With the recent advances in technology as a whole, the past decade has also brought about significant improvements far as press brake machines are concerned. All the new upgrades made to the conventional press brake system have made many buyers curious about the available options in the market.
Here is a simple explanation of the popular types of press brake machines that are hot right now to help you get a basic idea of all of them.
Overview of press brakes
A press brake is a machine used to bend and shape sheet metal into various angles and shapes. It works by clamping the metal between a punch and a die, and applying force to create the desired bend. Press brakes are commonly used in manufacturing, construction, and other industries that require precision metalworking.
They come in different sizes and configurations, and can be operated manually or with computer-controlled automation. Press brakes are essential tools for producing high-quality metal components and products.
Importance of press brakes
A properly functioning press brake system is a crucial piece of equipment for any kind of industry involving sheet metals and associated processing. Hence, it is very important to take all necessary factors into consideration beforehand and analyze them properly before deciding upon your press brake machines.
Hydraulic press brakes
When compared to your primitive mechanical brakes, hydraulic brakes are definitely safer because of their automaticity. The hydraulic press brake machine available right now come with high levels of flexibility and are known to be highly customer friendly. They are manufactured so as to comfortably meet the specific needs of a user by providing various degrees of options and settings which can be adjusted with ease.
How do they work?
The basic principle behind the working of a hydraulic press brake is the power obtained from a hydraulic motor, which is then applied in the form of a force onto the sheet metal. This force then compresses the metal into a die, thus forming the desired shape. The entire process is fully automatic and highly accurate and precise. This is why many renowned manufacturers choose these press brake systems as their machine of choice.
The bending device and die
The bending device per se is the stamping process. Here, the metal is literally stamped on the template or die, where it is cast into the given shape. The force applied further helps in shaping it as per the cast. The die itself is the major determinant of the shape of your metal pieces or sheet metal. The vibration-free nature of the current hydraulic press brake machines allows for high levels of accuracy with your metal shaping process.
Benefits of hydraulic press brakes
The usage of hydraulic press brake systems has benefitted many firms and industries greatly regarding several aspects involved in metal manufacturing and related sectors. Here are a few significant ones worth mentioning.
● They are great energy-saving options.
Most of the modern hydraulic press brake systems come with built-in energy-saving times and pump mechanisms.
● Can sustain high levels of power.
The industries working with bigger metal parts require huge amounts of energy, which can easily extend over 250 metric tonnes. Hydraulic machines tend to be a better option in such cases.
Hybrid press brakes
As the name subtly hints, the hybrid press brake is a machine that combines the best features of both hydraulic and all-electric press brake machines. Unlike hydraulic press brakes, hybrid machines do not have any gear pumps, but they operate with the assistance of hydraulics in the process of metal bending.
Similar to the all-electric counterpart, they help work in a more environmentally friendly manner. They turn off on their own when not in use.
Parts of a hybrid press brake
To understand the functioning, it is important to first have an idea about how the machine is structured. The basic outline of a hybrid press brake system is composed of the following parts.
● Machine frame:
The frame itself is further inclusive of left and right columns, oil tanks, working tables, and cylinders for when the crowning system is used. Along with this, there are other supportive parts as well. The crowning system is mainly for the compensation of the work deflection which is prone to occur in the working table.
This is important to make the working table produce pre-deformation which is used to track the movements of the slider. These movements are then studied to control the angle change of the workpiece along with control of the bending length and tolerance range.
● Sliding block:
It is composed of the left and right cylinders connected and secured together with the help of bolts, along with the system comprising of the piston rod and slider joined with the spherical blocks and screws. This block is in association with the frame through the guide rail. On moving the slider, the position data acquired is instantly fed to the CNC system. Then, the measures help in proper control of the output flow of the electro-hydraulic valves and the synchronization.
● Crowning table:
It helps in ensuring the parallel fixation of the working table and sliding block throughout the process.
● Light curtain:
It is an electrosensitive protective measure to ensure safety.
● Bending angle laser detection device:
In most cases, it is software-mediated and helps in improving productivity and quality.
● Bending mold and clamping:
It has two parts, the upper bending punch, and the bottom die.
● Front support and back gauge:
The font support is a standard part of the working table, while the back gauge is a floor standing independent structure.
● Hydraulic system:
It is similar to the hydraulic press brake, but a simpler version.
● CNC control system:
This is in charge of all the calculations and corrections.
Benefits of a hybrid press brake
As was mentioned earlier, a hybrid press brake holds all the good stuff from both hydraulic and all-electric press brake systems. However, they cannot be employed in industries that work with high energy levels which exceed 250 metric tonnes. They are highly sustainable and environmentally friendly, unlike hydraulic systems which do not possess any auto shutting down mechanisms.
All-electric press brakes
The currently available electric press brake systems are the most effective and modernized edition of all press brake machines in history. Apart from simply making the process more effective and promoting fast functioning and manufacturing, a servo-electric press brake has also shown great progress in the aspect of the overall safety of the working as well. They are also highly accurate when compared to relatively older methods of functioning.
How does it work?
The electric press brake systems are completely free from any form of hydraulic support and run entirely on electricity. That being the case, they are relatively eco-friendly and offer greater levels of safety and accuracy. This is all thanks to the recent advances and progresses in the field of mechanics and so.
In the electric press brake system, the movable part is solely operated by electricity rather than any form of direct force, which is the case in hydraulic systems. This is brought about with good precision with the help of several in-built attachments and software control.
With such high degrees of innovation and automation, these devices greatly decrease production costs. They also help reduce production costs, as well as energy expenditure. As a result of the above, they are considered to be highly economical options when compared to the others in the line.
Tandem Press Brakes
A tandem press brake is a powerful and versatile machine used in the fabrication and manufacturing industry for bending and shaping large and thick sheet metal components. This machine consists of two or more press brakes working in tandem to handle bigger and heavier materials than traditional press brakes. Some of the main benefits that tandem press brakes offer are:
- Increased Bending Capacity: With its unique design, tandem press brakes can handle larger and thicker materials, increasing bending capacity and flexibility in the manufacturing process.
- Greater Precision and Accuracy: The tandem press brake’s multiple press brakes working together provide superior precision and accuracy in the bending process.
- Versatility: Tandem press brakes can handle a wide range of materials and offer flexibility in the manufacturing process, making them ideal for various applications.
- Increased Productivity: With its larger bending capacity and precision, the tandem press brake can increase productivity and efficiency, reducing production time and costs.
- Cost-Effective: Using a tandem press brake can be more cost-effective than purchasing multiple single press brakes, reducing overall equipment costs.
Finding a press brake machine that suits all aspects of your work and industry along with the general expectations can vary with every firm or business. So make sure to spend enough time on appropriate research and thought before buying your press brake system and machine.