The press brake plays a vital role in metal fabrication.
It is used for bending and shaping metal sheets, widely used in manufacturing automotive parts, electronic equipment casings, or building structural elements.
Its significance also is its excellent accuracy and controllability, which can bend the metal sheet into a highly precise shape, and keep consistency in mass production.
However, a high-quality press brake itself can’t ensure the best production results.
In the metal fabrication industry, each detail is of pivotal importance, which is why press brake accessories should be emphasized.
Press brake accessories are the additional tools to optimize press brake properties, which include but are not limited to blades (used to cut the metal sheet), dies (used to bend the metal sheet), back gauge (used to control the bending angle, and length), clamp (used to fix the metal sheet), support shelves (used to support the metal sheet).
Our passage will discuss the importance of the press brake accessories and their excellent functions in optimizing the properties.
II. Understanding Press Brakes
Position: the press brake positions the sheet via a back gauge to make the bending accuracy.
Bending: the press brake exerts pressure on the metal sheet to achieve bending via the upper die and bottom die.
Control: the modern press brake is usually equipped with a CNC system to achieve accurate control during the bending process.
Types of press brake
Mechanical press brake: this is a traditional type of press brake, powered by an electric motor and flywheel. It achieves sheet bending by mechanical force. Although the mechanical press brake has its advantages in speed and repeatable precision, its safety and energy consumption are generally inferior to modern hydraulic and electric press brakes.
Hydraulic press brake: this hydraulic press brake adopts hydraulic oil as the working medium. It bends the sheet through the pressure generated by the hydraulic cylinder to push the ram (that is top die). Its advantages lie in offering more powerful bending force and better control, especially when dealing with thick sheets.
Electric press brake: the electric press brake utilizes a servo motor to drive the ram movement directly, which can achieve faster speed and higher precision. Electric press brake stands out in energy-saving and environmental aspects, also the cost of maintenance is relatively low.
Role in metal fabrication
The press brake is an important metal sheet production equipment, that can achieve various metal manufacturing via high accuracy bending operation.
It can create complex shapes of components to meet multiple design needs.
It can keep parts accurate and consistent which is important for mass production.
It also can improve working efficiency, and reduce working time and labor cost.
It can reduce material waste through precise control during the processing and cutting period.
III. The Need for Accessories
Using proper press brake accessories can significantly improve the press brake functionality.
For example, using dies with different shapes and sizes can achieve various bending operations.
The fast-changing die system can reduce die replacement time, improving working efficiency.
The CNC back gauge also can provide higher repeatable positional accuracy, optimizing the bending process.
Press brake safety is an important factor to consider.
The assistant equipment can protect operators from injury in the bending process, like safety bezel, laser protective equipment, and safety linear scale.
What’s more, emergent stop buttons and safety sensors are also indispensable accessories for securing operators.
Extending the Capabilities of Press Brakes
The press brake properties can be further improved via a high-level control system and software.
These systems can help operators better control the bending process, and achieve more complex bending tasks, like 3D pressing.
The automatic loading and unloading system can not only relieve the labor intensity but also make the press brake handle larger and heavier sheets.
Increasing Efficiency and Reducing Waste
Accurate measurement and position systems can ensure each bending achieves the anticipated precision.
This not only increases the efficiency but also reduces the material waste because of error.
Automatic programming and simulation software can predict the problem that may occur before bending, and optimize the bending path, reduce the need for trial products.
IV. Must-Have Press Brake Accessories
Dies and Punches
Standard set: the standard set includes dies and punch in normal shape and size, which is suitable for most standard bending tasks. These are the basics of bending works, which should be prepared fully in various types to adapt to various bending requirements.
Special dies worked for intricate works: when bending sheets with special shapes and sizes, the special dies are deemed important. These dies are specially designed for complex or nonstandard bending tasks, which can help finish special design requirements.
Manual back gauge: manual back gauge is an economical and practical choice for small-scale or custom works. It allows operators to adjust the position of sheets manually, to fit the bending work not required for high precision.
CNC back gauges for precision: the CNC back gauge system controls the sheet location via computer programming, achieving high precision and repeatability, which is an ideal choice for tasks requiring mass scale and high precision.
Manual crowning: the manual crowning system allows operators to compensate for bending the bottom die of the machine tool via manual adjustment. This is suitable for working situations that uncommonly change the bending specification.
Automatically crowning system to ensure consistent bending: the automatic crowning system can adjust the press brake pressure automatically to compensate for the deformation of the machine tool bed, thus ensuring that each bend can achieve consistent accuracy, suitable for long-term consistent production.
Tool Clamping Systems
Quick-change clamping for efficiency: a quick-change clamping system can significantly reduce the die replacement time, improving production efficiency, especially suitable for production lines that require frequent replacement dies.
