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Press brakes are depended on in engineering industries for sheet bending requirements. It shows higher performance and speed production for large engineering requirements. However, buying a press from a reputed manufacturer is more important than just investing for the sort of bending requisites and Bhavya Machine Tools is one among the best options.
A press brake is workshop equipment that is mainly used for bending metals and metal sheets. Wherein, it can be done either in V shape or U shape in accordance with the industrial requirement. It consists of two C frames fixed in the sides of the machine, which is then fixed over a movable upper beam. The speed of the upper beam increases when the process of bending is tuned to work fast if there are more requirements for production. The whole unit is mounted on a table hence, this equipments like a press brake is a space saving option too. In addition, press equipment is mostly preferred to obtain precision in the process. The precision is expected in terms of angle finalization, finishing, accuracy in measurement, etc. It is possible to obtain it for a range of metals such as aluminum, brass, and cold rolled carbon steel, hot steel, stainless steel, wood, etc.
Applications of Press Brake in Workshops and industries
Press brakes for metal sheet are used mostly in machining industries. The applications also vary according to the production demands. The shape variations can be adjusted with the help of selecting the type of die. Hence, these are found to be most suitable equipment. Selecting the right die design will get your requirement done with precision. There are different types of die designs available which can be applied in accordance with the predetermined angle bend.
The process of metal bending and sheet bending with press brake
The process of these works with the support of punch angle and punch tip which are called the top and bottom tool respectively. The bottom tool contains a V shape open on which the pressing force works to get the desired shape and angle. The bending on the other hand is done in different types such as
Mechanical Press brake–works with an electric motor. In which only the bending radii contact with each other. It is a universal application.
Pneumatic press brake– Works with air pressure
Hydraulic press brake-Works with hydraulic cylinders
Servo-electrical press brake-Works with servo-electrical motor
Different types of sheet metal bending with Press Brake
There are different types of process that can be achieved through it. This can be done by selecting the type of die to be installed in the sheet bending machine. The die on the other hand is usually installed in the bottom part of the brake and some of the popular die designs are
Rotary bending dies
90 degree dies
Acute angle dies, etc
It is quiet difficult to manage with bottoming. However, for greater precision and more production preferring the right type of die will give better results. Click here to know more about Press Brake.
Different types of sheet metal bending such as radius bend, open hat channel bend, double form bend, offset bend, V Bottom bend, etc can be achieved by selecting suitable dies. This will help for better productivity also.
Press brake or break press is a equipments used for bending sheets of metals, or other materials. Prior to using a metal plate or a sheet it has to be shaped or formed. To do this a machine or a press brake is required.
There are many kinds of devices like mechanical, pneumatic, hydraulic and servo-electric. These are available in different sizes and specifications and are used in repairing workshops, auto service stations, industries etc.
Mechanical press brake
In this an electric motor supplies energy to a flywheel which powers a crank mechanism to move the ram vertically. These devices are fast and accurate. This is the conventional version of it.
Hydraulic press brakes
This is operated with the help of two hydraulic cylinders. It has a C-frame which moves the upper beam. It is a very agile punching machine as it can punch as well as foam in both upward and downward direction. This is a mechanized version.
Ways in which Press brakes are employed for sheet metal bending:
They are very adaptable kind of machines. It is the perfect press for forming metal as the force is applied in a longitudinal region. Some of the materials that are used for forming on a press brakes are alloy steel, stainless steel, low carbon steel, aluminum alloys, copper alloys etc.
It is extensively employed for multiple purposes in the industries. The metal is subjected to immense stress and shaped using dies. The metal to be shaped is clamped between a punch and a die and pressure is applied. The metal takes the shape of the die every time the force is applied with the punch. The inside angle of the bend is formed with the punch and the outside angle with the die.
Repeated operations using suitable dies help to cast the metal into the desired shape. Different methods are used to cast the metal like U –die bends, V-bending, bottoming, double die bending etc. A strong firm table forms the base of the machine and the beam on top moves up and down to punch the metal.
Metal can be cut to required shape and size using press breaks. Mechanical press breaks are a good choice for small scale manufacturing units as the job done is very accurate and facilitates easy cutting work. If bulk production in short period of time is needed then hydraulic press brakes is a better alternative. Since it works by hydraulic power system, the machine can be set according to the production requirement. These multi-purpose press brakes can be modified for varied operations.
Select a press brake according to your requirement, type of work, frequency of work and the size of metal sheets to be formed. Mechanical and hydraulic are generally used to form the metal. In order to perform metal bending jobs efficiently, it is important to select the right.
It is a kind of bending machine used for bending sheet metal into a predetermined shape. The bending depends upon the shape of the punch and the die. These are being widely used in metallurgy, aircraft and ship building, production of container and many other metal products.
