A device utilized in sheet steel fabrication helps decide the suitable pressure required for bending operations. This digital device considers materials properties like tensile power and thickness, in addition to the bend size and die opening, to compute the mandatory pressure. As an example, bending a thick piece of stainless-steel into a pointy angle requires considerably extra pressure than bending a skinny sheet of aluminum right into a gradual curve. Precisely calculating this pressure is crucial for choosing the proper press brake and avoiding expensive errors like machine injury or workpiece failure.
Exact pressure calculation is essential for stopping half defects, optimizing machine lifespan, and enhancing general manufacturing effectivity. Traditionally, figuring out bending pressure concerned advanced guide calculations and infrequently relied on expertise and approximations. Fashionable digital options streamline this course of, offering fast and correct outcomes, minimizing materials waste, and maximizing productiveness. This evolution has revolutionized the precision and effectivity of sheet steel bending.
The next sections will delve deeper into the elements affecting bending pressure calculations, several types of instruments out there, and greatest practices for utilizing them successfully. Matters coated will embrace materials properties, bend allowances, die choice, and the influence of assorted bending strategies.
1. Materials Thickness
Materials thickness performs a crucial function in figuring out the pressure required for bending sheet steel. Correct evaluation of this parameter is crucial for correct utilization of a tonnage calculator, enabling exact pressure calculations for press brake operations. Understanding this relationship is prime for attaining desired bend outcomes and stopping tools or materials injury.
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Affect on Bending Drive
Thicker supplies require considerably extra pressure to bend than thinner supplies. This relationship shouldn’t be linear; doubling the fabric thickness requires greater than double the bending pressure. For instance, bending a 1/8″ thick metal sheet could require 10 tons of pressure, whereas a 1/4″ thick sheet of the identical materials and bend size may require over 40 tons. This exponential enhance highlights the significance of correct thickness enter into the calculator.
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Influence on Die Choice
Materials thickness additionally influences the number of the suitable die. Thicker supplies typically require dies with bigger openings to accommodate the elevated materials quantity throughout bending. Choosing an incorrect die can result in inaccurate bends, materials injury, and even press brake injury. A tonnage calculator typically incorporates die specs to supply complete pressure calculations.
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Consideration of Materials Properties
Whereas thickness is a main issue, materials properties additionally contribute to the general pressure requirement. Excessive-strength supplies, akin to stainless-steel or titanium, require extra pressure to bend in comparison with delicate metal or aluminum of the identical thickness. The calculator accounts for these variations primarily based on materials sort enter, guaranteeing correct pressure calculations throughout totally different supplies.
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Sensible Implications in Manufacturing
In a manufacturing atmosphere, inaccurate thickness measurement or neglecting its influence in calculations can result in vital points. These could embrace half inconsistencies, machine downtime attributable to overload, and elevated materials scrap. Correct utilization of a tonnage calculator, coupled with correct thickness measurement, minimizes these dangers and contributes to environment friendly and cost-effective manufacturing processes.
Correct materials thickness measurement is paramount for the efficient utilization of a tonnage calculator. By understanding the interrelation of fabric thickness, materials properties, and tooling choice, producers can leverage these instruments to optimize bending processes, guarantee product high quality, and maximize press brake efficiency.
2. Materials Sort
Materials sort considerably influences the pressure required for bending operations, making it a crucial think about correct tonnage calculations. Totally different supplies exhibit various mechanical properties, together with tensile power, yield power, and elongation, which straight influence their resistance to bending. Correct materials identification and property enter are important for leveraging a tonnage calculator successfully and guaranteeing profitable press brake operations.
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Tensile and Yield Power
Tensile power, a measure of a cloth’s resistance to breaking beneath pressure, and yield power, the purpose at which a cloth begins to deform completely, are essential elements affecting bending pressure necessities. Increased power supplies require better pressure to bend. As an example, high-strength metal necessitates extra tonnage in comparison with delicate metal of the identical thickness and bend parameters. The tonnage calculator incorporates these power values to supply exact pressure estimations.
