Francis Pan

Press brake tooling play a vital role in any sheet metal bending operation. Faced with different sheet metal materials to be bent, bending types, and size, length, thickness, etc., we need to choose the right matching tooling before the machine runs. Therefore, for professionals or technology enthusiasts in the manufacturing industry, it is basic to understand the role of press brake tooling, all structures, material matching, style and type differences, and selection. If you still have a vague understanding of press brake tooling, then you have come to the right place. This article will explain it in all aspects. All the knowledge you want to know about press brake tooling, please check below!

1.Basic concepts of press brake tooling

1.1 What are press brake Tooling?

Press brake molds refer to a series of tooling and molds used in the bending process of press brakes, such as punches, lower molds, tooling holders, etc. The molds and press brake equipment complement each other and work together to finally bend the sheet metal into an ideal shape.

Facing the changing and diverse bending requirements of the market, there are many types of press brake tooling.Therefore, it is not directly embedded in the machine when the press brake manufacturer develops the equipment, but is sold as a flexible and replaceable component to match the machine. In addition, a number of excellent professional press brake tooling manufacturers have emerged in the market, and they have developed a variety of molds for large and small brands of machines for users to choose from, covering almost all bending needs.

1.2 The role of press brake tooling in bending operations

The purpose of press brake tooling is to cooperate with press brakes to perform various metal bending operations. Its shape and size can directly determine the bending form, such as angle, curvature radius, etc. Any difference in parameters will affect product quality.Therefore, if there is no press brake tooling. The bending type, size and radius that the press brake can complete will be greatly limited. This is the role of press brake tooling in bending operations.

2.Types of press brake tooling

There are various types of press brake tooling, but the mainstream on the market are the following four categories:

2.1 American precision tooling

As a traditional North American style, American tooling are the most popular type of press brake tooling.

  • Features: 30-degree bevel on both the punch and the die, 0.50-inch shank width, and a small surface area of​​the clamping mechanism;
  • Application: Suitable for bending operations of various material thicknesses and contours, often used in environments where frequent die changes are required, and compatible with older hydraulic and mechanical press brakes.
  • Advantages:
  • Cheaper than other types of tooling;
  • Quick setup, easy operation, durable and reliable;
  • Due to the simple design, maintenance and current structural modifications are relatively easy.
  • Disadvantages: Continuous replacement will reduce the accuracy of this style.

2.2 European precision tooling

  • Features: Known as the “Promecam” tooling, both the tooling and the punch have a 60-degree sharp angle, the shank is 13 mm wide, the punch has a rectangular groove facing the operator, and has a high clamping pressure and a secure locking mechanism.
  • Application: Often used in CNC press brakes, and is more common in the aerospace and automotive industries that require precise control.
  • Advantages:
  • Reduce springback due to the sharp angle and improve bending accuracy.
  • More geometric options because the profile requires thinner.
  • High-precision compatibility, and all its tooling are the same as those in the European precision product line;
  • Disadvantages: The price is higher than that of the American style, and the functional options are lower than those of the American style.

2.3 New Standard tooling

  • Features: A combination of American and European styles, with 45-degree sharp angles on both the punch and the die, and compatible with American and European press brakes.
  • Application: Suitable for a variety of different bending requirements, and favored in production environments that require high precision and flexibility.
  • Advantages: Combining the versatility of American and the high precision of European, it can be quickly replaced without a lot of machine modifications.
  • Disadvantages: Relatively expensive, the self-positioning and self-centering characteristics make adjustment during the bending process more difficult, requiring a higher clamping system and a shorter punch, so the supporting tooling is less open.

2.4 Wila Trumpf style tooling

  • Features: Commonly used in TruPunch system press brakes, the width of the shank is 20mm, there is a groove at the front and rear ends of the mold, and it is equipped with an automatic clamping mechanism, which can automatically position it in place.
  • Application: Mainly used in high-precision stamping environments where frequent tooling changes are required, such as precision component processing.
  • Advantages:
  • High precision ensures accurate bending and consistent results, especially suitable for applications requiring strict tolerances;
  • Designed specifically for quick tooling replacement, it enhances better tooling lifespan and accuracy, minimizes downtime and increases productivity;
  • High tooling compatibility, compatible with most press brakes and can be upgraded.
  • Disadvantages: Expensive, with a steeper initial learning curve, more stringent technical training requirements for operators, and difficulty in fine-tuning for specific bends.

