and the sample parts are then sent to you.
When you see this symbol, enter the following data:
Dimensions of your product

Tolerances
Material type
Sheet thickness
Please send a copy of this information to your TRUMPF sales

partner.
For further questions, contact your TRUMPF sales partner.
We would be happy to advise you.
0-4
Table of contents
1.
TRUMPF makes it possible...............................................8
2.
2.1
2.2
2.3
2.4
2.5
Radius tools .....................................................................10

Forming tools for radius bend (U-part) ..............................10
Forming tool for radius bend (circular part) ......................12
Radius embossing tools for large radii ..............................14
Tool with a plastic insert ....................................................16
Tools for radius bending in individual steps
(bumping/stepping) ............................................................18
3.
3.1
3.2
3.3
3.4
3.5
3.6
Tools for U parts ..............................................................20

Tool goosenecked for U part .............................................20
Tool holder (OW308) goosenecked for U part ..................22
Tool with an goosenecked adapter for U part....................24
Tool for a wide U part in one step......................................26
Tool for a narrow U part in a single step............................28
Embossing tool 30/60 .....................................................30
4.
4.1
4.2
Rotating jaw tool (U part) ................................................32

Small rotating jaw tool........................................................32
Large rotating jaw tool .......................................................34
5.
Tools and auxiliary tools for reduced-mark
5.1
5.2
5.3
5.4
5.5
5.6
bending .............................................................................36
Tools for reduced-mark folding..........................................36
TRUMPF bending foil ........................................................37
Die with R3 working radii ...................................................38
KEV die with plastic inserts................................................39
WingBend.........................................................................40
Undivided tools ..................................................................43
6.
SBW Swivel bending tool.............................................44
7.
DV adapter........................................................................46
8.
8.1
8.2
8.3
Horn tools .........................................................................48

Moveable horn tool ............................................................48
Left/right horn.....................................................................50
Horn window tool ...............................................................52
9.
9.1
9.2
9.3
Window tools ...................................................................54

Tool with a slewable window .............................................54
Window tool with countersinking .......................................56
Window tool with adapter...................................................58
10.
Hinge tools .......................................................................60
0-5
10.1
10.2
10.4
10.5
Hinge tool complete (producing hinge in two steps)..........60

Tool holder with hinge inserts (producing hinge in
three steps)........................................................................62
Hinge tool complete (producing hinge in three
steps) .................................................................................64
Tool for special hinge forms...............................................66
Tool for hinges with 90 bend ............................................68
11.
Punch and die rotated .....................................................70
12.
12.1
Tools for bracing beading...............................................72

Tools for diagonal beading ................................................72
Beading bar for diagonal beading.................................72
Tool with alignment pins for diagonal beading .............74
Tools for longitudinal beading............................................76
Tool for longitudinal beading (running through
the sheet metal) ............................................................76
Tool for longitudinal beads without presser foot
plate (ending in the sheet metal) ..................................78
Tools for longitudinal beading with presser foot
plate (ending in the sheet metal) ..................................80
10.3
12.2
0-6
13.
13.1
13.2
Number embossing and logo tools ...............................82

Number embossing tool with steel types ...........................82
Logo embossing tool..........................................................84
14.
14.1
14.2
Louver tools .....................................................................86

Louver tool for closed tool contour ....................................86
Louver tool for endless louver ...........................................88
15.
15.1
15.2
Countersink shaped tool.................................................90

Round countersink shaped tool .........................................90
Countersink shaped tool (bridge) ......................................92
16.
16.1
16.2
Reshaping tools (cups) ...................................................94

Embossing tools for cups...................................................94
Cupping tool without presser foot plate ........................94
Cupping tool with presser foot plate .............................96
Embossing tool for special shapes ....................................98
17.
17.1
17.2
Adjustable dies ............................................................. 100

Adjustable die VLM......................................................... 100
Adjustable die W20 W90 ............................................. 102
18.
Die with rollers .............................................................. 104
19.
19.1
19.2
Folding tools ................................................................. 106

Folding tools (standard) .................................................. 106
Folding tools FEV die (standard) .................................... 108
19.3
19.4
19.5
19.6
19.7
19.8
Folding tool with holder OW209/S .................................. 110

Flat tools ......................................................................... 112
Special folding tool (die with U-shape) ........................... 114
Folding tool for double fold ............................................. 116
Folding tool for reduced-mark folding ............................. 118
Folding table ................................................................... 120
20.
20.1
20.2
Z bending tools ............................................................. 122

Z bending tools (standard).............................................. 122
Z bending tools (special solutions) ................................. 124
21.
21.1
21.2
Tools for corner reshaping .......................................... 126

Tool for outward corner reshaping.................................. 126
Tool for inward corner reshaping.................................... 128
22.
22.1
22.2
22.3
Tools for closed profiles .............................................. 130

Tool for closed profile (with integrated folding)............... 130
Tool for closed profile (thick sheet frame) ...................... 132
Tool for closed profiles (freely pressed together) ........... 134
23.
Displaced bending line in a stroke ............................. 136
24.
Tool for round rods ...................................................... 138
25.
25.1
25.2
Tools for frames............................................................ 140

TRUMPF individual tools for frames............................... 140
WILA double-level tool for frames (pneumatic) .............. 142
26.
Bending various materials........................................... 144
27.
Safety Click.................................................................. 146
28.
Surfaces and heat treatment of tools ......................... 148
29.
29.1
29.2
Equipment and stop aids ............................................. 152

Quickstop ........................................................................ 152
Stop aids ......................................................................... 154
30.
Modifying the tools....................................................... 156
31.
Programming ................................................................ 158
0-7
1.
TRUMPF makes it possible
Product Overview
0-8
Page 13
Page 15
Page 19
Page 19
Page 21
Page 23
Page 27
Page 31
Page 35
Page 37
Page 38
Page 41
Page 43, 105
Page 49
Page 51
Product Overview
Page 55
Page 61
Page 75
Page 79
Page 83
Page 87
Page 89
Page 97
Page 99
Page 117
Page 127
Page 129
Page 131
Page 137
Page 155
0-9
2.
Radius tools
Radius bends can be produced in various ways.
2.1
Application
Application range
Advantages
Tool
Forming tools for radius bend

(U-part)
A U-part is produced through a positive lock between the upper

and the lower tool. The bending radius ("R") is specified through
the tool radius (depending on the sheet thickness, material
type,).
Up to 8 mm sheet thickness (depending on the bending radius).
Exact product radius.
High repeatability.
U part manufactured in two steps.

Drawing
Measure the drawing (incl. length).

Specify the tolerances.
Specify the material type: ______________________
Specify the sheet thickness: ____________________
0-10
Producing a U-part in two steps

1
Product
0-11
2.2
Application
Application range
Advantages
Tool
Forming tool for radius bend

(circular part)
A circular part is produced through a positive lock between the

upper and the lower tool. The bending radius is specified with the
help of the tool radius (depending on the sheet thickness, material
type,). Circular parts can be used as hand rail for steps for
example.
Exact product radius.
High repeatability.
Circular part manufactured in three steps.
Drawing

0-12
Producing a circular part in three steps

1
Product
0-13
2.3
Application
Application range
Advantages
Radius embossing tools for large radii
A tool with a large radius is embossed mostly in several steps

through a positive lock between the upper and the lower tool. The
bending radius is specified with the help of the tool radius
(depending on the sheet thickness, material type,). Parts with
large radii can be used for a brake jaw for example.
Alternative to rolling machine.
High repeatability.
Optimum rounding compared to "bumping".

Tool
Drawing

0-14
Select the material type: _______________________

Select the sheet thickness: _____________________
Embossing large radii

1
Product
0-15
2.4
Application
The lower tool having a plastic insert can be combined with various
upper tool radii.
Application range
Advantages
Note
Tool
Tool with a plastic insert
Plastic insert
EV holder
Up to around 3 mm sheet thickness.
Reduced-mark production.
Flexible application:
Can be combined with various upper tool radii.
Plastic inserts can be supplied in various dimensions

(80x50, 100x50, 130x50,..).
Suitable for radius segments running down.
Greater bending lengths (>1000 mm) might lead to inaccuracies in

the parallelism of parts.
Drawing

0-16
Bending the radius on a plastic insert (OW radius R50)

1
Bending the radius to the plastic insert (OW radius R15)

1
0-17
2.5
Application
Application range
Advantages
Tip
Tools for radius bending in individual

steps (bumping/stepping)
Radius bending in individual steps is also known as "bumping" or

"stepping". The rounding is divided into individual segments that
are bent towards each other. The "bumping" is mostly covered with
standard tools and is thus a cost-effective solution.
A part is generally bended using standard tools (low tool

costs).
Striking optics through segmented surfaces.
Various radii and roundings possible.
Stop aids on the blank ease exact positioning bending.
Drawing