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Elongation and Ductility
Elongation, the measure of a cloth’s capacity to stretch earlier than breaking, and ductility, its capacity to deform beneath tensile stress, additionally affect bending calculations. Supplies with greater elongation and ductility can face up to better bending deformation earlier than fracturing. This attribute impacts the bending angle and radius achievable with out cracking. The calculator considers these elements to make sure the calculated pressure avoids materials failure.
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Materials Composition and Grain Construction
Materials composition and grain construction affect a cloth’s response to bending forces. Totally different alloys and warmth therapies can considerably alter materials properties, affecting bending traits. For instance, stainless-steel, attributable to its particular composition and grain construction, displays totally different bending conduct in comparison with aluminum. Inputting correct materials specs into the calculator ensures the calculated tonnage aligns with the precise materials being bent.
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Sensible Implications in Manufacturing Processes
Choosing the mistaken materials sort in a tonnage calculator or neglecting materials property variations can result in vital manufacturing points. These can embrace inaccurate bends, materials fracturing, and press brake injury. Appropriate materials identification and property enter are crucial for guaranteeing product high quality, optimizing machine efficiency, and minimizing manufacturing prices.
Understanding the connection between materials sort and bending pressure is prime for environment friendly and efficient press brake operations. Precisely accounting for materials properties inside tonnage calculations ensures the number of acceptable bending parameters, minimizes materials waste, and maximizes general manufacturing effectivity.
3. Bend Size
Bend size, a vital parameter in sheet steel bending, straight influences the pressure required for the operation. It represents the size of the bend alongside the sheet steel’s impartial axis. Correct bend size enter is crucial for tonnage calculators to find out the suitable press brake pressure, stopping underbending or overbending and guaranteeing half conformity. Understanding the connection between bend size and bending pressure is paramount for environment friendly and exact sheet steel fabrication.
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Affect on Bending Drive
Longer bend lengths require extra pressure to bend in comparison with shorter lengths with the identical materials thickness and bend angle. This relationship stems from the elevated space of the fabric being deformed. As an example, bending a 10-inch lengthy piece of sheet steel requires extra pressure than bending a 5-inch piece of the identical materials with the identical bend angle and die configuration. Tonnage calculators account for this by factoring within the bend size as a key enter parameter.
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Influence on Die Choice
Whereas not as direct as materials thickness, bend size can affect die choice. Extraordinarily lengthy bends could require specialised tooling or segmented dies to accommodate the prolonged size and distribute the bending pressure evenly. Calculators could incorporate die specs to supply extra exact pressure estimations primarily based on the bend size and chosen tooling.
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Relationship with Materials Properties
The mixed impact of bend size and materials properties determines the general bending pressure. An extended bend size in a high-strength materials would require considerably extra tonnage in comparison with a shorter bend size in a lower-strength materials of the identical thickness. Correct enter of each materials properties and bend size into the calculator ensures correct pressure calculations.
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Sensible Implications in Manufacturing
Inaccurate bend size measurements can result in half inconsistencies, elevated materials scrap, and potential press brake injury. Correctly measuring and inputting the bend size into the tonnage calculator ensures correct pressure calculations, contributing to environment friendly manufacturing and minimizing expensive errors. Moreover, understanding the influence of bend size on bending pressure permits for higher course of optimization and materials utilization.
Correct bend size measurement and its integration into tonnage calculations are basic for profitable press brake operations. By understanding its affect on bending pressure, producers can optimize tooling choice, enhance half accuracy, and maximize manufacturing effectivity.
4. Die Opening
Die opening, the gap between the higher and decrease dies in a press brake, is a crucial parameter affecting the pressure required for bending sheet steel. This dimension straight influences the bending radius and the quantity of fabric deformation through the bending course of. Consequently, die opening considerably impacts the tonnage required, making it a vital enter for correct calculations inside a tonnage calculator. A smaller die opening necessitates the next bending pressure, whereas a bigger opening requires much less pressure for a similar materials and bend angle. This relationship stems from the mechanics of bending, the place a smaller die opening forces the fabric to bend extra acutely, requiring better pressure to beat the fabric’s resistance to deformation.
