A comprehensive summary of knowledge about press brake tool materials

Definition of press brake tool material

1. What is a press brake tool

A press brake is a tool used to bend metal sheets, and a press brake tool is a key component in the bending process. It usually consists of an upper die and a lower die, which are mainly used to control and guide the metal sheet to bend into a specific shape under low pressure in the press brake.

2. What is a press brake tool material

Bending machine tools are made of various materials, each of which is selected according to its specific properties and bending process requirements. The following are the main types of materials commonly used in sheet metal manufacturing.

Common types of materials for press brake tools

Steel is the most commonly used material in press brake tools at present.Bending machine tools include T8 steel, T10 steel, 42CrMo and Cr12MoV.

1. Low alloy tool steel

This type of steel contains a certain proportion of other alloy elements,such as molybdenum, Vanadium, manganese, silicon, etc.,have balanced performance, and have a certain degree of hardness and toughness. Suitable for various bending operations, including harder materials such as stainless steel. It is moderately priced, has good processing performance, and is suitable for conventional sheet bending. Low alloy steels used for tool manufacturing include CrWMn,UMn2V,7CrSiMnMoV(code CH1), GCrNiSiMnMoV (code GD), etc.

2. Carbon tool steel

The main components are carbon and manganese, and a higher hardness can be obtained after simple heat treatment. However, its load-bearing capacity is low, and it is usually used to manufacture general manual tools and tools. Due to its low cost,it has become an economical choice for many bending applications. Commonly used carbon tool steels for tools are T8A,T10A etc.

3. High carbon high chromium tool steel

This type of steel has good hardenability and wear resistance, small deformation during heat treatment, and belongs to high wear-resistant tool steel, small deformation ability, and load-bearing capacity second only to high-speed steel. However,due to the obvious carbide segregation,axial upsetting and radial drawing are required to reduce the unevenness of carbides and improve its performance. Commonly used high carbon high chromium tool steels for tools are Cr12,Cr12MoV,Cr12Mo1V1(code D2).

4. High speed steel(HSS)

This type of steel is the steel with the highest hardness, wear resistance and compressive strength among tool steels, and its load-bearing capacity is extremely strong. It can maintain its performance even under high thermal stress. It is very suitable for applications with high thermal stress,but its cost is relatively high. It is generally used for difficult bending and special requirements of tools,such as aerospace and automotive industries. Commonly used high-speed steels for tools include W18Cr4V(code 841)and tungsten-containing WGMo5Cr4V2(code G542, called M2 in the United States), as well as low-carbon and low-vanadium high-speed steel GWGMo5Cr4V (code GWG or low-carbon M2)developed to improve toughness.

5. Base steel

Base steel refers to a type of steel that adds a small amount of other elements and appropriately adjusts the carbon content on the basis of the basic components of high-speed steel to improve the performance of the steel. This type of steel is collectively referred to as base steel. Compared with high-speed steel,This method improves the wear resistance,hardness and toughness of high-speed steel,so it is more cost-effective than high-speed steel. Commonly used matrix steels in tools include GCr4W3Mo2VNb(code G5Nb), 7Cr7Mo2V2Si(code LD), 5Cr4Mo3SiMnVAL(code 012AL), etc.

6. Cemented Alloy

This alloy is composed of tungsten carbide and cobalt,with extremely high hardness and wear resistance, suitable for extremely high-intensity operations and ultra-large-scale production. However, its cost is slightly higher, and it is difficult to process and repair. However,its long life and high efficiency can make up for this shortcoming.

7. Combination of steel and carbide

This type of alloy is a new material that combines carbide and steel. It has the high hardness and wear resistance of carbide, as well as the toughness and machinability of steel, so it is suitable for tools that are highly wear-resistant and need to withstand large impacts.

8. New materials

The material required for press brake tools is a cold-working die steel, which is characterized by high density, good toughness and good wear resistance. Therefore, in recent years, people have tried to use new materials with these characteristics, such as ceramic reinforced steel and super carbide.

9. Chromium-molybdenum steel(Chromoly)

It has high tensile strength and toughness,and can reach a hardness level of 45HRC after heat treatment. Its robustness and resistance to wear and corrosion extend the life of the tooling,making it suitable for bending thick metal plates and handling high-tonnage operations. Because it has less deformation after heat treatment, it is suitable for heavy-duty and high-precision tools, such as those in the aerospace and defense industries.

10. Special materials

Special materials include plastics,polyurethanes,polymers and other special applications for special forming, special-shaped processing or protective bending. For example, polymers have high flexibility and durability, greatly reduce the risk of scratching or marking, and can withstand considerable bending cycles. Suitable for use in Consumer electronics and decorative metal products where surface finish is critical.