Specify the material type: _________________________
Specify the sheet thickness: _________________________
0-18
Radius bending using standard tools (OW 200/S and OW 210) in individual steps
1
1
2
OW 200/S
EV-W8/84
1
2
OW 210
EV003
Product
Product
(channel)
(clip)
0-19
Application
Application range
Advantage
Note
Tool
3.
Tools for U parts
3.1
Tool goosenecked for U part
U parts are usually manufactured using gooseneck tools. Their

height and throat depth can be adapted individually.
Tool heights up to ~ 500 mm possible.
Throat depth up to ~ 200 mm possible.
The tool is extremely flexible and can be used for various U

part versions.
The "Tool gosseneck for U part" is adapted as per the

customer-specific U part.
Can be used for various U parts.
Pay attention to the installation height of the machine in case of

high upper tools.
Drawing

0-20
Producing U profile with OW200/S (special)
Upper tool adapted to C parts
1
2
3
OW200/S standard H=220

OW200/S special H=300
OW200/S special H=400
Product
1
2
OW/K special H=120

C profile in various sizes
Product
0-21
3.2
Application
Application range
Advantages
Note
Tool
Tool holder (OW308) goosenecked for

U part
U parts are usually manufactured using goosenecked tools. Their

height and throat depth can be adapted individually. The tool
holder OW308/S goosenecked with round material (from R10
onwards) makes it possible to create various product radii on the U
part.
Various product radii can be produced.

high upper tools.
Drawing

0-22
Producing a U part with an goosenecked OW308/S and round punch

1
Upper tool with round material
1
2
OW308/S goosenecked
Round material (can be exchanged)
Product
0-23
3.3
Application
Application range
Advantages
Tool with an goosenecked adapter for

U part
U parts are usually manufactured using goosenecked tools. Their

height and throat depth can be adapted individually. The
goosenecked adapter with Modufix clamping enables combination
with the widest possible range of TRUMPF standard tools.
Tools can be used individually (TRUMPF standard tools).
Various product radii can be produced.
Suitable for high boxes.
Note
Tool

high upper tools.
Drawing

0-24
Producing U part with an goosenecked adapter and OW202/K
Goosenecked adapter
1
2
Goosenecked adapter
Modufix clamping
Product
0-25
3.4
Application
Application range
Advantages
Note
This tool makes it possible to manufacture extremely high

U profiles in a single step. In order to prevent the product from
getting stuck in the die, the profile is pressed out from the lower
tool using ejectors and gassprings.
Up to 5 mm sheet thickness.
U parts manufactured in a single step.
Cost-effective for large quantities.
Single removal of the bending parts.
Tool
Tool for a wide U part in one step
This is often the only practical option to manufacture

extremely high U parts.
Upper and lower tools are precisely adapted to your material
(sheet thickness) and can thus be determined only in the test.
Drawing

0-26
Producing a wide U part in a single step

1
Upper tool
Lower tool
1
2
3
4
Lower tool
Ejector ledge
Gassprings
Positioning screws
Product
0-27
3.5
Application
Application range
Advantages
Note
This tool makes it possible to manufacture extremely high and

narrow U parts in a single step. In order to prevent the product
from getting stuck in the die, the profile is pressed out from the
lower tool using ejectors and gassprings.
U parts are manufactured in a single step.
Tool
Tool for a narrow U part in a single

step
This is often the only practical option to manufacture

extremely high and narrow U parts.
Upper and lower tools are precisely adapted to your material
(sheet thickness) and can thus be determined only in the test.
Drawing

0-28
Producing a narrow U part in a single step

1
Upper and lower tool
1
2
Upper tool
Gassprings
3
4
Ejector ledge
Die body
Product
0-29
3.6
Embossing tool 30/60
Application
When bending using 30/60 embossing tools, U parts in the

bending process are tilted such that collisions with the press
beams or punches are avoided.
Application range
Up to max. 3 mm sheet thickness (depending on the material type

and product length).
Advantages
Note
Tool
No auxiliary bending for deep U parts.
Lower tool costs compared to elbowed special tools.
Installation height of the machine is not important.
When using 30/60 embossing tools, the machine power is an

important point for long parts.
Drawing

0-30
Producing a U part with 30/60 embossing tools

1
Upper tool 30/60
Lower tool 30/60
Product
0-31
4.
Rotating jaw tool (U part)
4.1
Small rotating jaw tool
Application
Extremely high (deep) U parts can be manufactured with the

"Small rotating jaw tool". The rotating jaws balance the spring-back
of the material through overbending. With this tool, pre-bending
and folding is no longer necessary.
Application range
Up to 4 mm sheet thickness (in case of thin sheet, possible from

Ri= 2 mm onwards).
Advantages
Note
Tool
High repeatability.
Saves "Pre-bending and folding".
This is often the only practical option to manufacture extremely

high (deep) U parts.
Drawing

0-32
Producing U parts in a single step

1
Lower tool
1
2
Rotating jaw
Rotating jaw body
Upper tool
1
2
Tool holder OW209/S

OW320 insert
Product
0-33
4.2
Application
Application range
Advantages
Note
Tool
Large rotating jaw tool
Extremely high (deep) U parts can be manufactured with the

"Large rotating jaw tool". The rotating jaws balance the spring-back
of the material through overbending. With this tool, pre-bending
and folding is no longer necessary.
Up to 12 mm sheet thickness (min. R 20).
High repeatability.
Saves "Pre-bending and folding".
This is often the only practical option to manufacture extremely

high (deep) U parts.
Drawing

0-34
Producing U parts in a single step

1
Lower tool
1
2
3
Upper tool
Rotating jaw
Return spring
Rotating jaw body
Product
0-35
5.
Tools and auxiliary tools for reducedmark bending
TRUMPF has developed a range of solutions for reducing or

avoiding traces of abrasion and marks on the surface of the
material:
Reduced-mark folding.
TRUMPF bending foil.
Dies with R3 working radius.
Dies with plastic inserts.
WingBend dies.
Undivided tools.
5.1
Tools for reduced-mark folding
With plastic inserts in the working area, TRUMPF provides a

solution for reduced-mark folding (refer to chapter 19).
1
2
0-36
KEV insert for folding

KEV insert with ground V-opening
5.2
TRUMPF bending foil
Application
The bending foil is placed over the lower tool and thus prevents
imprints that can occur on the workpiece due to friction with the
metal. The TRUMPF bending foil is available in 30 meter rollers.
Other dimensions available are: width 100 mm; strength 0.4 mm.
Advantages
Can be used with all dies and materials.
High friction resistance during correct application.
The TRUMPF bending foil prevents imprints on the workpiece
TRUMPF bending foil available in 30 m roller
Product
0-37
5.3
Die with R3 working radii
Application
The dies have considerably larger working radii. They are used to
ensure that the foil does not rip when bending foil-coated sheets or
that traces of abrasion become visible on the material surface.
Advantages
For foil-coated sheets (less foil loading).
Reduction of indents on sheets without foil.
Available for dies EV001 R3 to EV005 R3 ex warehouse.
Bends of up to 30 are possible.
Note
The minimum side length increases while die widths with small
inflow radius remain the same.
Foil does not rip
EV001 R3
Product
0-38
5.4
Application
Application range
Advantages
KEV die with plastic inserts
KEV dies have exchangeable plastic inserts in the area of the

working radii. Standard KEV dies are air bending tools with an
opening angle of 30.
Maximum loads: 200 kN/m.
Up to max. 2.5 mm hick stainless steel sheets.
Best suitable for parts without protective foils.
Also suitable for painted and coated sheets.
Plastic inserts can be exchanged.
Standard die widths: 8, 10, 12, 16, 20, and 24.
Bends of up to 30 are possible.
Part with KEV die possible
Part without KEV die possible
KEV dies
1
2
3
Special KEV die +K-ZDL combined

Standard KEV dies 30 (W6-W24)
Special KEV die (insert completely ground)
Product
0-39
WingBend
5.5
Application
Application range
Advantages
Note
During the bending procedure, the sheet metal is pressed

uniformly by the contact surfaces. Thus, there is almost no relative
movement between the tool and the workpiece.
WingBend can be used on all TRUMPF bending presses.
From 0.5 mm to 6.5 mm sheet thickness (on request up to

10 mm with WB950).
For foil-coated sheets, but also for painted and coated

surfaces
Painted or powdered surfaces are not damaged.
Bends of 180 to 90 possible.
Recesses and holes even near the bending line can be

produced without deformation.
Extremely short sides can be produced.
Sheet thickness variable.
Hardened jaws.
Guaranteed exchangeability through highest precision.
ACB (automatic angle measurement system) cannot be used in

combination with WingBend!
Press force table

WingBend
120
Sheet
thickness
[mm]
0.3
WingBend
230
WingBend
350
R0.2
R1.0
R0.2
R1.0
R3.0
40
50
40
50
50
R0.2
R1.0
WingBend
650
R3.0
R0.2
R1.0
R3.0
R0.5
R10.0
0.5
50
60
50
50
50
40
40
40
100
100
100
100
220
0.8
100
130
70
80
90
40
50
50
100
100
110
130
230
1.0
150
190
80
100
130
60
60
70
110
120
120
140
250
1.2
240
300
110
140
180
70
70
80
110
120
120
150
270
1.6
200
220
250
120
130
140
110
120
130
160
280
2.0
300
330
190
200
220
120
130
140
160
360
2.3
400
420
240
240
260
140
140
150
190
390
2.6
340
360
470
180
190
200
240
510
3.2
550
660
250
270
280
310
4.0
410
430
440
510
4.6
500
530
540
660
6.0
970
1000
1070
kN/m
R=Punch-radius
0-40
Using WingBend to bend a part in an imprint-free manner