Contemplate bending a 1/8″ thick delicate metal sheet to a 90-degree angle. Utilizing a slim die opening, for example, 1/4″, requires considerably extra tonnage than utilizing a wider opening, akin to 1/2″. This distinction arises as a result of the narrower opening forces the fabric right into a tighter bend radius, growing the stress and pressure inside the materials and thus requiring extra pressure. Conversely, the broader opening permits for a gentler bend radius, lowering the pressure wanted. Choosing an inappropriate die opening can result in a number of points, together with extreme tonnage necessities, probably exceeding the press brake’s capability, or inadequate tonnage, leading to incomplete bends. Moreover, the die opening influences the ultimate bend angle and might have an effect on the fabric’s floor end. Utilizing a die opening that’s too slim may cause materials to pinch or deform excessively, whereas a gap that’s too huge can result in springback, the place the fabric partially returns to its unique form after bending.
Correct die opening choice is essential for optimizing bending operations and attaining desired outcomes. Tonnage calculators incorporate die opening as a key enter, permitting operators to find out the required pressure for particular bending parameters. Understanding the connection between die opening, bending pressure, and ensuing bend traits is crucial for environment friendly and efficient press brake operation. This information aids in deciding on the proper tooling, minimizing materials waste, and stopping machine overload or injury. Cautious consideration of die opening contributes considerably to general course of optimization and ensures the manufacturing of high-quality bent elements.
5. Bend Angle
Bend angle, the angle fashioned between the 2 legs of the bent sheet steel, is a vital parameter in press brake operations. This angle straight influences the quantity of pressure required to deform the fabric. Correct bend angle enter inside a tonnage calculator is crucial for figuring out the suitable press brake pressure, guaranteeing half conformity, and stopping machine overload. Understanding the connection between bend angle and bending pressure is prime for environment friendly and efficient sheet steel fabrication.
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Affect on Bending Drive
Bigger bend angles require extra pressure to realize than smaller angles, assuming fixed materials properties, thickness, and bend size. It’s because a bigger bend angle represents a better diploma of fabric deformation. As an example, bending a sheet to 120 levels requires considerably extra pressure than bending the identical sheet to 90 levels. Tonnage calculators incorporate the bend angle as a key enter, permitting operators to find out the mandatory pressure for particular bending necessities.
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Relationship with Materials Properties
The interaction between bend angle and materials properties is crucial for figuring out the general bending pressure. A bigger bend angle in a high-strength materials necessitates considerably better tonnage in comparison with a smaller bend angle in a lower-strength materials of the identical thickness and bend size. Correct enter of each materials properties and bend angle inside the calculator is essential for exact pressure calculations.
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Influence on Springback
Bend angle additionally influences the diploma of springback, the tendency of the fabric to partially return to its unique form after bending. Bigger bend angles usually exhibit extra springback, requiring changes to the bending course of or tooling to compensate. Tonnage calculators typically incorporate springback compensation elements primarily based on the fabric and bend angle to make sure correct remaining bend angles.
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Sensible Implications in Manufacturing
Incorrect bend angle enter or neglecting its influence on bending pressure calculations may end up in half inconsistencies, elevated materials scrap, and potential press brake injury. Exact bend angle measurement and its integration inside tonnage calculations are important for environment friendly manufacturing, optimized materials utilization, and attaining desired half geometries.
Correct bend angle dedication and its inclusion in tonnage calculations are important for profitable press brake operations. By understanding the connection between bend angle, bending pressure, materials properties, and springback, producers can optimize tooling choice, refine bending processes, and make sure the manufacturing of high-quality elements with exact geometries.
6. Bending Technique
Bending methodology considerably influences tonnage necessities in press brake operations. Totally different strategies, akin to air bending, bottoming, and coining, apply pressure to the sheet steel in distinct methods, impacting the mandatory tonnage and ensuing bend traits. Precisely specifying the bending methodology inside a tonnage calculator is essential for figuring out the suitable press brake pressure, stopping machine overload and guaranteeing desired bend outcomes. Understanding the nuances of every methodology and their respective tonnage implications is crucial for environment friendly and efficient sheet steel fabrication.