Key performance factors of press brake tool materials

1. Hardness and strength

The hardness of the material determines its ability to resist deformation during bending. The higher the hardness, the better the wear resistance, but its toughness will also decrease.

2. Wear resistance

Highly wear-resistant materials can reduce tool maintenance and downtime frequency,thereby improving production line efficiency. Wear resistance is very important and can directly affect the service life of the press brake dies. High stress environments may wear softer materials too quickly.

3. Heat treatment performance

The material needs to be easy to heat treat to achieve the desired hardness and small deformation. Therefore, the ability to not undergo structural changes during heat treatment is a crucial factor in maintaining tool performance.

4. Toughness and ductility

The toughness of the material is used to withstand the impact load during the bending operation. Good toughness can prevent the tool from breaking due to instantaneous impact or processing errors. Ductility ensures that the tool can withstand unexpected stress during use.

5. Cost-benefit analysis

Materials with higher comprehensive performance can greatly reduce the overall cost, and higher initial investment in high-quality materials can reduce maintenance and replacement rates.

Bending machine tool material selection criteria

1. Type and thickness of metal plate

The thickness and material type of the bent plate are important factors affecting the selection of tool materials. Thick plates and hard sheet metal materials choose tools with high hardness and high toughness, while thin plates and small batches of plate processing can use economical material tools. In addition, different sheet metal materials to be bent(such as stainless steel,aluminum,copper,etc.) have different wear on the tool, so the material selection also has different requirements.

2. Output

The output is basically divided into three types: low, medium and high.The expected output will determine the type of tool material selected. For mass production,it is recommended to use press brake tools made of highly wear-resistant hard materials, such as 219 materials.

3. Requirements for precision and height difference

According to the actual work situation,select materials that can ensure that the entire batch of parts always meet the necessary tolerances. For example, the electronics and aviation industries have strict requirements on the precision of the bent workpieces, so it is necessary to select press brake tools made of small deformation and wear-resistant materials.

4. Special considerations

Special considerations include corrosion resistance, custom applications and other factors. These factors suggest the selection of tools made of stainless steel or special coating materials.

5. Tool life estimation

Understanding the expected life of the tool under specific conditions can provide a reference for its material selection. Of course,the correct use of the press brake dies can also reduce the number of tool replacement and maintenance, thereby improving productivity and efficiency.

Requirements for press brake tool materials in different industries

1. Metal processing

Low alloy and carbon steel tools are commonly used, taking into account flexible production and cost efficiency.

2. Automotive industry

The material must be durable enough to withstand multiple cycles without performance degradation, so high carbon high chromium steel and CrMo steel are commonly used.

3. Aerospace

Aerospace applications pay special attention to lightweight and strong composite materials, tools are usually made of advanced alloys and composite materials to ensure performance under stress.

4. Electronic product manufacturing

Tools need to adapt to very strict tolerances and fine details, and require high-precision materials that can achieve fine bending without damaging sensitive parts.

How to maintain and manage press brake tools

1. The importance of regular inspection and maintenance

Regular inspections are crucial to ensure that press brake tools are in optimal operating condition. Early detection of cracks,wear and other hidden dangers can effectively avoid tool failure and production safety accidents.

2. Cleaning and surface treatment

The correct use of cleaning solvents,lubricants and protective coatings can prevent rust and wear, thereby effectively extending the service life of the tool and ensuring its stable performance.

3. Storage requirements

Keep the tool racks stored in a dry, the temperature-controlled environment can effectively prevent the tool from rusting and deforming.

4. Regrinding and repair of tools

Worn parts should be repaired or welded in time. Regrinding worn tools can restore their geometric shape and extend the service life of the tool.

5. Maintenance and storage according to the properties of tool materials

Different materials require different levels of maintenance. Regular inspection,cleaning and lubrication can extend the service life of the tool. For example,carbon steel tools are prone to rust, so you need to pay attention to moisture and mildew prevention.

Recent progress and future trends

1. Innovation of tool materials

New materials include new high-performance alloys and coating technologies,which effectively improve wear resistance while reducing friction.

2. The impact of automation and intelligent manufacturing on tool materials

Automated manufacturing enables it to manufacture more complex shapes and shorten production time without affecting quality,And it can reduce human intervention.

3. Sustainable development and environmental protection

In order to reduce the emission of harmful substances in the production process, the industry is promoting the development of sustainable materials and processes,including the recycling of tool materials and the adoption of more environmentally friendly manufacturing methods.

4. Future research directions

Future research may focus on micro-modification of material structure, surface intelligent self-repairing materials and AI-assisted tool life.

Conclusion

The correct and reasonable selection of materials is the most direct guarantee of tool life, quality and production cost, and plays a vital role in achieving its expected manufacturing results. Manufacturers and metal workers should consider product requirements, equipment conditions and budgets to meet the changing industry needs.

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