Working principle of Press Brake
The metal sheet to be bended is placed between the punch and the die. The punch and die are placed in such a way that they are aligned in the same vertical axis and the shape of the punch matches that of the die. The metal sheet is clamped at both ends to prevent it from slipping during the bending process. After fixing the metal sheet, pressure is exerted on the punch which bends the metal sheet or plate against the die. The force applied is measured in tons and the capacity of a machine is measured in terms of tonnage. Depending on the means of application of pressure, they are classified as
Mechanical press brake
Hydraulic press brake
Pneumatic press brake
Press Brake set up
It set up refers to the work carried out by the operator to change the settings of the device according to the job. Every part will not be of the same size and shape. When a new part is to be pressed, some changes must be made in the device to get the shape of the metal sheet or plate as per the design. This set up procedure must be done very carefully because it directly affects the quality of the product. The operator must not take much time in setting up the machine as this may affect the production.
Key to set up Mechanical Press Brake
The key points in setting up it are listed below
· The operator must go through the drawing completely and know the type of material, the dimensions, blank size and the angle required.
· The type of tool should be selected depending upon the dimensions (internal radius in particular). For example, if the inside radius is less than the thickness of the material, bottom tooling can be used.
· The pressure or force required for the particular job must be determined.
· The position of the tool on the bed is selected based upon the tonnage. If maximum tonnage of the machine is to be used, then the tool must be positioned at the centre. If it is less, then the position of the tool can be offset.
·The selected tool must be installed at the determined position. The tool installation is the most time consuming procedure.
·While installing the tool, a safety tag must be used while placing the punch over the die.
·The die and punch must be aligned correctly and the distance between them must be set to get the exact slide length.
·The pressure or force to be exerted must be set by trial and error method to get the exact pressure required for the job.
·A test bend must be made on waste material to check the settings. If the settings are correct, the production can be started immediately.
Key to set up Hydraulic Press Brake
It is similar to that of the mechanical regarding the selection and position of tooling. Some additional points to be taken into consideration while setting up it are listed below
· The hydraulic oil must be clean and the level of the reservoir in the oil must be checked.
·The tool which is selected must be installed as per the manufacturer’s instruction.
·The distance piece must be set to compensate for the difference in penetration between punch and die.
·The slide length of the punch should be set using the controls.
·A test bend is carried out and if not satisfactory necessary changes must be made in the device.
·Most of the hydraulic devices are electronic controlled and so the operator must be familiar with the controls used for the set up of the machine.
Note: Even if the set up is perfect, the production won’t be efficient if the tool is worn out. Worn out tool must be sent to the manufacturer for re-conditioning.
Industrial Press brake are used in many industries and they come in various sizes and types for specific jobs. With the development of automation engineering, CNC Brake press have been developed which are computer controlled and the set up of the equipment can be done in a short period of time. The accuracy of the bend depends upon the set up of the equipment; so much care must be taken while setting up the device. Even if it takes a little longer to set up the equipment, the production should not be started until the operator is confident about the set up of the machine. Click Here to get more information on Press Brakes.
The various sheet metal machineries for shearing, bending and cutting are described below:
The mechanical press brake has a sturdy frame built from high grade steel. It also consists of steel plates with appropriate thickness and machined guide ways. This strain-free equipment supports ram and bed from unnecessary deflection under tolerable loads. The power is transmitted via two individual gear drives to uniformly distribute load throughout its length. While the hydraulic press brake comprises of superior quality hydraulic components. It has two cylinders mounted at back side and connected through mechanical links. They are also synchronized for parallel motion between ram and table. The heavy duty steel frame can absorb heavy shocks caused by overloading. All edges are accurately machined and welded for durability. The power unit is fixed appropriately on the wall; hence the operator can easily reach the push button and foot switch.
The hydraulic shearing has a squaring arm on left and right side with hardened lines for even load distribution. The front gauging has stops and scales on squaring arm. The recessed table includes hardened rods to feed sheets easily. The sheet is supported by long plates; and the ramp on back side slides to allow cutting sheets outside shear area. It also has a finger safety guard that provides clear view of cutting area. The movable foot switch provides easy and convenient operation. It also has an efficient, compact power pack with least piping. The neat electrical wiring enables easy trouble shooting. Whereas the under crank shearing device is precise and robustly constructed for uninterrupted production, repeatability. It has a foot pedal, fly wheel, gear guard, self lubricating system, motor pulley, and a pair of four edged shear blades. The front and back gauge is manually operated and the finger guard in the front protects the operator. Further, the over crank shearing is accurate and works constantly and repeatedly. It consists of four edged, single segment knives for longer durability. They can be easily assembled and minimizes downtime. The scale on back gauge enables instant reading of distance between shear and back gauge.