Air bending, a standard methodology, kinds the bend by making use of pressure to the sheet steel with out totally contacting the die backside. This methodology typically requires much less tonnage in comparison with bottoming or coining. Bottoming, because the identify suggests, forces the sheet steel towards the die backside, producing a extra exact bend angle however requiring greater tonnage attributable to elevated materials deformation. Coining, probably the most force-intensive methodology, goes past bottoming by squeezing the fabric between the punch and die, making a exactly outlined radius and angle however necessitating considerably greater tonnage. For instance, attaining a 90-degree bend in a 1/4″ thick delicate metal sheet utilizing air bending would possibly require 20 tons of pressure, whereas the identical bend utilizing bottoming would possibly require 40 tons, and coining may necessitate upwards of 60 tons. These variations spotlight the significance of precisely deciding on the bending methodology in tonnage calculations.
Choosing the suitable bending methodology inside a tonnage calculator permits for exact pressure calculation and optimization of the bending course of. Understanding the tonnage implications of air bending, bottoming, and coining ensures correct machine choice, prevents overloading, and minimizes materials waste. Precisely accounting for the chosen bending methodology contributes considerably to environment friendly manufacturing, improved half high quality, and prolonged press brake lifespan. Selecting the proper bending methodology is integral to profitable and cost-effective sheet steel fabrication.
7. Tonnage Calculation
Tonnage calculation kinds the core perform of a tonnage calculator press brake. It represents the method of figuring out the mandatory pressure (tonnage) a press brake should exert to bend a selected materials to a desired angle. This calculation considers a number of interlinked elements: materials properties (sort, thickness, tensile power), bend size, die opening, and the bending methodology employed (air bending, bottoming, coining). A exact tonnage calculation ensures correct bending, prevents machine overload and injury, and minimizes materials waste. As an example, if inadequate tonnage is utilized, the fabric could not bend to the required angle, leading to a flawed half. Conversely, extreme tonnage can injury the press brake, tooling, or the workpiece itself. Contemplate bending a 2-meter lengthy, 3mm thick stainless-steel sheet to a 90-degree angle utilizing a V-die with a 10mm opening. The tonnage calculation should contemplate the stainless-steel’s excessive tensile power and the comparatively lengthy bend size. An inaccurate calculation may result in both an incomplete bend or potential injury to the machine. Understanding the elements influencing tonnage calculation allows knowledgeable selections concerning machine choice and course of optimization.
Precisely calculating tonnage is essential for attaining desired bending outcomes and maximizing manufacturing effectivity. The complexity of this calculation arises from the interplay of a number of variables. Materials thickness straight influences the required forcethicker supplies demand greater tonnage. Equally, greater tensile power supplies require extra pressure for bending in comparison with lower-strength supplies of the identical thickness. Bend size additionally performs a major function: longer bends require extra tonnage. Moreover, the die opening impacts the pressure wanted; smaller openings necessitate greater tonnage. Selecting the proper bending methodair bending, bottoming, or coiningis essential, as every methodology requires totally different pressure ranges. Failing to precisely account for these variables can result in expensive errors and manufacturing delays. Fashionable tonnage calculators simplify this course of, offering correct and environment friendly calculations, enabling operators to enter related parameters and shortly decide the required tonnage for a selected bending operation.
Exact tonnage calculation, facilitated by tonnage calculator press brakes, represents a major development in sheet steel fabrication. Correct tonnage dedication ensures half conformity, maximizes machine lifespan, and optimizes materials utilization. Whereas the underlying calculations are advanced, trendy instruments streamline this course of, offering important data for environment friendly and profitable bending operations. Challenges stay in guaranteeing correct enter parameters and understanding the constraints of the calculations, significantly regarding springback and materials variations. Nevertheless, the flexibility to precisely predict required tonnage empowers operators to make knowledgeable selections, minimizing dangers and enhancing the precision and effectivity of press brake bending processes.
