The installation cost for a press brake setup is the highest.
No materials are created throughout the setup, and the number of expenses keeps growing as the longer setup continues. The quantity of finished, accurate items you can create in a particular amount of time determines a press brake’s effectiveness and profit margins. Because less time is spent on creating parts if the setup is too time-consuming, the price of each part rises.
Making a lot of components with a similar setup is the sole method to lower the cost per component on old hardware. Each operator should strive to master all the quick-setup techniques to produce more components for less cost.
This can be facilitated by employing a standard setup technique, which will also significantly improve the effectiveness of your press brake.
Analyze The Sketch
Operators must be fully versed in their components. A revision of the design might not be required if the pieces have already been manufactured, but eventually, the operator must be aware of:
- Type of material and density.
- Dimensions and tolerances for flanges.
- Angles necessary and angle tolerances.
- Inside the arc of an angle.
- Blank size.
In the absence of any of this data, the supervisor will be required to make an educated assumption. The part now runs the danger of being inaccurate. An important initial step is to have detailed drawings.
The sketch is used to select the tooling. There are a few options available to you: air bending, bottom bending, coinage, or customized usage.
For instance, if the layout calls for a bottoming tool and the inside arc length is equivalent to the metal density.
For that specific type of machinery, you should use tooling which is least as precise as what the tool maker recommends. No matter how precise the press brake installation is, worn equipment cannot create correct products.
Operators should have little trouble estimating the necessary tonnage.
Regarding air bending, there seem to be tonnage graphs available. A reasonable calculation for bottom bending is nearly three times the tonnage of an air bend. About eight times as much air bend tonnage is needed for coining. The supplier will offer tonnage estimates for customized application tooling. Never try a bend before determining the required tonnage and comparing it to the tonnage provided.
Choose The Press Brake
If your shop has just one press brake, you can skip this step. If you have more than one brake, make sure the one you choose is the most appropriate for the task at hand.
A tons-per-inch limit is located in the center of press brake machines. Multiply the length across the lateral panels by 0.6 to find the tonnes per inch for the brake then start dividing the machine tonnage with your estimate.
The highest tonnage in the center of the machine shouldn’t be higher than 25 tonnes for a 12-in.-wide item. A condensed overload is produced by exceeding 25 tonnes over 12 inches. This is a poor decision because it could harm the ram permanently. When using a tonnage control, both manual and CNC, make sure to only use the quantity necessary to twist the part and not to go over the tonnage threshold in the middle.
Additionally, keep in mind that overloading a press brake is only permitted while bottoming, coinage, or utilizing specialty tooling for air bending.
Choose A Tooling Position
You might be able to complete the task off-center if the required tonnage surpasses the focussed weight limit in the system’s center.
Nevertheless, you should first confirm that your press brake’s supplier permits off-center loading for proceeding. Working off-center is acceptable so long as you stay within the manufacturer’s guidelines.
Set Up The Tooling
Assemble the tooling and line up the top and lower tools to create the bend after determining the tooling placement on the bed.
The task in the setting process that requires the most funds and duration is tool installation.
You will be required to release your brake’s mechanical clamping bars just slightly to put the tools into place if it comes with them. The bottom tool (die) should be installed first and left loose for a while. Reduce the ram to a position that is roughly 1/4 inch higher than the punch’s vertical position just above the die.
Now position the punch so that the tang is behind the clamping rods and move it onto the die. In this process, the die is bearing the punch’s mass. Regardless of whether there is a security label on the punch, use the same approach.
Descend the ram to place the punch and position the die, then snugly compress the clamping bars along a tang. The clamp rods and die set screws should then be tightened.
This process is made simpler and faster by employing a hydraulic press brake for tooling, and it is even more effective when snap tooling is used. All press brakes can be retrofitted with either of these functionalities.
Create A Press Brake Programme
The brake must be appropriately configured to make the bend regardless of whether it is manual or CNC. Even though manual programming may need some experimentation, CNC machines can typically be automated extremely rapidly.
Programming takes the second-longest amount of time during setup.
The fact that some operators lack the necessary training could be one factor in why programming takes so long. Operators devote a lot of time to learning how to use the brakes, but they rarely devote much effort to program development. Coding a CNC brake requires much less time than setting a manual model, but both mechanical and CNC systems require sufficient knowledge of the subject. You may need to find someone who has knowledge on different types of machinery such hybrid press brake and electric press brake
Now You Can Run The Parts
You are prepared to operate high-quality parts after the correct setup. Don’t count on everything being flawless though. A testing and evaluation process will be established by your supervisor for the components you are producing.
Remember your setup technique and use it for each new element you create. Your setup period will quickly go down, and your precision will noticeably increase.