1
WingBend versions
1
2
3
WingBend 120
WingBend 230
WingBend 350
4
5
6
WingBend 650
Exchangeable 13 mm TRUMPF adapter ledge
"Wing Unit consisting of hardened jaws and tension springs
Products
0-41
Standard values for minimum flange

length (outside dimensions)
Side length [mm]
Material Sheet
thickness
[mm]
WB 120
WB 230
WB 350
WB 650
Upper tool radius [mm]
Steel
R0.5
R1
0.50
2.80
3.00
R0.5
R1
R1
0.80
3.20
1.00
3.40
R1
R4
3.40
5.00
4.80
5.70
3.50
5.50
5.40
7.00
6.80
7.30
1.50
5.90
6.10
8.00
8.10
9.20
2.00
5.70
6.60
8.30
10.40
10.80
2.50
8.80
11.80
12.30
3.00
9.40
13.40
13.90
4.00
15.00
15.80
5.00
16.20
16.10
6.00
Stainless
steel
0.50
2.90
3.10
0.80
3.40
3.50
5.40
5.20
6.50
1.00
3.60
3.70
5.80
5.60
7.50
7.40
8.20
1.50
6.00
6.00
8.60
10.00
10.50
2.00
6.50
6.30
8.60
12.00
11.90
2.50
9.00
13.00
13.00
3.00
9.30
14.20
13.90
15.10
15.20
4.00
5.00
6.00
Aluminum
0.50
2.60
2.80
0.80
3.10
3.20
3.80
3.60
4.70
1.00
3.30
3.40
5.00
5.00
6.00
5.10
8.30
1.50
5.80
5.90
7.50
7.20
9.00
2.00
6.40
6.50
8.00
10.00
10.40
2.50
8.80
10.40
11.70
3.00
9.20
12.10
12.80
4.00
13.80
14.70
5.00
15.00
16.10
6.00
0-42
5.6
Application
Application range
Advantages
Undivided tools
Tool change-overs are generally not desirable for high-gloss

surfaces (e.g. reflecting surfaces). Complete tool solutions (apart
from WingBend + KEV) can also be produced as undivided tools.
This is primarily also required for the punches.
In case of large punch-radii (air bending and embossing) and

for dies with continuous work edges.
For high-gloss
surfaces,).
Undivided tools of up to 4000 mm can be manufactured.
The radius on the reflective surface is embossed without

unevenness using the undivided tool.
surfaces
(mirror
sheet,
ground
sheet
Embossing a part with reflective surface without unevenness
Undivided lower tool
Product
0-43
6.
Application
SBW Swivel bending tool
The patented swivel bending tool offers huge advantages

compared to conventional bottom bending: not only does it save
bending time, but it also provides better ergonomics. Because,
when bending narrow metal strips, small joint pieces and for
window edges, that is small joint pieces in the middle of a blank,
the workpiece does not execute any swiveling movement on the
operator's side. The metal leg in front of the machine drops by only
a few millimeters.
If BendMaster executes the bending process automatically,
"Tracking" is not required, which in turn saves time. In certain
bending situations re-gripping the workpiece is not necessary,
which in turn saves even more time.
The workpiece is placed on the swivel unit and positioned through
the back gauge as usual. The swivel bending upper tool clamps
the workpiece between the support areas. As soon as the beam
moves down, the swivel level bends the link plate around the tip of
the swivel bending upper tool.
Application range
Advantages
From 0.5 1.5 mm sheet thickness.
Can be used from 75 to 140.
Min. flange length 7 10 mm.
Bending length: 10 50 mm.
Fast bending of small joint pieces.
No time-consuming tracking of the high swiveling bending

shaft.
No reverse bend, as manual tracking unnecessary.
Possible to rotate installation by 180.
Can be combined with conventional bending tools.
Various edge lengths possible due to interchangeable tool tips

with various widths.
A blank is clamped between
the upper and the lower tool
0-44
The swivel lever bends the

joint piece upwards
Producing small joint piece

1
Swivel unit
Swivel bending upper tool
Swivel lever
Product
(Joint piece)
0-45
7.
DV adapter
Application
With DV adapters, two different lower tools can be used.These can

be tools that have the same opening angle but different die widths,
or vice versa. Other possibilities are lower tools with different
working radii, or narrow lower tools combined with lower tools of
normal width.
Advantages
Station operation, where the individual stations produce a

longer length of bend as the length of bend of the machine
(drawing 2). Various lengths of bend can be produced at one
station.
Increase in lower tool height by 50 mm.
Double sheet bends, i.e. different sheet thicknesses in one

product (depending on the die width), refer to drawing 1 below.
Shorter and longer bending sides in one product (dependent

on the die width).
Technological advantages, e.g. through the use of 84 and 30

lower tools.
Two different bending radii can be produced with one upper

tool.
Note
Displacement is done via the I-axis (therefor it is not suitable for

TruBend series 3000/TrumaBend C-series).
Tool
Drawing 1

Specify the material type: _____________________
Specify the sheet thickness: ___________________
Drawing 2

0-46

Two different radii can be produced with one upper tool

1
DV adapter with two different EV dies
1
2
3
DV adapter
EV-W8
EV-W16
0-47
Application
Application range
Advantages
8.
Horn tools
8.1
Moveable horn tool
Movable horns make it easy to remove a completely bent

workpiece (nesting).
Slewable horn for up to 38 mm recess.
Can be combined with standard tools (e.g. OW320).
Easy removal of boxes with inner bends.
Advantageous for automated systems.
Tool
0-48
Mobile horn swivels back

1
Moveable horn OW320 with tool holder OW209/S
1
2
OW209/S
OW320 moveable horn
Product
0-49
8.2
Application
Application range
Advantages
Note
Tool 1
Left/right horn
Left/right horns are used to bend parts with inner bends.
Standard horn with 31 mm recess.
Special design up to ~ 100 mm possible.
Closing a product (e.g. box) with inner bends edges in the

collision range.
Opening for cable of the ACB angle sensor possible.
Cost-effective horn tools (standard design) are supplied with

every standard upper tool set (except holder + inserts).
The horn design can be individually adapted to a product at the

customer's request.
Horn tools are available even for use with dies.

Drawing

Tool 2
0-50
Standard horn tool left/right

1
Product
0-51
8.3
Application
Application range
Advantages
Horn window tool
Horn tools can be structured such that it leads to a window

solution. This enables easy production of deep U parts.
Standard horn with 31 mm recess.
Special design up to ~ 100 mm possible.
Low tool costs.
Mostly realizable with standard horn tools.
Flexible application.
Tool
0-52
Part swivels in the horn recess

1
Product
(Frame part for the car industry)
0-53
Application
Application range
Advantages
Note
9.
Window tools
9.1
Tool with a slewable window
The tool with a slewable window is used to bend closed profiles or

U parts. Use of a slewable adapter enables or facilitates the
removal of products. This leads to savings of both time and money!
Up to max. 1000 mm length of bend (depending on the profile

form).
Up to max. 6 mm sheet thickness (depending on the profile

form).
Parts can be removed easily and conveniently using a

slewable adapter.
Time-saving production.
Cost-effective production of closed profiles.
Welding of parts not required.
Flexible application.
Alternative production options by means of "Tools for U parts" (refer

to chapter 3) or "Tools for closed profiles" (refer to chapter 23).
Tool
Drawing

0-54

Producing closed profile

1
1
2
3
Slewable adapter
Adapter with holder magnet
Handle for opening and closing
Product
0-55
9.2
Application
Application range
Advantages
Window tool with countersinking
The window tool with countersinking is used to bend U parts or

profiles running off diagonally. An important advantage here is that
this tool can be mostly modified from a standard tool. This leads to
savings of both time and money!

form).

form).
Can be mostly modified from a standard tool.
Cost-effective tool solution.
Tool
Drawing

0-56

U part swiveling in the countersinking

1
Product
0-57
9.3
Application
Application range
Advantages
Note
Window tool with adapter
The window tool with adapter is used to bend U parts or profiles

running off diagonally. An important advantage here is that this
solution can be mostly realized using the TRUMPF standard tool.
This leads to savings of both time and money!

form).

form).
Mostly realizable with standard tools.
Extremely flexible application.
Observe the machine's installation height when assembling

several adapters.
If necessary, the die must be constructed with a low working

height.
Drawing

Specify the material type: __________________________
Specify the sheet thickness: __________________________
0-58
U part swiveling in the recess

1
Product
0-59
10.
Hinge tools
Hinges can be produced in various ways.
10.1 Hinge tool complete

(producing hinge in two steps)
Application
Application range
Advantages
Note
Tool
This hinge tool is adapted to the hinges with fixed dimensions

(sheet thickness, hinge diameter and hinge haft length). This
solution is used without a backgauge. The stop is integrated in the
tool. This enables quick production of door hinges, for example.
di=min. 2 2.5 x sheet thickness (steel, aluminum).
di=min. 2.5 3 x sheet thickness (stainless steel).
The quickest TRUMPF option for producing hinges.
Produce optimum rounding.
Low tool costs as only one tool station is required.
The "Step 2 method" is limited through the hinge haft length