8. Security Issue
Security elements play a vital function in tonnage calculations for press brake operations. A security issue is a multiplier utilized to the calculated tonnage to account for potential variations and uncertainties in materials properties, machine efficiency, and tooling situations. This added margin of security helps forestall machine overload, tooling failure, and workpiece injury. And not using a security issue, unexpected variations may result in catastrophic penalties, akin to press brake injury or operator harm. As an example, if the calculated tonnage for a selected bend is 100 tons, making use of a security issue of 1.2 ends in a goal tonnage of 120 tons. This extra 20 tons offers a buffer towards potential variations, guaranteeing the press brake operates inside secure limits. The magnitude of the protection issue relies on a number of elements, together with the fabric’s consistency, the press brake’s situation, the tooling accuracy, and the complexity of the bend. Advanced bends or supplies with inconsistent properties usually warrant greater security elements.
Contemplate a situation the place a press brake is used to bend a batch of high-strength metal. Because of slight variations within the materials’s tensile power inside the batch, the precise pressure required for bending would possibly exceed the calculated tonnage. And not using a security issue, this might result in machine overload or workpiece injury. Incorporating a security issue safeguards towards such variations, guaranteeing constant and secure bending operations. One other instance entails tooling put on. Over time, press brake tooling can put on down, affecting the pressure distribution throughout bending. A security issue compensates for this put on, stopping incomplete bends or extreme pressure on the machine. Moreover, a security issue accounts for potential variations within the press brake’s efficiency itself. Hydraulic strain fluctuations or mechanical put on can affect the precise pressure delivered by the press brake. The security issue ensures that even with these variations, the machine operates inside its secure working limits.
Understanding and making use of acceptable security elements is crucial for secure and environment friendly press brake operations. Tonnage calculators typically incorporate default security elements, however operators ought to alter these primarily based on particular circumstances. Neglecting security elements can result in expensive errors, machine injury, and potential security hazards. Conversely, excessively excessive security elements may end up in inefficient machine utilization and elevated vitality consumption. Discovering the best stability ensures secure operation whereas maximizing productiveness. Integrating security elements into tonnage calculations demonstrates a proactive strategy to danger administration, selling a safer and extra environment friendly manufacturing atmosphere. Future developments in tonnage calculation would possibly incorporate extra refined algorithms that dynamically alter security elements primarily based on real-time machine and materials knowledge, additional enhancing operational security and effectivity.
Ceaselessly Requested Questions
This part addresses widespread inquiries concerning tonnage calculations for press brake operations, offering readability on crucial features of this course of.
Query 1: How does materials thickness have an effect on the required tonnage?
Materials thickness is straight proportional to the required tonnage. Thicker supplies require considerably extra pressure to bend attributable to elevated resistance to deformation. Even small variations in thickness can considerably influence the mandatory tonnage.
Query 2: Why is correct materials sort choice vital in tonnage calculations?
Totally different supplies possess various mechanical properties, together with tensile and yield power, which straight affect bending pressure necessities. Correct materials choice ensures the calculator makes use of the proper materials properties, main to specific tonnage calculations.
Query 3: How does bend size affect the required tonnage?
Bend size is straight proportional to the required tonnage. Longer bends necessitate extra pressure as a result of elevated space of fabric being deformed. Correct bend size measurement is essential for exact tonnage calculations.
Query 4: What function does die opening play in tonnage calculations?
Die opening inversely impacts the required tonnage. Smaller die openings require greater forces as a result of tighter bend radius and elevated materials deformation. Conversely, bigger openings cut back the mandatory tonnage.
Query 5: How does the bending methodology (air bending, bottoming, coining) have an effect on tonnage necessities?
Totally different bending strategies apply pressure in distinct methods, impacting tonnage necessities. Air bending typically requires the least pressure, adopted by bottoming, whereas coining necessitates the best tonnage attributable to elevated materials compression.
Query 6: What’s the significance of a security think about tonnage calculations?
Security elements account for potential variations in materials properties, machine efficiency, and tooling situations. They supply a crucial security margin, stopping machine overload and workpiece injury by guaranteeing the press brake operates inside secure limits.