The plate bending machine can handle heavy stresses and loads. It is highly safe, requires minimum power and reduces running cost. It is designed to deliver top quality products, increase unit durability; prevent breakdown and revenue loss. Further the section bending tool includes motorized drive for bottom rolls; foot switch control switch and reverse forward starter for easy, quick changeover of rolls; a scale for adjusting rolls; and hardened, grinded shafts.
The various applications of mechanical, hydraulic press brake; hydraulic, under crank, over crank shearing; plate, section bending includes electric panels, roofing, bus bodies, kitchen equipments, generator enclosures, steel tanks, stainless steel equipments, coil cutting industries, air condition ducts, container manufacturing, flour making, industrial structures, rail coaches, tipper trucks, wind mill manufacturing, turbine enclosures, etc. Hence these sheet metal machineries for shearing, bending and cutting are used in several industries.
A number of machines are used in the process of fabrication of sheet metal parts. Fabrication is the process of collective operations which are used to give a shape to the metal sheet. This involves a number of equipments like metal shears, laser cutting, press brakes, rollers, welding machines etc.
What are Press Breaks?
Press brake, also called break press, is a machine that is used to bend the metal sheets and plates. A considerable amount of force is applied using mechanical or hydraulic processes or both. In order to get perfect bends free from any defect, care must be taken to use proper methods. The commonly used metals for fabrication are carbon steel, stainless steel, and aluminum.
Types of Press Breaks
Press brakes are available in two categories:
Mechanical press brakes – A mechanical press is faster and more accurate as compared to other.
Hydraulic press brakes – These help to create goods of superior quality which use less power and are dependable. These are safe to use but are more expensive. For accurate bending of sheet metal and metal plates it is widely used in many industries.
The process of applying force on the metal to change its shape without cutting it is called metal forming. The sheets are bent or stretched into an array of complex shapes.
In the process of sheet metal fabrication, first the basic flat shape of the metal sheet is attained, the metal is then sent to machines to make the bends. The metal sheet is placed between a punch and a die. This process is called forming. According to the specifications on the prints, dies in a range of shapes and radius are used to make one or a number of bends to form the metal.
Applications of Press Breaks
In order to increase the inflexibility of a metal, and to shape the pieces of metal in shapes of one’s choice and design the metal is bent using it. Bending is a flexible process in precision sheet metal fabrication and it permits the formation of different shapes by using hammering and press brakes.To find the correct bend allowance for the compressionand stretching of the material, intricate mathematical formulas are required.
Press brake forming method is used for different functions like metal framing, metal housing for a definite part, brackets for tools and machines etc. It is also used for punching, bending, piercing etc. of the metal sheet.
Metal fabrication is done for a large array of industries and applications. Car parts, aircraft components, boat propellers, holding tanks, shark cages, weapons, etc. are fabricated from metal. Different tools are used for different purpose during fabrication of metal, so a technician can shape the metal according to his desire.
So, without the press brake machinery the work of a fabricator would be very difficult. To give shape to the metal sheet before it is cut, It play a very significant role. These are used in every metal industry and for almost every metal fabrication be it a piece of art or a part of a car.
The press brake is primarily a machine tool that is utilized for bending a metal sheet or plate, into a shape which is determined by its die set. It forms preset bends by tightly holding the workpiece between the punch and die set. Usually it has two C shaped frames on both the sides. It is firmly connected to a table at the bottom and has a moveable beam at the top. The top tool is mounted on the upper beam, whereas the bottom tool is mounted on the table. It is actually a multi purpose fabricating machine, and therefore suitable for several types of metal forming operations.
It has the capability to deliver force in a limited vertical space in order to punch or bend the metal sheet. A variety are now available in the market. However, they are mainly categorized as mechanical or hydraulic, depending on the means of applying force. In the early days, mechanical brakes were mostly used. And later on with the advancement in technology, the hydraulic press brakes were introduced in the market.
Choosing a specific type mainly depends on the material to be used, the type of operation, as well as the rate of output. This versatile press brake is utilized for various types of forming operations using different kinds of dies. The numerous applications of different kinds of press brakes are described further. Actually these are regarded as an essential part of several manufacturing industries. Hence they are commonly used in a wide range of industrial segments such as wood, metal, automobile, rubber, plastic, etc. It can be used to produce the metal plates of front, back and side panels of a computer. It is also utilized for manufacturing metal brackets, frames and cabinets.
Mechanical Press Brake
It has a flywheel that is powered by an electric motor. It also has a clutch that engages the flywheel to initiate the crank mechanism, for moving the ram in the vertical direction. This machine exerts pressure in order to form, shape, or cut a material; extract liquids, or compress solids. A mechanically driven has a fixed tonnage, and exerts more force at the bottom of its stroke as compared to the halfway point. The two major benefits of mechanical press brake are speed and accuracy.
