When deciding which Press Brake will meet your metal bending needs, it's crucial to consider the various sheet metal characteristics and options available. Here are five essential questions to guide you before investing in a new press brake for your fabrication shop.
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1. What type of material do you need to bend?
Consider the metal bending projects you will undertake and the type of metal you will use. Evaluate all specifications of your metal and finished parts, including:
- The maximum thickness and length of the metal you'll be working with
- The flange lengths required
- Any specific characteristics that need to be considered when calculating a bend
Your goal is to invest in a machine with the shortest worktable and lowest tonnage capable of accomplishing the task. Choose incorrectly, and you'll face higher manufacturing costs. Thus, a thorough evaluation of your production needs is imperative.
2. Which is the best machine to handle your tonnage?
Tonnage, or the bending force/capacity of the press brake, is crucial when purchasing a new machine. Generally, thicker material requires more tonnage. Softer metals like aluminum need less tonnage compared to high-strength steel. Length, die opening width, and the process type (air bending requires less force than bottom bending and coining) also factor into tonnage calculations.
To estimate the required tonnage, consult a press brake air-bending tonnage chart like the one in Durma’s Press Brakes product specifications (see page 7). Always oversize the press brake capacity by 20-30% to account for metal variability and avoid working at the machine's limit.
3. How much deflection is likely to occur?
Consider the potential deflection in a machine. Deflection refers to the deformation of the press brake ram and bed under load. A longer machine will experience more deflection than a shorter one, requiring less shimming for better part quality.
Industry standards for materials dictate an acceptable stress value of 8.5 kg/mm2. Durma machines meet a stricter value of 5-6 kg/mm2, ensuring reduced deflection, enhanced frame durability, and prolonged accuracy under heavy use. All incoming plates meet stringent Durma standards to maintain this quality.
4. What is the inside bend radius of your parts?
Accurately calculating bend allowances, outside setbacks, and bend deductions improves the chances of producing a quality part on the first try. The inside bend radius is a crucial factor; smaller inside radii increase material flexibility.
The press brake bending method affects the inside radius—if you determine the correct bend deduction for a radius, you facilitate manufacturing and reduce errors. For lower tonnage requirements, aim for an inside radius greater than the metal thickness and use air bending.
5. Do you have the right tooling?
The type of tooling you need depends on the materials you are bending. Select tooling that provides the strongest profile suitable for your project without exceeding load limits. Ensure compatibility if you plan to use current tooling with your new press brake and inspect for wear by measuring from the punch nose to the shoulder and from shoulder to shoulder on the dies.
For assistance in selecting the right press brake for your needs, contact our team at 03 9794 6675. Click here to view our range of press brakes.
If you are thinking of buying a press brake, or are in the market already, take a moment to read these important notes. Before shopping, understand what type of press brake you need and the features that will benefit you. Don't rely solely on your machinery sales rep; perform due diligence in your shop to ensure you know exactly what you need.
What Is a Press Brake?
Let's start with a brief description of what a press brake is compared to other metal working machines. A press brake is designed to bend or fold sheets of metal using upper ram and lower bed tooling. It controls the distance between tools manually or via CNC, bending the material to the desired shape while accounting for spring back. Common applications include fabricating metal parts such as electrical boxes, enclosures, and signs.
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In a previous article, we discussed choosing between a press brake and a folder. That piece outlined metal folding and the differences between these two bending processes. It's crucial to revisit this point, as fabricators often overlook a folder’s accuracy and versatility, believing they need a press brake.
Important Considerations When Buying a Press Brake
Assuming a press brake is the right tool, you must answer several critical questions. Despite numerous press brake solutions, only a few will meet your needs and budget. Whether you choose mechanical, hydraulic, electric, or hybrid drive technologies depends on your shop's unique requirements. Make notes on your current bending process, its weaknesses, and needed improvements. Identify your motivation for shopping for a press brake—is it:
- More Capacity in Tonnage
- Longer Bed
- Reduce Setup Times
- Reduce Maintenance
- Improve Safety
- Easier to Use
- Improved Part Accuracy/Reduce Scrap
Follow the 80/20 rule when buying machinery: buy for 80% of your usual workload and avoid buying a larger machine for occasional use. For instance, buying a machine that can handle 10 gauge mild steel should not be upgraded to handle 1/2" plate if seldom used. It's more economical to outsource occasional heavy tasks.
Tooling: What type of tooling do you currently use? If you already have a press brake, consider if your existing tools are compatible with a new machine. Different tooling styles include American, European, Trumpf, and Amada. These tools vary in manufacturing processes, tolerance levels, and bending angles. Identify your current tooling style but don’t let it exclusively determine your new press brake choice.
Common Types of Press Brakes
- Down Acting: The majority of machines are down-acting—upper tooling moves up and down.
- Up Acting: The bed moves up towards a fixed punch.
Press brakes can be mechanically, hydraulically, or electronically driven.
How to Choose the Right Press Brakes For Your Shop
Material Type & Thickness: Determine the hardest and thickest material you'll work with. Press brakes are classified by their ability to bend mild steel, but modern steels are often harder. Numerous bending charts, including ours, can help you determine tonnage. Plan to use 80% of capacity to prolong machine life.
Maximum Material Length: Know the widest material you need to bend and the flanges' heights. If you bend up to 10" material but need 12" flanges, you might require a 12' bed to fit the material.
Complexity of Bends: Simple 90-degree bends might only need a 2-axis CNC machine, while complex parts require sophisticated gaging systems and controls. More axis in the machine’s gauge offers greater flexibility and accuracy.
Accuracy of Bend: Several factors impact bend accuracy, including material properties and equipment setup. Start with precision-ground tooling. For precise bending, consider manual or CNC crowning devices and angle measuring gadgets. Beware of over-relying on add-ons that might not perform well on the shop floor.
Number of Parts Required Per Day: Production rate influences equipment configuration and potential for automation. Evaluate if automation (e.g., robotics) is needed to meet your output requirements.
Part/Tooling Changeouts: Determine how often you change tooling. Frequent changes could benefit from hydraulic clamping and precision tooling to reduce setup times significantly.
Operator Skill Level: Consider the skill level of your operators. More advanced controls can reduce the skill required by automating calculations for bend allowance, sequences, and gage points, making setup quicker and more consistent.
Ready to start your press brake search? Ensure you know your needs and get the tools before talking to sales reps. For expert advice, contact Southern Fabricating Machinery Sales at 1-813-444-4555. For more information, view our press brake inspection checklist and cnc iron plate press brake supplier. Our team looks forward to helping you find the right press brake for your needs and budget, whether new or used.
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