Correct tonnage calculations are important for environment friendly and secure press brake operations. Understanding the elements influencing these calculations ensures optimum machine efficiency, minimizes materials waste, and contributes to high-quality half manufacturing.
The following part delves into sensible functions and case research, illustrating real-world examples of tonnage calculations and their influence on bending outcomes.
Ideas for Efficient Tonnage Calculation
Exact tonnage calculations are basic for profitable press brake operations. The following tips present sensible steerage for optimizing calculations and guaranteeing correct bending outcomes.
Tip 1: Correct Materials Identification:
Correct materials identification is paramount. Inputting incorrect materials properties into the calculator results in inaccurate tonnage estimations. Confirm materials specs utilizing mill certificates or dependable materials testing strategies.
Tip 2: Exact Measurement of Materials Thickness:
Make the most of calibrated devices like micrometers or calipers to acquire exact materials thickness measurements. Even minor variations in thickness can considerably influence tonnage necessities. A number of measurements at totally different areas on the sheet guarantee accuracy.
Tip 3: Appropriate Bend Size Dedication:
Precisely measure the bend size alongside the fabric’s impartial axis. For advanced bends, contemplate the developed size, accounting for the fabric’s elongation throughout bending. Exact bend size enter is essential for proper tonnage calculations.
Tip 4: Applicable Die Choice:
Choose the proper die primarily based on materials thickness, bend angle, and desired bend radius. The die opening straight influences the required tonnage. Seek the advice of die producer specs for optimum die choice.
Tip 5: Bending Technique Issues:
Specify the proper bending methodair bending, bottoming, or coiningwithin the calculator. Every methodology has distinct tonnage necessities. Understanding these variations is essential for correct calculations.
Tip 6: Considered Security Issue Software:
Apply an acceptable security issue to account for potential variations and uncertainties. The security issue ought to stability danger mitigation with environment friendly machine utilization. Regulate the protection issue primarily based on materials consistency, machine situation, and bend complexity.
Tip 7: Common Tooling Inspection and Upkeep:
Repeatedly examine and preserve press brake tooling. Worn or broken tooling can have an effect on pressure distribution and necessitate greater tonnage. Correct tooling upkeep ensures correct bending outcomes and prolongs tooling lifespan.
Tip 8: Verification of Calculated Tonnage:
At any time when attainable, confirm the calculated tonnage utilizing check bends on scrap materials. This step helps establish potential discrepancies and permits for changes earlier than processing manufacturing elements. Common verification enhances course of reliability.
Adhering to those ideas enhances the accuracy and effectiveness of tonnage calculations, resulting in improved half high quality, elevated machine lifespan, and a safer working atmosphere.
The next conclusion summarizes the important thing takeaways and emphasizes the significance of correct tonnage calculations in trendy sheet steel fabrication.
Conclusion
Tonnage calculator press brake performance represents a crucial component inside trendy sheet steel fabrication. Correct pressure dedication for bending operations hinges upon a number of interconnected elements, together with materials properties (sort, thickness, tensile power), bend size, die opening, bending methodology (air bending, bottoming, coining), and acceptable security issue utility. Exact calculations guarantee half conformity, optimize machine utilization, reduce materials waste, and improve general operational security. Neglecting any of those elements can result in inaccurate bends, machine overload, tooling injury, and potential security hazards. Understanding the interaction of those parameters empowers knowledgeable decision-making, enabling environment friendly and efficient press brake operations.
As manufacturing processes proceed to evolve, leveraging superior calculation instruments turns into more and more important for sustaining competitiveness and producing high-quality elements. Continued developments in materials science and press brake expertise necessitate ongoing refinement of tonnage calculation strategies. Emphasis on correct knowledge enter, coupled with a radical understanding of bending rules, stays essential for profitable integration of tonnage calculators inside the sheet steel fabrication panorama. Striving for exact tonnage calculations contributes considerably to optimized manufacturing processes, decreased materials consumption, and enhanced office security.