(b=max. 100 mm).
Always specify bolt diameter of the pin to be put through

(corresponding to the hinge).
Drawing

0-60
Producing a door hinge in two steps

1
1
2
3
Upper tool
Lower tool
Stop integrated in the lower tool
Bending sequence
1
2
Part pre-bent
Part rolled in
Product
0-61
10.2 Tool holder with hinge inserts

(producing hinge in three steps)
Application
Application range
Advantages
Note
Tool
Hinges with smaller diameters can be produced with the help of

tool holders combined with hinge inserts. The hinge inserts are
adapted to hinges with fixed dimensions (sheet thicknesses and
hinge diameters). In the case of this version, the hinge haft length
is not limited.
di=min. 3 x sheet thickness (steel, aluminum).
di=min. 3.5 x sheet thickness (stainless steel).
No limitation for the hinge haft length.
Standard tools can be integrated in a station operation without

collision.
Cost-effective version for small hinges.
Always specify bolt diameter of the pin to be inserted

Drawing

0-62
Producing smaller hinges in three steps

1
Hinge inserts
Bending sequence
1
2
3
First pre-bending
Second pre-bending
Ready product rolled-in
Product
0-63
10.3 Hinge tool complete

(producing hinge in three steps)
Application
Application range
Advantages
Note
Tool
Thanks to the use of a torque stay rod, it is possible to produce

hinges with larger sheet thicknesses and diameters. When rolling
in (step 3), the upper tool is stabilized by the torque stay rod. The
production process of the hinges is controlled via the I-axis
displacement.
This hinge tool is adapted to the hinges with fixed dimensions
(sheet thickness and hinge diameter). In the case of this version,
the hinge haft length is not limited.
di= min. 2.5 x sheet thickness (steel, aluminum).
di= min. 3 x sheet thickness (stainless steel).
No limitation for the haft length.
The torque stay rod allows greater sheet thicknesses than with
inserts.
This version is primarily used with thicker sheets and greater

diameters.
Always specify bolt diameter of the pin to be inserted

Drawing

0-64
Producing a hinge in three steps

1
Complete tool
1
2
3
Torque stay rod with slide rail

Punch for pre-bending and rolling in
Die for pre-bending and rolling in
Product
0-65
10.4 Tool for special hinge forms

Application
Application range
Advantages
Note
Tool
The tools are specially adapted to the hinge forms as per the
customer's request. An example of a special hinge form is given in
this section.
Numerous hinge forms possible on customer request.
If required, compromises for a tool solution can be found. You can
consult the TRUMPF bending tool team for this.
Drawing

0-66
Producing special hinge forms

1
Hinge inserts
Product
0-67
10.5 Tool for hinges with 90 bend

Application
Application range
Advantages
Tool
Hinges with a close 90 bend require an adapted hinge tool. The

90 bend and radius bend is already produced before rolling in.
The advantage of this tool is that the 90 bend can be very close to
the hinge.
Up to around 1.5 mm sheet thickness.
di= min. 3 4 x sheet thickness.
A 90 bend can be very close to the hinge.
Ideal for short lengths of edge.
Drawing

0-68
Producing a hinge very close to the 90 bend

1
Upper tool
1
2
Spring-loaded presser foot

Compression spring
Lower tool
1
2
Torque stay rod

Stop
Product
0-69
11.
Application
Application range
Advantages
Note
Punch and die rotated
The "Punch and die rotated" application is primarily used for largesurface parts. Moreover, manipulation time is saved for parts with
Z-contours.
Same as air bending.
Time saving and easy handling parts with Z-contour do not

have to be rotated during manual operation or in automated
systems.
Collisions can be prevented using a table for parts with

Z-contours with long bending sides.
Cost-effective Tools are combined with standard tools in the

station operation.
Parts with inner bends and long bending sides thus do not
collide with the floor.
Easier handling of large parts.
In order to be able to construct two tool stations you must observe

the machine length.
Tool
0-70
First bend upwards

1
Second bend downwards

2
Upper tool rotated
Die rotated
Product
0-71
12.
Tools for bracing beading
Beading is usually differentiated as diagonal beading (angular

bracing) and longitudinal beading (sheet bracing).
12.1 Tools for diagonal beading

Tools for diagonal beading are used to stabilize angles.
Beading bar for diagonal beading

Application
Application range
Advantages
Tool
By using beading bars, angles can be produced with bracing in a

single step. Beading bars can be set at any point between
individual segments of the standard lower tools. The upper tools
are provided in this area. The beading bars are comprised in the
TRUMPF standard tool range.
Angles and bracing can be produced in a single step.
Bending sides can be braced even with thin sheet metals.
Available as a standard tool.
Beading bars provide maximum flexibility beading distances

freely selectable.
Drawing

0-72
Application of standard beading bars (standard values)
Lower tool
80 84 86 (30)
0.8
EV W6
EV W8
EV W10
3.5
10
5
12
6
14
EV W12
1.5
Lower tool
80 84 86 (30)
EV W12
4.5
12
6
14
7.5
16
Beading height X
Distance of the upper tools (R1 mm)
6.5
15
7.5
17
10.5
21
1.5
4
10
5.5
10
3.5
12
5
12
8
12
3
14
5
16
8
16
11
18
EV W24
Lower tool
80 84 86 (30)
6
16
7.5
18
10
22
2.5
Beading height X
Clearance of the upper tools (R1 mm)
Beading height X
Beading bar R1/60

H=97.5 mm
4
Beading height X
Beading height X
7.5
18
10.5
20
13
18
1.5
2.5
6
14
9
20
5
18
8.5
20
11.5
20
EV W30
Product
Beading height X
Beading height X
10.5
22
13
22
Beading height X
Beading height X
Beading bar R2.5

H=95.5 mm
Sheet thickness (mm)

1
EV W24
3
Beading height X
EV W20
EV W20
2.5
EV W16
EV W16
EV W16
EV W10
Beading bar R2
H=99.0 mm (149.0)
4
Beading height X
8
20
11
20
Beading height X
10.5
26
15
28
Beading height X
Beading height X
Beading bar
X = Beading height
0-73
Tool with alignment pins for diagonal

beading
Application
Application range
Advantages
Tool
By using tools with alignment pins, angles can be produced with

bracing in a single step.
In the lower tool, alignment pins are mounted diagonal to the
bending line. The upper tool is adjusted freely or is left in the area
of the alignment pin. The bending process can be carried out using
the free bending or embossing procedure.
Up to max. 4 mm sheet thickness.
Angles and bracing can be produced in a single step.
Bending sides can be braced even with thin sheet metals.
Optimum for bracing beads that are extremely close to one

another.
Drawing

0-74
Producing a 90 bend and bracing in a single step

1
Upper tool
Free positioning on the upper tool

for alignment pins
Lower tool
Alignment pin
Product
0-75
12.2 Tools for longitudinal beading

Tools for longitudinal beading are used to stabilize sheet metals
(surfaces).
Tool for longitudinal beading

(running through the sheet metal)
Application
Application range
Advantages
Note
Tool
By forming on the press brake, longitudinal beads running through

the sheet metal can be produced (alternative to punching
machine). The production of the beading tool depends on the
material type, sheet thickness, beading depth and beading width.
Beading can be produced in a single step.
Turning and rotating of parts against the individual bends is not

required.
Can be used for large quantities.
High press forces are required if the sheet metals are thick.
Drawing

0-76
Producing longitudinal beading in a single step

1
Upper tool
Lower tool
Product
0-77
Tool for longitudinal beads without presser

foot plate (ending in the sheet metal)
Application
By forming on the press brake, longitudinal beads running down to

machine). The start and the end of the bead is within the sheet
metal. The production of the beading tool depends on the material
type, sheet thickness, beading depth and beading width.
Application range
Up to 3 mm sheet thickness (for lesser beading depths up to max.

2 x sheet thickness).
Advantages
Note
Tool
Beading can be produced in a single step.
Can be used for large quantities.
Reduced-noise production.
Upward or downward embossing is possible.
A large range of beading depths and beading widths are

possible on customer request.
Neglecting to use a presser foot plate can lead to severe

deformation of the sheet metal. In case of deep beading forms and
in case of stainless steel sheets, the deformation of the sheet
metal increases.
Drawing

0-78
Producing longitudinal beading in a single step

1
Product
0-79
Tools for longitudinal beading with presser

foot plate (ending in the sheet metal)
Application
By forming on the press brake, longitudinal beads running down to

machine). The start and the end of the bead is within the sheet
metal. If a presser foot plate and pneumatic spring (integrated in
the tool) are used, it leads to less deformations on the sheet metal
than that in production without a presser foot plate. The production
of the beading tool depends on the material type, sheet thickness,
beading depth and beading width.
Application range
Up to 3 mm sheet thickness (for lesser beading depths up to

max. 2 x sheet thickness).
Advantages
Note
Less deformation of the sheet metal by using a presser foot

and a gasspring.
Tool can be used for various beading lengths.
A large range of beading depths and beading widths are

possible on customer request.
In case of deep beading forms and in case of stainless steel

sheets, the deformation of the sheet metal increases.
Drawing

Specify the sheet thickness: ________________________
0-80
Complete beading tool
Lower tool (gasspring view)
1
2
gasspring
Presser foot plate
1
2
Upper tool (view from below)