Hydraulic clamping for enhanced safety: a hydraulic clamping system provides a more stable and safer die clamping way. It can ensure the die can be fixed firmly during the bending process, thus reducing the accident risks that may caused by die movement.
V. Advanced Accessories for Press Brakes
Some advanced press brake accessories include laser safety systems, angle measurement systems, and robotic bending cells.
The laser safety system utilizes a laser sensor to monitor the bending area. When the system detects any intruding goods, the machine can be stopped immediately.
Thus, the operator can be protected from any injury.
The angle measurement system can detect the bending angle of the sheet during the bending process, and compare it with the pre-set angle.
If the detected angle deviates from the angle set by programs, the system can automatically adjust the bending pressure, ensuring the precision and consistency of the final production.
Robotic bending cells can not only unload and load the material automatically but also can proceed with highly accurate bending operations.
This highly automatic unit can be operated without supervision, and greatly improve production efficiency and consistency, reducing labor cost and operational false.
What’s more, robotic bending cells are highly flexible, can adapt to various production needs, and are the ideal choice for mass scale, multiple sorts of working environments.
VI. Accessory Selection and Compatibility
Press brake accessories must be compatible with the press brake model to ensure the best properties and safety.
It is essential to choose the proper accessories to achieve precise bending, reduce waste, and improve final product quality.
Some press brake accessories are custom to meet specific requirements, such as the size and shape of the workpiece.
When choosing the press brake accessories, it is necessary to know the compatibility between it and the press brake model.
These accessories must be compatible with the press brake tonnage, bed length, and stroke length.
Compatibility not only contains physical size and interfaces but also software systems.
Choosing the wrong accessories may lead to press brake damage, thus resulting in high-cost maintenance and shutdown.
Right accessories are beneficial to achieve precise bending, reduce waste, and improve product quality.
For example, the back gauge can help ensure the correct position of the metal sheet, clamping tools can fix the sheet firmly.
Other accessories such as angle measuring tools, radius gauges, and tool holders can also be used to improve precision and efficiency during the bending process.
It is possible to develop and custom accessories to meet the specific requirements. For example, custom punches and dies can be designed to produce specific shapes and angles.
Cooperation with manufacturers to custom the accessories. The manufacturer can optimize the press brake according to specific application, and achieve better results.
VII. Maintenance and Care for Press Brake Accessories
Press brake accessories need to be maintained regularly to ensure the best properties and safety.
It is significant to plan regular maintenance, practice restoring correctly, and solve common problems.
Plan regular maintenance plans to ensure the accessories are in good condition.
Also need to obey the correct storage measurements to avoid accessories damage.
Troubleshooting for die wear, punch damage, and back gauge malfunction is beneficial to avoid expensive maintenance and shutdown.
Maintaining the press brake accessories based on the manufacturing’s instructions is pivotal.
The manufacturing instruction can offer guidance related to maintaining frequency, types of lubrication, and other important information.
Following the manufacturing instructions, the manufacturer can ensure the press brake accessories are in good working condition and achieve the best properties.
What tools are needed for a brake press operator?
Tools used by press brake include press brake punch and die, back gauge, protractor, hydraulic device, protective device, etc.
High-quality press brake tools are essential parts of the high-property press brake.
Is a press brake better than a hydraulic press?
Mechanical press brake offers precision and adaptability for materials from thin to medium, while the hydraulic press brake offers power and consistency for heavy-duty applications.
What are the disadvantages of press brakes?
The initial cost is high. Because of purchasing and maintenance, the press brake needs a large amount of initial investment.
Besides, the machine requires specialized equipment and training, which may increase the initial cost of setting up the machine.
What’s more, it needs more power, so this will increase the operational cost.
Press brake accessories are of pivotal importance in achieving precise bending, reducing waste, and improving the final product quality.
It is necessary to choose the right accessories to ensure the best properties and safety.
Some important press brake accessories include punch and die, back gauge, crowning, and tool clamping system.
Press brake accessories must be compatible with the press brake model to ensure the best performance and security.
Follow the manufacturer's instructions related to press brake accessories maintenance, thus ensuring the accessories work in good condition.
The future of press brake accessories is exciting, the advancement of technology will bring about an industry revolution.
With the use of robotic and artificial, the press brake improves efficiency and accuracy, thus increasing the press brake automatic technology.
Besides, the role of IoT and Industry 4.0 in press brake accessories is also expected to increase as sensors and data analytics are integrated to optimize the bending process.
If you want to know more about press brake accessories, we encourage you to consult experts to acquire personalized suggestions.
You can also visit our product website to search for more information on your own.