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How to Solve Springback in Copper Busbar Bending: The Ultimate Guide for Switchgear Manufacturers

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total servo busbar bending machineEvery switchgear manufacturer faces this headache: You set your machine to bend at exactly 90°, but once the pressure is released, the copper bar springs back to 92° or 93°. This phenomenon, known as springback, leads to material waste and endless manual adjustments.

In this guide, we will analyze why springback happens and how to overcome it using both manual techniques and advanced high precision CNC busbar machines.

1. What Causes Springback in Busbar Processing?

Springback is the elastic recovery of the metal after unloading. Unlike soft aluminum, copper (especially hard-drawn copper) has higher tensile strength, making the springback more pronounced.

Several factors influence the degree of springback:

      • Material Hardness: Harder copper springs back more than annealed copper.

      • Bending Radius: A larger minimum bending radius usually results in greater springback.

      • Thickness: Thicker bars behave differently than thinner ones.

    2. The Traditional Way: Calculation and Trial

    For workshops using manual or simple hydraulic benders, operators often rely on experience. They use a method called “Over-bending.” To achieve a 90° angle, they might bend to 88° or 87°.

    Experienced engineers often look for a calculation formula for copper busbar bending deduction to estimate the springback value. However, this method has a major flaw: inconsistency. Even copper bars from the same supplier can vary in hardness from batch to batch, making manual calculation unreliable for mass production.

    3. The Modern Solution: CNC Auto-Compensation

    To completely eliminate the guesswork, modern manufacturing has shifted towards automation. This is where a high precision CNC busbar machine with Siemens PLC system becomes a game-changer.

    Unlike traditional machines, advanced CNC benders utilize Closed-Loop Control Systems:

        1. Probe Detection: The machine bends the bar.

        1. Springback Measurement: High-precision grating rulers measure the actual angle after the initial release.

        1. Auto-Compensation: The system automatically calculates the springback degree and performs a secondary bend to reach the perfect angle.

      This technology is critical for automatic busbar punching and cutting machine for mass production, ensuring that every single piece is identical without manual intervention.

      4. Hydraulic vs. Servo: Which One Controls Springback Better?

      When selecting a machine, you might wonder about the difference between servo motor and hydraulic busbar bending.

          • Hydraulic Systems: Powerful and cost-effective, ideal for thick bars (e.g., 12mm x 120mm). Modern hydraulic CNC machines equipped with linear guides can handle springback effectively.

          • Servo Systems: Offer superior speed and precision control, ideal for thinner bars or complex shapes.

        For most switchgear manufacturers, a hybrid CNC system offering the power of hydraulics with the precision control of servo electronics is the optimal choice.

        Conclusion & Call to Action

        Solving the springback problem isn’t just about operator skill; it’s about equipping your workshop with the right technology. Reducing scrap rates means higher profit margins.

        Are you looking for a machine that handles springback automatically? Check out our latest [CNC Busbar Bending Series] or [Contact our Engineering Team] for a free consultation on your specific material specifications.


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