How to Use a Press Brake Machine for Precise Bending: Essential Settings, Tools & Tuning

1. Introduction

A press brake is a machine that applies pressure to sheet metal and processes it into the desired shape. And press brakes have a profound impact in many fields such as sheet metal processing and automobile manufacturing. Press brakes can be roughly divided into hydraulic press brakes with strong bending capacity and suitable for thick plates, mechanical press brakes driven by mechanical transmission systems and fast production speed, and servo motor driven press brakes with integrated electronic control and machinery that provide precision.

This article will detail how to use press brakes, as well as safety precautions, to help beginners or experienced press brake operators understand their correct usage and ensure safe and efficient machining activities.

2. Preparation before using the brake press

2.1 Installation and positioning of brake presses

2.1.1 Equipment fixation: For newly purchased press brakes, they must be fixed on the ground to prevent the brake press from shaking or shifting during high-pressure operation, affecting operation and safety.

2.1.2 Level stability: Use a level to measure whether the feet of the brake press are horizontally aligned, if they do not touch the ground horizontally, adjust it artificially so that all the feet are firmly in contact with the ground. If necessary, the height of the feet can be adjusted to achieve a horizontal state.

2.2 Safety equipment and protection

2.2.1 Press brake operator safety awareness training: Press brake operators should receive professional training and be familiar with all structures and corresponding systems of equipment. Understand the key points and safety procedures for the operation of press brakes. Make it a habit to wear protective equipment, and quickly judge the cause and deal with it in place when there is an emergency failure.

2.2.2 Regularly inspect equipment: Regularly check the original safety equipment to see if it is damaged, and if so, actively replace it. Replenish lubrication on time to prevent frosting of mechanical surfaces.

3. The process basis for the correct operation of the press brake

3.1 Selection of press brake tools

3.1.1 Key points for selecting punches and molds

Related technical reading : Press Brake Dies Explained: Types, Applications, and golden rule of selection

3.1.2 The difference between empty bending and die sticking

3.2 Calculate the required tonnage

The common formula in industry is P= K×L×T 2 /V×C.

The meaning of each parameter is:

Related technical reading : Press Brake Tonnage Explained: Learn How to Calculate for Optimal Performance

4. Detailed explanation of the operation steps of the press brake

4.1 Detailed explanation of the operation steps of the press brake

4.1.1 Use back gauges to ensure bending accuracy

The back gauge is the basis of CNC bending precision machining to ensure that the material maintains a stable position during bending and achieves the accuracy of dimensions during bending. Especially in mass production, it can effectively improve the repeatability accuracy.

4.1.2 Advantages of CNC back gauge

After programming, the CNC back gauge can automatically adjust complex bending parameters, which is not only efficient and accurate, can greatly reduce human error, but also can achieve the effect of multi-section bending only once, greatly improving production efficiency, and is suitable for a wide range of industrial and mass production lines.

4.2 Bending angle setting and adjustment

4.2.1 Control the descent depth of the upper beam: The purpose of this method is to obtain the target angle, and on the basis of adjusting the hydraulic system, with the angle sensor, the descent depth of the upper beam gradually approaches the pre-set value. The process is carried out slowly to ensure that the bending angle meets the production requirements.

4.2.2 correct the die clearance: The operator should adjust the clearance between the male and female dies to a reasonable range according to the material thickness, material and bending angle. To find the optimal range, it is necessary to gradually try and error in the process of adjusting the die clearance to avoid die damage and other situations.

4.2.3 Correction of bending allowance: The bending allowance depends on the rebound effect, which is related to the yield strength of the material and the mold itself. Operators can try to slowly tighten the mold gap, control the air bend depth, and apply the film to get the best results in the process of repeated deviations and improve the uniformity of multiple bends.

4.3 Multi-stage continuous bending skills

4.3.1 Continuous bending sequencing method: When setting up multiple sections of continuous bending, it is necessary to comprehensively consider the bending angle, movement spacing, and the characteristics of the mold itself. After all, the bending angle of each section is particularly important, and only by ensuring that each section angle is correct can it be possible to ensure the quality of the final product.

4.3.2 Maintain precision and consistency at every step: Operators generally ensure the accuracy of the foundation through programming, but this is not completely accurate, and the actual production still requires manual fine-tuning by the operator. The significance of manual fine-tuning is to keep the bending depth and interval the same each time on the basis of programming control accuracy. While ensuring the quality of products, it does not drag down production efficiency.

Related technical reading : The Golden Rule: How to Operate a CNC Press Brake Correctly

5. Frequently Asked Questions

5.1 Calculation method of opening modulus of press brake

5.1.1 Calculation method and formula of die opening

The general formula is W=K×t, where W refers to the width after the lower die is opened, t is the thickness of the material, and K is the coefficient, which is specifically related to the yield strength of the material.

Special Scenarios:

5.1.2 Relationship with bending angle and plate thickness

5.2 How to compensate for the rebound of a press brake?

5.2.1 Definition of bending rebound

Bending rebound refers to the phenomenon that when the bending material recovers its elasticity, the final bending angle is lower than the preset angle.

5.2.2 Factors affecting rebound

The type of material, thickness, strength, angle of the bent finished product, etc. will all have an impact on the rebound.

5.2.3 Commonly used rebound compensation techniques and practical adjustment methods

Generally, it is calculated empirically that 0.5 degrees of rebound compensation is reserved for every 10 degrees of bending angle. In fact, for the sake of accuracy, the factory will use the CNC system to set parameters to compensate for the rebound and adjust itself according to the actual situation.

6. Maintenance and care

6.1 Daily inspection items

6.1.1 Hydraulic oil volume: Focus on checking the oil level of the fuel tank, adjust the oil level to a moderate position, not too low, not too full, and ensure that the system is smooth.

6.1.2 Horizontal correction: If abnormalities are found, recalibrate and adjust immediately to avoid loss of accuracy.

6.1.3 Leg fastening: Only when all the pin bolts and connectors are connected firmly can the stability of the whole equipment be ensured and avoid the harm caused by minor looseness that is not noticed.

6.2 Regularly check and calibrate the tool and optical sensor

6.2.1 Tool: Pay attention to the wear of the tool, if foreign objects are found to be blocked or the surface is worn, it must be replaced or repaired. If the wear is not serious, the tool should be cleaned and calibrated regularly to ensure bending accuracy.

6.2.2 Optical sensor: After production, the light curtain and laser should be adjusted to a suitable safe position on time to ensure that the sensing distance and response time meet the standards. When there is a failure or deviation, it is necessary to call back in time or find someone to repair it. In addition, it is important to clean the optical parts on a daily basis to avoid dust affecting accuracy.

Related technical reading : Ultimate Guide to Hydraulic Press Brake Maintenance: Top Tools, Schedules & Expert Tips

7. Summary

This article focuses on how to use the brake press efficiently and safely, and also mentions the relevant knowledge of installation, operation and daily maintenance. For press brake operators, proficient and efficient use of the brake press can not only improve work efficiency, but also ensure the quality and safety of the final product.

Customers who need to purchase press brakes or technicians from large factories can visit the Raymax website, where users can obtain necessary technical support, bending calculation tables and detailed video tutorials. If users feel that this website is too unhelpful, they can also contact after-sales staff online at any time for free technical consultation.