Lower tool (view from above)
Product
0-81
13.
Application
Application range
Advantages
Number embossing and logo tools
Number embossing and logo tools are used to label parts. This
enables the safe and easy storage and identification of various
parts.
Additional work cycle not required outside the machine.
By using an off-center tool form, parts can be produced by

shifting the lower tool load (I-axis) without intermediate deposit.
The depth of the embossed digits (logo) is regulated by the

penetration depth of the beam. If required, the labeling is
clearly visible even after finishing.
Holder plate for steel types can be mounted on the upper tool
(OWholder) or on the lower tool (EVholder). Upward or
downward embossing is thus possible.
13.1 Number embossing tool with steel

types
The steel types (numbers) are changed by loosening a screw. The
steel types are identical to those of TRUMPF punching tools and
can be supplied with various dimensions (refer to the table).
Dimensions of the steel types

Font size
[mm]
Dimensions
[mm]
A3
3.0
6.0
19.0
A4
4.0
8.0
19.0
A5
5.0
8.0
19.0
Other font sizes available on request
0-82
Number tool (view from below)
1
2
3
OW holder
Holder plate for steel types (mounting on OW holder or EV holder possible)
EV holder (off-center)
Product
0-83
13.2 Logo embossing tool

Application
Application range
Advantages
A wide range of company logos, fonts, number codes, etc. are

milled or vertically eroded on the logo embossing tool on customer
request. There is also an option of embossing (e.g. logo, number
code,) and executing a radius bend in a single step.
Every graphic (e.g. company logo) can be embossed.
Form and size of the graphic can be determined by the

customer.
Embossing and radius bending is possible in a single step.
Drawing

Specify the sheet thickness: ________________________
0-84
Logo embossing tool
Logo embossing tool and radius bending
Detailed views
Product
Product
0-85
14.
Louver tools
14.1 Louver tool for closed tool contour

Application
Application range
Advantages
Note
Tool
Louver cuts are mostly used as ventilation slots in housings.

Louver cuts can be produced by forming on the press brake
(alternative to punching machine).
Hardly any wear on tools.
High-quality surface.
Mostly not dependent on the louver cut length and louver cut
height.
Several parallel louvered areas can be produced in a single

step.
A louver tool can be used for various sheet thicknesses/material types.
Separating slot must be accommodated in the sheet thickness

(mostly laser cut).
Drawing

0-86
Complete louver cut formed in a single step

1
Lower tool (view from above)
Upper tool (view from below)
Product
0-87
14.2 Louver tool for endless louver

Application
Application range
Advantages
Note
Tool
Louver cuts are mostly used as ventilation slots in housings.

Louver cuts can be produced by forming on the press brake
(alternative to punching machine).
Not dependent on the louver cut length and louver cut height.
Several parallel louvered areas can be produced in a single

step.
Various louver cut lengths can be produced with one tool.
A louver tool can be used for various sheet thicknesses/

material types.
Separating slot must be accommodated in the sheet thickness

(mostly laser cut).
Easy transitions can be partially identified.
The louver cuts can show unevenness from the tool transition.
Drawing

0-88
Various louver cut lengths can be produced with one tool

1
Lower tool
Upper tool
Louver tool is open on the side
Product
0-89
15.
Countersink shaped tool
15.1 Round countersink shaped tool

Application
Application range
Advantages
Note
Tool
Round countersink shapes are mostly used as depressions for

countersink screws. Round countersink shapes are produced by
forming on the press brake (alternative to punching machine).
Several countersink shapes can be produced in a single step.
Reshaping can be done either upwards or downwards.
By using EV/70 holders, other bends can be produced in the

part without using an intermediate store (I-axis).
A hole must be produced before bending.
Drawing

0-90
Producing round countersink shapes
Upper tool (holder with an insert)
1
2
3
Holder OW/K90
Insert
Countersink shape pin
Lower tool (holder with an insert)
1
2
Holder EV/70
Insert
Product
0-91
15.2 Countersink shaped tool (bridge)

Application
Application range
Advantages
Note
Tool
Bridge countersinks are used as racks for blanks (guides), for

example. Bridge countersinks are produced by forming on at the
press brake (alternative to punching machine).
Several bridge countersinks can be produced in a single step.
Punching not required.
Reshaping can be done either upwards or downwards.
By using EV/70 holders, other bends can be produced in the

part without using an intermediate store (I-axis).
Two separating slots must be produced (mostly laser cut).
Drawing

0-92
Producing two bridge countersinks in a single step

1
Tools can be used above/below
Blank with separating slots
Product
0-93
16.
Reshaping tools (cups)
16.1 Embossing tools for cups

Cupping tool without presser foot plate
Application
Application range
Advantages
Note
Cups can be produced by forming on the press brake (alternative

to punching machine). The design of the cupping tool (inserts)
depends on the material type, sheet thickness, cup diameter and
cup height. For example, cups are used as spacers between two
sheets or as positioning tools between two parts.
Producing a cup in a single step.
Several parallel cups can also be produced in a single step.
A large range of cup diameters and cup heights can be made

available on customer request.
Neglecting to use a presser foot plate can lead to severe

deformation of the sheet metal. In case of deep cup shapes and
stainless steel sheets, the deformation of the sheet increases.
Drawing


Specify the material type: _______
Specify the sheet thickness: _____
0-94
Producing a cup in a single step

1
Lower tool (insert)
Upper tool (insert)
Product
0-95
Cupping tool with presser foot plate

Application
Application range
Advantages
Cups can be produced by forming on the press brake (alternative

to punching machine). If a presser foot plate and pneumatic spring
(integrated in the tool) are used, it leads to less deformations on
the sheet metal than that in production without a presser foot plate.
The design of the cupping tool depends on the material type, sheet
thickness, cup diameter and cup height. For example, cups are
used as spacers between two sheets or as positioning tools
between two parts.
Producing a cup in a single step.
Several parallel cups can also be produced in a single step.
A large range of cup diameters and cup heights can be made

available on customer request.
Less deformation of the sheet metal by using a presser foot

and a gasspring.
Note Deep cup shapes can lead to a deformation of the sheet. This
behavior increases in case of stainless steel sheet.
Drawing


Specify the material type: _______
Specify the sheet thickness: _____
0-96
Cupping tool with presser foot plate
Upper tool
Upper tool/cup insert
Lower tool
1
2
3
Presser foot and ejector

Gasspring
Cup bolt
Product
0-97
16.2 Embossing tool for special shapes

Application
Application range
Advantages
Note
Tool
By forming on the press brake, numerous special shapes can be

produced on the product (alternative to punching machine).
Several parallel cups can also be produced in a single cycle.
A large range of shapes can be supplied on customer request.
Deep special shapes can lead to a deformation of the sheet. This

behavior increases in case of stainless steel sheet.
Drawing

0-98
Special shape reshaped in one step

1
Lower tool (from above)
Upper tool (from below)
Product
0-99
17.
Adjustable dies
17.1 Adjustable die VLM

Application
Application range
Advantages
The VLM die from TRUMPF helps in convenient bending of various

sheet thicknesses in one set-up in the thick sheet area. The die
widths can be adjusted as per the request of a customer quickly
and easily using setting bars.
VLMBN: 3 15 mm sheet thickness (max. 1250 kN/m).
VLMDN: 5 20 mm sheet thickness (max. 2000 kN/m).
Wide die width range from W24 W182 possible. Continuous

die replacement is thus not required.
Reduced-imprint bending of rotating and hardened track rollers

(minimum wear).
Lower press forces required.
Production of various bending radii.
Decrease in the down times by up to 30% through the fast and

easy replacement of the setting bars.
Minimum maintenance costs:

Replaceable rack rollers.
Replaceable plastic strips protecting the die parts against

contaminations.
Low collision contour compared to the conventional adjustable

dies.
VLMBN
VLMDN
Technical data
Technical data
Adjustable from W24 W124
Adjustable from W62 W182
Can be loaded from 800 1250 kN/m
Can be loaded from 1500 2000 kN/m
250, 500, 1000 mm long part pieces
250, 500, 1000 mm long part pieces
Weight: ~220 kg/m
Weight: ~330 kg/m
0-100
VLM die individually adjustable

1
VLMBN set to W124
VLMBN set to W44
1
2
Setting bar
Track roller
The die jaws can be clamped using a clamping screw
0-101
17.2 Adjustable die W20 W90

Application
Application range
Advantages
Note
The adjustable die W20 W90 helps in convenient bending of

various sheet thicknesses in the thin and medium sheet range. The
die width is set by changing the setting and working bar.
Up to max. 400 kN/m.
Various bending radii can be produced by adjusting the die

widths.
Die width range from W20 W90 possible (10 mm steps).
Cost-effective solution for adjustable lower tools.
The die provides a low collision contour.
Adjustable dies available in the length of 200 mm.
Tool
0-102
Radius bending R40 to die width 90