Hydraulic Press Brake
It functions through two synchronized hydraulic cylinders on the C frames, in order to move the upper beam. This machine exerts a great force on the larger piston in a pair of hydraulically coupled cylinders; whereas a relatively smaller force is applied to the smaller piston. They use hydraulic oil or fluid pressure as a source of energy. These are easy to use and maintain. They are basically high speed, compact machines that are more precise and use less power. Moreover, this machine is highly reliable and hence much safer than the mechanical press brakes.
The objective of this article is to educate readers about different types of press brakes and their industrial applications.
A press brake is also referred to as a brake press. It is basically a powerful machine tool that is commonly used for bending sheets and plates; particularly for bending sheet metal. It forms preset bends by holding the work piece in between the suitable punch and matching die. These are normally classified as per the means of applying force. The different types available in the market include the mechanical, hydraulic, pneumatic, and servo-electric press brake.
Why Buy Press Brake?
There may be many reasons for buying and using it. Hence selecting the right one for your workshop is very important. Thus, first of all it is necessary to determine the type of work that needs to be done. Nowadays, several manufacturers provide a wide range of press brakes in different dimensions and specifications. You can select a particular model, of the required size and quality, as per your specific needs and budget.
How to Select Press Brake?
Moreover, before selecting, it is recommended to take the advice of an expert, or a reliable supplier and reputed manufacturer; since they have in-depth knowledge and vast experience about the various types and models available in the market. There may be various reasons for purchasing a press brake such as; for starting a new workshop, for expanding your manufacturing capacity, for fulfilling a specific requirement, or just for replacing an existing press brake.
Further, it also depends whether you a need it for a short term and on a temporary basis; or for a long term and on a permanent basis. Another significant factor is your financial plan. This refers to your budget limit, and whether you are ready to purchase a costly machine. In case, you have a limited budget and temporary requirement, you can also select used or second hand one. On the other hand, if you can afford a new, it will be more effective and also last for many years. Besides, a new and good quality machine will assure better accuracy, higher efficiency, and total safety.
Moreover, another important factor is finding a renowned and trustworthy supplier. This is relatively confusing, because today there a numerous local and international companies that supply new as well as old machinery. You also need to confirm that the required model is of high quality, and is also available at the appropriate price.
The Bottom Line
Hence, you should contact a reliable supplier who has sufficient knowledge about the various types and models. And this supplier must be capable to properly guide and suggest the buyers, to select a particular type of machine that suits their specific purpose, meets their individual needs, and is within their budget limits. Moreover, it is better to select a supplier that also provides all the related spare parts and even offers services for repairing and maintaining various press brakes.
These days, various types of press brakes are available in the market, including mechanical and hydraulic. The main differences between a mechanical and a hydraulic is as follows.
Hydraulic press brakes are simple to use and versatile for punching and forming sheet metal components. Even the tooling is easy for a hydraulic press and the material handling cost is also less. Stamping can also be done using economical tools on the same hydraulic press.
Mechanical presses use expensive dies and costly components, hence hydraulic presses are better. One more advantage of using a it is that they can be set up quickly, because they do not involve many other forming functions. It also reduces secondary forming operations such as moving the components to another machine. Hence, the hydraulic press is preferred since the tooling and set up time is less as compared to the mechanical press. Moreover, a hydraulic is a highly flexible punching, forming and stamping equipment. It can even punch and form in upwards as well as downwards directions. They also help to save manufacturing time of sheet metal parts.
The hydroforming operation is not possible on a mechanical press brake, because it does not have the speed control and cannot remain on the bottom for carrying out the high pressure forming operations. The slow speed of the hydraulic helps in the hydroforming process, in comparison with the mechanical. A hydraulic press brake provides dwelling and ram speed control which is not possible in mechanical. The hydraulic presses can be programmed to control the ram speed and ram position, whereas this facility is unavailable in mechanical presses.
Further, hydraulic press have exceptional speed, stroke and force; and have therefore increased the forming capacity of sheet metal industry. They can offer full force at any stroke position and also provide flexibility in the dies. The ram stroke can be easily adjusted from minimum to maximum position. Hence, a hydraulic press can have longer strokes to include different types of dies; and can be easily set for various operations. The major benefits of these hydraulic presses include the following.
They are multi-purpose machines, and are adaptable for diverse operations; deliver better force at any point of stroke; and are capable to function at various strokes on the same machine. The ram stroke can be simply adjusted throughout the length. Also the required speeds can be set and also easily reset at any position. It is possible to program and have total control over the ram stroke and position. A variety of operations can be performed at different pressures just by adjusting the command, pressure switch settings, or pressure control valve of the machine.
Ultimately, hydraulic press brakes deliver precise and high quality products. Hence, compared to mechanical press brakes, the hydraulic are much better. Therefore a wide range of operations are now done using hydraulic presses in various industries throughout the world.