Proper setup steps for Press brakes and analysis of common calibration issues

If you are a novice and have just purchased a new press brake,please be sure to read the following content!Next,I will share with you the steps to correctly set up the press brake.
First,we need to know the importance of accurately setting up a press brake for producing parts:
1.Significantly improve production efficiency and reduce the depreciation rate of sheet metal materials;
2.Accurate production settings directly determine the final product quality.Improper settings will cause errors in product bending size and angle;
3.Good settings can improve the efficiency of machines and workers and speed up production.
Then,please follow my steps one by one!

Tools and equipment required for installation

First,we need to prepare the following tools and equipment:

Basic tools:

Safety equipment:

Other equipment:

Safety precautions before starting the machine

Next,we will perform the necessary checks before setting up and installing:

Clean up the work area: ensure that the work area is clean and tidy to avoid any potential hazards;
Personal protective equipment: ensure that all operators wear appropriate protective clothing and equipment.

Distributed operation:a complete guide to pressure gate setting

1. Unpacking and inspection

Unpacking: First,we carefully remove the outer packaging.Please check the list to confirm whether the appearance of the machine and all parts are complete,and whether it is damaged during transportation.
Cleaning: Newly purchased machines are generally clean,but dust and debris are inevitably accumulated during transportation.At this time,we need to use industrial cleaners and lint-free cloth to preliminarily clean the machine.Note:The bed,pressure head,and back gauge will be in direct contact with the metal plate,so be sure to clean them carefully.

2. Mechanical installation

Frame installation: According to the instructions in the manual,place the press brake frame on a stable ground,use a level to ensure the levelness,and fix the bottom support device to obtain stability(Note:To ensure long-term effectiveness,we need to check the levelness of the machine regularly).
Jig installation: Make sure the jig is installed and aligned correctly to ensure that the material does not slide during bending;
Hydraulic connection: Connect the oil pipe correctly,ensure no oil leakage,the valve operates well,and ensure that the oil level is sufficient before each operation.

3. Installation and alignment of the press brake tooling(die)

Place the die in the fixture to ensure that it is aligned with the center of the press brake tooling,and tighten the die with a tool to ensure the accuracy of the bending;

4. Adjust the Back Gauge

Adjust the position of the rear gauge to ensure that it is suitable for the type and thickness of the material to be processed.The accuracy of the rear gauge can be finally checked with a comparison instrument.

5. Set the bending force and stroke length

According to the material specifications we are about to process,set the bending force to ensure that the stamping pressure is appropriate;
Set the stroke length to match the shape and size of the processed material;

6. Electrical and press brake control system settings

Refer to the instructions in the user manual,connect the electrical,set the parameters of the control panel,and ensure that all our settings meet expectations;

Adjust the machine to establish the crowning system

Next,adjust the machine to achieve the required accuracy.The specific steps are as follows:

1. Check Ram parallelism

The parallelism of the ram refers to the parallelism between the ram and the bending surface(the bed or worktable of the press brake).Here,a precision parallelometer and ruler are used to check and measure.
Inspection steps:
Put a precision parallelometer(or ruler)on the bending surface and lower the plunger(ram)just above the parallelometer;
Use a micrometer to measure the distance between the ram and the bed at multiple points along the length of the ram,and ensure parallelism by adjusting the guide rails or hydraulic cylinders;
Examples of precautions:
Improper alignment of the ram will result in uneven bending,which will affect the quality of the finished product.For example,if one side of the ram is close to the bed,the bending degree of the material on that side will increase,resulting in bending deformation.
After completing the parallelism adjustment of the ram,the back gauge needs to be calibrated to ensure accurate positioning of the material.

2. Bending angle

Adjust the bending tool to ensure the required angle is achieved to ensure the accurate bending angle of the subsequent processing of the metal sheet;

3. Crowning

Adjust the hydraulic cylinder on the bed to ensure the required curve;this is to adjust the convexity to compensate for the deformation caused by excessive bending pressure of the metal sheet.

4. Back gauge

Adjust the distance between the back gauge and the bending die to ensure that the subsequent processing of the sheet is positioned in the correct bending position.

est setup

1. No-load test

Start the machine without load,confirm that all operating indicators and automatic controls are working properly,and eliminate abnormal noise and vibration.

2. Perform load test

Apply load: first perform a small batch plate bending test;
Cost check: monitor and check the cost processing quality to ensure the bending angle and size;
Parameter adjustment: according to the test results,make necessary parameter adjustments to ensure bending accuracy.

Common problems: Identification and handling of calibration problems(FAQs)

1. Inconsistent bending accuracy

Inconsistent bending is the most common problem in the operation of the press brake. The leading factors are usually as follows:

2. Bending angle deviation

Bending angle abnormalities are usually caused by improper calibration:

3. Material rebound phenomenon

This is because the rebound difference caused by the different properties of sheet metal materials. We need to set the mold parameters and bending angles one by one according to the characteristics of each material. For example:the rebound of high-strength steel can be as high as 3°.

4. Hydraulic system related issues

5. Machine tool alignment problem

It is a commonplace to use a precision level to detect and adjust the guide rail or hydraulic cylinder to make it flush with the level. This is also one of the important tasks of daily maintenance.

6. Back gauge calibration

Use a laser measuring tool to compare the position of the back gauge and the mold,use screws and the machine tool control system to make fine adjustments,and then use a bending test to determine its accuracy.

7. Maintenance and setting of related tools

It is still the same old story:check the wear of punches and dies regularly,and ensure that they are correctly and firmly installed,otherwise it will cause inaccurate precision during processing. At the same time,different types and thicknesses of sheet metal materials require different die pressures and gaps to ensure the best bending effect.

8. Calibration records and data analysis

Maintenance tips for new press brake owners

In order to ensure the long-term stable operation of the press brake,it is recommended to perform the following maintenance measures:
Regular maintenance:Check the hydraulic system regularly to ensure that there is no leakage and the oil is sufficient;
Cleaning habits:Keep the work area and the machine clean to prevent the accumulation of dust and metal chips;
Component maintenance:Regularly lubricate moving parts to reduce wear and replacement;
Professional training:It is necessary to provide operation training for new employees!

Conclusion

Effective press brake settings can not only improve our production efficiency,but also ensure the quality of the bent products and reduce our production costs.It is recommended that users make comprehensive setting preparations before batch processing.If necessary,please consult professionals in time to get better results.RAYMAX20+professional press brake manufacturer provides a full range of professional installation and commissioning preparations,7*24 hours all-weather after-sales service,looking forward to your consultation!