1
Radius bending R4 to die width 20

1
Adjustable die die width 90
Adjustable die die width 30
1
2
Setting bar
Working bar
The bars can be secured using a straight-through screw
0-103
18.
Application
Production range
Advantages
Note
Die with rollers
This lower tool is equipped with hardened rollers instead of a die

inlet radius. Due to these track rollers, there are fewer imprints on
the product.
Die width range from W10 W250 possible.
Rollers from radius 2.5 30 mm.
Fewer imprints on the product.
Lower press forces possible.
Roller can be replaced easily.
The adjustable die VLM is also equipped with rack rollers (refer to
section "Adjustable die VLM").
Tool
0-104
Producing low-impression parts
Die with rollers
Hardened track rollers
Hardened track rollers
Product
0-105
19.
Folding tools
19.1 Folding tools (standard)

Application
Application range
Advantages
These folding tools (5 versions) can be used only in combination

with a TruBend series 5000/TrumaBend V-series, as the insert of
these tools requires an I-axis displacement.
Stainless steel up to 2 mm sheet thickness.
Steel, aluminum up to 2.5 mm sheet thicknesses.
Standard solution.
Flexible application (refer to the assembly options).
Minimum collision contour due to OW210/S, narrow or high

dies.
Assembly options for folding tools
Folding tool front
Folding tool back

(thin sheets)
Torque stay rods and

press-shut strips rear
Press-shut strips
rear
(thin sheets)
Folding tools and

press-shut strips
rear
I-axis position during folding
0-106
Flattening in the rear tool

position:
Flattening in the front tool

position:
I-axis is in the front.
I-axis is at the back
Producing frame part with rear folding tool

1
Product
(Window frame)
0-107
19.2 Folding tools FEV die (standard)

Application
Application range
Advantages
Note
This folding tool is mainly used for folding in the TruBend

series 3000/TrumaBend C-series, as I-axis displacement is not required for this tool.
Stainless steel up to 1.5 mm sheet thicknesses.
Steel, aluminium up to 2.0 mm sheet thicknesses.
Folding stroke of FEV 8-12 mm.
Insert can be fixed on H100.
Ideally in combination with OW 202/K, OW 202/S.
The groove basic radius is adapted to OW with R1.
More designs (other die openings, widths,) are available on

request.
Tools
0-108
FEV W6/30
FEV W8/30
FEV W10/30
FEV W12/30
Folding without I-axis displacement

1
Product
0-109
19.3 Folding tool with holder OW209/S

Application
Application range
Advantages
This tool system with OW209/S holder + insert OW320 can be

used only in combination with a TruBend series 5000/ TrumaBend
V-series, as the insert of these tools requires an I-axis
displacement.
Stainless steel up to 2 mm sheet thicknesses.
More flexible for various pre-bending radii (replaceable OW320

insert).
More stable tool tip compared to OW210/S (up to 1000 kN/m).
Standard solution.
Station operation due to the tool heights of 220 mm with

OW200/S, OW201/S, OW202/S (H=220 mm) possible.
I-axis displacement
Tool
Folding tool back

Displacement to the
front
Distance stop
EV001
25 mm
825778
31.2 mm
EV002
25 mm
825778
31.2 mm
EV003
25 mm
825778
31.2 mm
EV004
22.5 mm
825777
33.7 mm
EV005
20 mm
825776
36.2 mm
Folding tool front

Distance stop
Displacement to the
rear
EV001
35 mm
845425
17.7 mm
EV002
35 mm
845425
17.7 mm
EV003
35 mm
845425
17.7 mm
EV004
32.5 mm
861938
20.2 mm
EV005
30 mm
825780
22.7 mm
EV006
27.5 mm
825779
25.2 mm
EV007
25 mm
825778
27.7 mm
0-110
1
2
Holder OW209/S standard

Insert OW320 R1/28, b=13.5 mm
(ready for folding)
Folding a part with tool system OW209/S

1
Product
0-111
19.4 Flat tools

Application
Flat tools are mostly used to fold thicker sheets ( 2 mm).

Depending on the application, TRUMPF provides flat tools:
Application range
Advantages
Note
In holder + insert system.

In a one-piece design.
In special applications with support (slide bar).
Up to 4 mm sheet thickness depending on the type of tool.
A wide folding surface prevents the sheet from slipping during

the folding process (in case of sheet > 2 mm and even
surfaces).
Can be used to close closed profiles (section 22.2).
Flat tools can be adapted individually (OW212/K, OW212/S,

EV-W0, EV-W0 off-center, flat inserts, ..)
OW212/S is suitable for higher press forces (~ 2000 kN/m).
The pre-bending to 30 must be done at a separate tool station.
Flat tools OW212/K + EV-W0
Flat tools OW212/S + EV-W0
1
1
1
2
3
0-112
OW212/K + EV-W0
EV-W0 (b=30 mm)
EV-W0 (b=30 mm) off-center
1
2
OW212/S (b=30 mm)

EV-W0 (b=50 mm)
Flat inserts
2
1
2
3
4
OW/K90
EV/70
Insert flat (B=25 mm)
EV/70-M
Folding solution for "open" folds

(U bending)
Folding solution for 4 mm thick sheet
1
2
3
4
5
OW209/S
OW320 R5
EV005-W16/30
OW212/S
EV-W0 with slide bar
1
2
3
4
5
OW209/S
OW320 R1,6
EV006-W20/30
OW212/S
EV-W0 with slide bar
0-113
19.5 Special folding tool (die with U-shape)

Application
Application range
Advantages
Note
This folding tool is mainly used for folding in the TruBend

series 3000/TrumaBend C-series, as I-axis displacement is not
required for this tool.
The lower tool (U form) and the upper tool is produced depending
on the sheet thickness and the material type as per the customer
request.
Upper tool and lower tool are solid tools.
The lower tool is more economical than the FEV folding tools.
More stable tool tip than OW210/S.
Low loadability compared to standard dies.
Max. inlet radius of the die:
Up to W12: max. R1.
W16, W20: max. R1,6.

Tool
0-114
Pre-bending and folding parts on the solid tool system

1
Upper tool
Lower tool (U shape)
Product
0-115
19.6 Folding tool for double fold

Application
Application range
Advantage
Note
Tool
TRUMPF has developed these folding tool inserts in order to be

able to produce a double fold on the product.
Producing double fold in two steps.
Standard tools can be integrated in a station operation without

collision.
Flat inserts can be used for normal folds as well.
Dimension "b" in the drawing should not exceed 20 mm; else, the
material expands too much during pre-bending.
Drawing

0-116
Producing double fold with inserts

1
Inserts for pre-bending
Flat inserts for folding
Bending sequence
1
2
3
Pre-bend parts
Double fold not closed
Double fold closed
Product
0-117
19.7 Folding tool for reduced-mark folding

Application
Application range
Advantages
Note
TRUMPF provides this solution with plastic inserts in the working

area for low-impression folding parts.
Up to max. 200 kN/m.
Up to 1.5 mm sheet thickness.
Sheets with or without protective foil.
Plastic inserts can be exchanged.
Traces of abrasion of the tool can be prevented (if required,

plastic is set in the folding area of the upper tool).
Pay attention to the press forces during folding.
Sheets with protective foil must be realized with standard

solutions in a low-impression manner if possible (a test is
sometimes required).
Tool
0-118
Producing markless fold

1
Tools with KEV inserts
1
2
KEV insert for folding

KEV insert with ground V opening
Product
0-119
19.8 Folding table

Application
Application range
The folding table is mounted on the table plate of the machine

table instead of the standard lower tool clamp. The horizontal lower
tool displacement (I-axis) is thus placed still, and the pneumatic
system is used for to and fro movement of the folding table. The
folding table is again equipped with a hydraulic tool clamp that can
accommodate the standard TRUMPF lower tools (single V-dies).
The folding table available in versions with and without replaceable
wear bars on the folding edges.
Folding table without a wear bar (not suitable for stainless steel
sheets):
Stainless steel up to 1.5 mm sheet thicknesses.
Aluminum up to 2 mm sheet thicknesses.

Folding table with a wear bar:
Steel, aluminum up to 3 mm sheet thicknesses.
Advantages
Note
The folding equipment (the folding table) becomes a part of the

machine no folding tools set-up.
Individual adaptations to the TruBend series 5000 is carries

out by our Machine Sales Department (the axis position is
adapted in the TASC6000 control system; a visualization of the
folding table is not given on the control system).
The folding table (from Wila) is larger than the standard

TRUMPF lower tool clamp, the machine thus loses around
130 to 150 mm installation height (depending on the type of
the folding table).
No I-axis.
A folding table is mounted and fixed on the machine
1
2
0-120
Pneumatic cylinder to open the folding area

Hydraulic tool clamp
Folding the part with folding table

1
Folding table open
Folding table closed
Product
0-121
20.
Z bending tools
20.1 Z bending tools (standard)

Application
Application range
Z bending tools are used to brace sheets or to overlap of

two sheets. With a standard, you can achieve either 4, 6, 8 or 10
mm jogglings with 90 to 90 (coining process) or achieve different
jogglings and angles > 90 in the air bending process.
Maximum sheet thicknesses during Z bending:
Z dimension
Advantages
Tool
[mm]
Coining
[mm]
Air bending
1.5
1.5
2.5
10
2.5
[mm]
Modified Z dimensions, e.g. Z5/90 available on request.
Tools with holder system are suitable for station operation (with
EV/70).
OW/K90 + EV/70 provides a cost-effective solution for using

several inserts (Z inserts, shape inserts,).
Drawing

0-122
Air bending
Coining 90/90
OWZ/K + EV-Z (undivided version)
Holder + insert system (OW/K90 + EV/70 + ZE 6/90

1
Product
Product
0-123
20.2 Z bending tools (special solutions)

Application
Application range
Note
Tool
Z tools can be individually adapted to their products (large and

small jogglings in the thin sheet area in coining and air bending
process, small jogglings in the thick sheet area in the air bending
process).
Up to max. 30 mm jogglings (in the thin sheet area).
These applications mostly require great press forces.
Shape and accuracy in case of large Z dimensions (> 15 mm)

is mostly disadvantageous as against individual bends due to
the diagonal forces.
Drawing

0-124
Air bending
Coining 90/90
Flat joggling in 6 mm thick material
Large Z dimension (30 mm)
Product
Product
0-125
21.
Tools for corner reshaping
Parts with corner reshaping are used in housing construction,

electronic field, kitchen construction and ventilation technology.
Ideally, they can be embossed during the bending process itself.
21.1 Tool for outward corner reshaping

Application range
Advantages
Tool
Up to 2 mm sheet thickness (depending on the corner radius).
When using a suitable flange height deformation is low.
Costly welding and grinding of lateral parts not required.
Drawing

0-126
Producing outward corner reshaping

1
Lower tool with lateral support
Upper tool
Product
(Cover in ventilation engineering)
0-127
21.2 Tool for inward corner reshaping

Application range
Advantages
Up to 2 mm sheet thickness (depending on the corner radius).
When using a suitable flange height deformation is low.

Costly welding and grinding of lateral parts not required.
Tool
3
6
7
8
1
2
3
4
Standard extension (adapter)

Slewable adapter
Adapter with a magnet
Handle
5
6
7
8
Punch
Left support
Right support
Die
Drawing

0-128

Producing inward corner reshaping

1
Lower tool with lateral support
Product
(Housing for gastronomy deep fryer)
0-129
22.
Tools for closed profiles
22.1 Tool for closed profile

(with integrated folding)
Application
Application range
Advantages
Tool
Profiles with integrated folding can be mostly produced without any

restrictions (deformation,).
Up to max 2.5 mm sheet thickness.
The profile can be closed without deformation.
Non-standardized profiles can be thus produced quickly and

cost-effectively.
Can often be realized with a standard tool (refer to section

"Folding tools standard)".
Welding seam is no longer required.

Drawing

0-130
Producing closed profile with integrated folding

1
Product
0-131
22.2 Tool for closed profile

(thick sheet frame)
Application
Application range
Advantages
Note
Tool
Thick sheet frames are used in heavy mechanical engineering,

vehicle and land mechanical engineering, in stroke technology
(crane, excavator,). The profile is closed almost completely. The
gap is either filled with a welding seam or is pressed together with
a flat punch (OW212) in another work cycle.
The profile can be closed with almost no deformation.

cost-effectively.
Thus, at least one welding seam can be omitted.
Depending on the product or the tool shape, it is possible the

profile has to be removed laterally.
In case of short profile lengths, you can also work with the
"Slewable windows" (refer to chapter "Window tools").
Drawing

0-132
Producing thick sheet frames

1
Product
0-133
22.3 Tool for closed profiles

(freely pressed together)
Application
Application range
Advantages
Note
Profiles are "pressed together freely" mainly if the optics is not of

immediate importance. These parts are mostly processed further
later on.

cost-effectively.
Costly welding is no longer required.
Profiles can be partially produced with standard tools as well.
In case of short profile lengths, you can also work with the
"Tool with slewable window" (refer to chapter "Window tools").
Mostly, the profile is slightly dished.

Tool
Drawing

0-134

Pressing closed profile together freely

1
Product
0-135
23.
Application
Application range
Advantages
Note
Displaced bending line in a stroke
TRUMPF has developed this tool for parts (boxes, covers,) for
which displaced bending lines are necessary. Minimally displaced
bending lines can be produced in just a single step using this tool.
Minimally displaced bending line (mostly around the sheet

thickness).
Saves time.
Fewer tool stations required.
The costs of these special tools count even when the quantity
is medium.
It is important to adjust the upper tool height, the center of the

punch tip as well as the symmetry of the die width.
Tool
Drawing

0-136

Producing a displaced bending line in a single step

1
Bending sequence in case of a box
Producing a displaced bending line in one step
Product
0-137
24.
Application
Application range
Advantages
Note
Tool
Tool for round rods
The recess on the upper and the lower tool is specified from the
diameter of the round rod or wire. There are fewer imprints on the
product due to this recess.
Up to 25 mm diameter.
Due to the specially adapted upper and lower tools, there are
fewer imprints on the product.
The recess in the lower tool also prevents lateral slipping of the
round rods when stopping.
Several round rods can be bent in a single step by adapting the

tools.
Drawing

0-138
Producing a low-impression round rod

1
Lower tool
Upper tool
Product
0-139
25.
Tools for frames
25.1 TRUMPF individual tools for frames

Application
Application range
Advantages
Note
Tool
The frame tool serves in the production of a door frame of any

shape, which can be accommodated during the final assembly of
the door frames. Adapted tool geometries are necessary,
depending on the size of the desired shape of the cover
accommodation.
Stainless steel up to 1.5 mm sheet thickness.
Steel, aluminum up to 2 mm sheet thickness.
Die height up to 200 mm: max. ~ 150 mm frame width.
Die height up to 400 mm: max. ~ 350 mm frame width.
Simple tool solution (partially possible with standard tools).
Cost-effective method for frame production.
Machine conversion not required.
Door frames can be produced without changing tools.
In case of die heights >200 mm, special stop blocks must be

built on the stop finger. The TASC 6000 machine control
system is adjusted by the Machine Sales Department.
Drawing

0-140
Producing frames
1
1
2
3
Folding tool
High lower tool in narrow design
Special punch for pre-bending and folding
Product
0-141
25.2 WILA double-level tool for frames

(pneumatic)
Application
Application range
Advantages
Note
The frame tool helps in producing a door frame of any shape,

which can be accommodated during the final assembly of the door
frames. Adapted geometries and inserts are available depending
on the size of the desired shape of the cover accommodation. The
frame tool is mounted on the table plate of the machine table
instead of the standard lower tool clamp.
Stainless steel up to 1.5 mm sheet thickness.
Steel, aluminum up to 2 mm sheet thickness.
Door frames can be produced with a single device without

changing the tools.
No frame width limitation.
The frame tool can be set to various sheet thicknesses.
Individual adaptations to the TruBend series 5000 are carried

out by our Machine Sales Department.
The axis positions are adapted in the TASC6000 machine

control system; a visualization of the folding table is not given
on the control system.
The horizontal lower tool displacement (I-axis) is thus placed

still, and the pneumatic system is used for up and down
movement of the frame tool.
The frame tool is again equipped with a tool clamp that can
accommodate the standard TRUMPF lower tools (single
V-dies.
Drawing

0-142

Producing door frame

1
Pneumatically operated lower tool
1
2
3
Die for pre-bending

Tool clamp for dies
Pneumatic system for up and down movement
Product
0-143
26.
Bending various materials
Every material requires customized work solutions. TRUMPF tests

special materials for their bending capability and then decides
upon the suitable tool.
A few tips for this:
Thick sheet
In addition to the numerous standard tools (dies of up to 120 mm

die width, punches with large radii), TRUMPF also provides
special versions, so that sheet thicknesses of up to 20 mm can
be cold-formed without heating.
Thin sheet
TRUMPF has punches with 0.5 mm radii and narrow dies with
a die width from 4 mm onward in the standard range for thin
sheet parts.
Spring steel sheet
Spring steel sheet can break while bending, thus, pay

attention to the "bendable" raw material.
Springback must be taken into consideration in the tool

geometry.
Can be mostly realized using standard tools.
Pay attention to the punching radius, as copper can tear up

on the outer side.
Copper
Manganese sheet, Hardox, Armox, Weldox, Domex
0-144
High material resistances require the following for the

bending process:
Large bending radii to prevent material breakage
e.g. dies with exchangeable track rollers.
Springback up to 20 must be considered when selecting

the tool.
Pay attention to the production guidelines for bending

materials.
Perforated covering sheet
The springbacks that often differ from part to part are the
main problem when bending a perforated covering sheet.
The best results are often achieved during the embossing

process.
High spring back (> 30).
Can be mostly realized using standard tools.
Plexiglass, Lexan,.
Plexiglass springs even after hours!
Bending without imprints is possible with standard tools.
Various springback values can be present within one part,

depending on the bending direction.

process.
Use of bending radii lead to low-impression results.
Depending on the bending direction (or depending on the

upper and lower side), various sheet thicknesses lead to
various springback values.

process.
These materials must be checked for bending capability by

us in the company.
Danger of counter-bug or deformation is present.
Structure sheet
Tear sheet (checker plate)
Compound materials
Painted, coated, foiled sheets

Refer to chapter "Tools and auxiliary tools for reduced-mark
bending".
TRUMPF bending foil.
Dies with R3 working radius.
KEV dies.
WingBend.
0-145
27.
Safety Click
Application
Safety Click secures the tool against falling out. Safety Click is
available from a tool length of 10 mm onwards. Upper tools from
TRUMPF are equipped with the patented Safety Click, one of the
spring-loaded safety mechanisms integrated into the tool. The
Safety Click enables vertical tool change. The tool is just vertically
clicked in and out of the machine clamp.
Application range
Safety Click can be used in:
Head-bearing tools from 10 mm onwards.
Shoulder-bearing tools from 25 mm onwards.
Tool lengths of up to 100 mm are equipped with one Safety

Click.
Tool lengths of up to 100 mm are equipped with two Safety

Clicks on request.
Max. permissible tool weight 12.5 kg.
Advantages
Note
Extremely short changeover times.
The tools can be naturally installed and removed horizontally.
In case of large weight (over 12.5 kg), the tools are equipped
with fixed locking pins and can be thus replaced only
horizontally.
For shoulder-bearing tools from 10 mm 25 mm, an adapted

safety system is provided by TRUMPF on customer request.
Drawing
Application situation, if the part pieces up to 300 mm piece are equipped with Safety Click and the 500 mm piece is
equipped with locking pins. Lateral pushing out is not required when modifying the station lengths.
0-146
Safety Click preventing the upper tools from falling out
Safety Click
Safety Click for head-bearing

(from 10 mm onwards) and shoulder-bearing
(from 25 mm onwards) tools
Part piece: 10 mm
2 Safety Clicks possible from a length of

100 mm onwards
Part piece: 300 mm
TRUMPF-adapted safety system for shoulder-bearing tools (10 mm 25 mm)
1
2
3
Length: 10 mm
Length: 15 mm
Length: 20 mm
0-147
28.
Surfaces and heat treatment of tools
This chapter describes the most common hardening methods and

surface treatments used for TRUMPF bending tools.
1
2
Laser-hardened or inductively hardened and
Short-term gas-nitrated
brightly ground
Chemically nickel-plated (+ Laser/induction-hardening)
Laser-hardened and sand blasted
Long-term gas-nitrated
0-148
Laser hardening
Short-time gas-nitrated
Long-term gas-nitrated
Inductive hardening
Chemically nickel-plated
Hardness: ~ 58 62 HRC (in case of 1.7225 42 Cr Mo 4).
Hardness depth: up to 4 mm (depending on the tool type).
The most common method for bending tools.
Ideal even if the tools are reground (re-hardening possible).
Tougher tool core.
Hardly any delay and thus possible as the last production

process as well.
Hardening depth: ~ 0.4 mm.
The entire tool surface is hardened.
Ideal for prototype tools, eroded special tools, complex tool

contour.
Provides more corrosion resistance than bright tool surfaces.
Danger of tool breaks and chipping is higher than in case of

laser hardening.

process as well.
Hardness depth: ~ 0.7 mm (more suitable for higher loads than

in case of short-term gas-nitrated).
The entire tool surface is hardened.
Ideal for prototype tools, eroded special tools, complex tool

contour.
Provides more corrosion resistance than bright tool surfaces.
Danger of tool breaks and chipping is higher than in case of

laser hardening.

process as well.
Machining duration more than in case of short-term gasnitrated.
Hardness depth: up to 3 mm (depending on the tool type).
Tougher tool core.
Grinding process is always necessary after hardening, rehardening not possible.
Surface treatment without corrosion.
Must be combined with laser-hardened or inductively hardened

tools.
0-149
Balinit layer
The Balinit hard material layer is ideally applied after nitroge

hardening.
Even tool surface.
Optimum rust protection.
Ideal for inserts and tools with small surfaces, as the

production of Balinit layers is more cost-intensive.
High tool life.
Balinit layer
0-150
Inserts with hard material layer of Balinit
Through-hardened tools
Hardness: ~ 55 HRC (UX210 Cr13)
Ideal for blade inserts, bars, etc. that are exposed to high
loads.
Better corrosion protection as compared to 1.7225 42Cr Mo 4.
Higher manufacturing costs compared to laser hardening,

nitriding and inductive hardening.
Through-hardened tools
1
2
Tool holders made of 42CrMo4

Press-shut strip + tool insert made of through-hardened material
0-151
29.
Equipment and stop aids
29.1 Quickstop
Application
Application range
Note
The stop aids for the TruBend/TrumaBend called short

"QuickStop" can be used in 2 and 4-axis machines. Here,
QuickStop can be used together on individual (mounted only on
one stop finger) as well as on both stop aids.
Bending of smaller and medium parts.
For 2 and 4-axis backgauge.
There might be unevenness in large or thick parts.
In case of the TruBend/TrumaBend with 6-axis backgauge,

QuickStop cannot be used due to the other stop finger shapes
as well as the programming option of the backgauges
separated without these.
Stop situation from above
5
4
1
2
3
4
5
Lateral stop
Front stop
Product
Die
Bending line
Side stop complete
Angle setting
1
1
3
4
1
1
2
3
4
0-152
Setting angle gauge

Height adjustment
Rocker
Side stop
1
2
3
Setting angle gauge

Holder for setting angle gauge
Gauge finger
Application examples
Stop plates round
2 x stop plates round
2 x 90 stop plates
Stop plates 90
Angle setting/lateral stop
Angle setting
Angle setting/lateral stop
QuickStop case
0-153
29.2 Stop aids

Application
Application range
Note
Stop aids are used as positioning aids for special tools that are
integrated into the tool. The following example shows a circular
part that can be positioned and bent extremely quickly and easily.
The stop aid system is adapted individually and must be tested
with the original customer blanks.
Tool
Drawing

0-154

Producing circular part with stop aid

1
Tool station with positioning and stop aid
1
2
Stop aid
Centering
P r o d u ct
0-155
30.
Modifying the tools
Some parts can be produced only by modifying the standard tools.

From the economic point of view, this must always be given priority
to a special solution.
Advantages
Note
Fast tool solution (depending on the tool 3 10 days delivery

time).
Cost-effective tools.
Modifying or regrinding existing customer tools (even ACB)

possible.
Modified tools can be simply supplemented with standard tools

for other parts as well.
Can be often combined with standard ACB tools.
The maximum loads are partially less!
Modification examples
Adapter released
0-156
Heel recess increased
Modified upper tools

Punching lug milled
Punching radius increased
Punching back milled
Modified lower tools

Die for link plates released
Die milled to a narrow design
Window tool
0-157
31.
Programming
TRUMPF provides programming drawings for all the modified tools

and special tools on a CD.
PDF data for DELEM control system.
DXF, WZG and/or ARV data for TASC6000 control system.
Importing data into TruTops Bend

Example 1
Simulation of a U profile at the TASC 6000 control system (refer to
section "Window tool with adapter").
0-158
Example 2
Simulation of a housing part at the TASC 6000 control system
(refer to section "Corner formings inwards").
0-159

Brake Applications Catalog

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Brake Applications Catalog

Uploaded by

Copyright:

Available Formats

Catalog for application examples

TRUMPF LASERdur bending tools for your products

This document was created by the Technical Documentation of TRUMPF

Before you read on...

In this catalog, we present to you the application examples and

 When you see this symbol, enter the following data:

Dimensions of your product

Please send a copy of this information to your TRUMPF sales

For further questions, contact your TRUMPF sales partner.

We would be happy to advise you.

TRUMPF makes it possible...............................................8

Radius tools .....................................................................10

Tools for U parts ..............................................................20

Rotating jaw tool (U part) ................................................32

Tools and auxiliary tools for reduced-mark

SBW Swivel bending tool.............................................44

Horn tools .........................................................................48

Window tools ...................................................................54

Hinge tools .......................................................................60

Hinge tool complete (producing hinge in two steps)..........60

Punch and die rotated .....................................................70

Tools for bracing beading...............................................72

Number embossing and logo tools ...............................82

Louver tools .....................................................................86

Countersink shaped tool.................................................90

Reshaping tools (cups) ...................................................94

Adjustable dies ............................................................. 100

Die with rollers .............................................................. 104

Folding tools ................................................................. 106

Folding tool with holder OW209/S .................................. 110

Z bending tools ............................................................. 122

Tools for corner reshaping .......................................... 126

Tools for closed profiles .............................................. 130

Displaced bending line in a stroke ............................. 136

Tool for round rods ...................................................... 138

Tools for frames............................................................ 140

Bending various materials........................................... 144

Safety Click.................................................................. 146

Surfaces and heat treatment of tools ......................... 148

Equipment and stop aids ............................................. 152

Modifying the tools....................................................... 156

Programming ................................................................ 158

TRUMPF makes it possible

Page 43, 105

Radius bends can be produced in various ways.

Forming tools for radius bend

A U-part is produced through a positive lock between the upper

Exact product radius.

U part manufactured in two steps.

 Measure the drawing (incl. length).

Producing a U-part in two steps

Forming tool for radius bend

A circular part is produced through a positive lock between the

Exact product radius.

Circular part manufactured in three steps.

 Measure the drawing (incl. length).

Producing a circular part in three steps

Radius embossing tools for large radii

A tool with a large radius is embossed mostly in several steps

Alternative to rolling machine.

Optimum rounding compared to "bumping".

 Measure the drawing (incl. length).

 Select the material type: _______________________

Embossing large radii

When you see this symbol, enter the following data:

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Select the material type: _______________________

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).

Measure the drawing (incl. length).