Don’t know which press brake tooling is more suitable for you?No problem, feel free to contact us.Our professional technicians will provide free 7*24-hour professional solutions!

3.Key components of press brake tooling

Collection of punch types
Collection of punch types

3.1 Upper die tooling type(punch)

The working principle of the press brake is completed by the cooperation of several different components,including:

The punch is a tooling located on the top of the press brake tooling and installed on the slide of the press brake.It is responsible for applying the force required to bend the workpiece.In order to cope with different sheet metal bending requirements and sheet metal material types,there are many types of punch designs.Let’s take a look at them one by one:

General punch
Standard punch

3.1.1 Standard punch

  • Features: The standard punch has a thick blade, a narrow tip, a slightly concave inside, and a flat outside, which enables it to fold shorter flanges.
  • Application: Standard punches are often used for general bending tasks and high-tonnage applications.They are very suitable for bending thicker materials and creating standard bends on various materials.For example:Standard punches can create right-angle bends in batches on mild steel plates to ensure consistent workpiece results.

3.1.2 Sharp-angle punching

  • Features: Sharp-angle punching has a large volume, sharp tip, and the tip angle is usually between 28°and 34°.
  • Typical size: Working width is 1 to 1.5 inches, working height is usually 3.75 inches, and tip radius varies from 1/32 to 1/8 inches.
  • Application: Commonly used for bends less than 30°, and can also be used for angles of 30°to 60°.
Acute punch
Narrow punching

3.1.3 Narrow punching

  • Features: The overall uniform thinness and small thickness are also called”sword-shaped punches”.
  • Application: Suitable for bending operations in narrow spaces with small gaps that other punches cannot adapt to. Common uses are closed square or box-shaped contours.

3.1.4 Belt puncher

  • Features: Also known as “window sash puncher”, the main structure is narrow, the tip is beveled, and can be bent toward the inside of the press brake.
  • Application: The inclined tip enables it to bypass corners to form bends, so the belt puncher is often used for bending and corner processing, and is very suitable for punching holes at corners such as doors, windows, and window sashes.
Straight punch
Swan Neck Punch

3.1.5 Swan Neck Punch

  • Features: Also known as the “gooseneck punch”, its special shape design, elongated body and concave profile, can achieve complex bending and prevent the workpiece legs from colliding with the die.
  • Application: Often used for marking applications, or U-shaped contour processing, such as creating a deep U-shaped channel on a metal sheet, the gooseneck punch can provide the necessary clearance to avoid material damage. In addition, compared with other punches, the gooseneck punch has no support force line, so the punch strength is lower, which is suitable for bending operations with lower tonnage.
Z-bending (or step bending) set
Z-type tooling

3.1.6 Twist Punch

  • Features: Also known as the””engagement punch(Z-type tooling)” “, it is specially designed for offset bending at corners. Compared with standard punches, the engagement punch has a thinner profile, so it is particularly suitable for making S-shaped bends.
  • Application: Engagement punches are not common and are generally used in some specific niche punch jobs to perform two bends at the same time.
Formed radius punch
Rounded Top Punch

3.1.7 Rounded Top Punch

  • Features: Rounded top punches have a rounded tip instead of a sharp edge, which allows for rounded bends such as “U-bends”instead of “V-bends”.
  • Application: Rounded top punches are often used for marking operations, or in conjunction with U-shaped dies to form properly rounded corners.
Straight punch
Narrow Punch/Sword Punch

3.1.8 Narrow Punch/Sword Punch

  • Features: Also known as a “narrow punch”, it has a uniform thickness over the entire length and a non-angled, straight tip geometry.
  • Application: Suitable for limited space operations with narrow gaps, such as the final bend when closing a box.
Collection of die types
Collection of die types

3.2 Types of lower die tooling(die)

A die(also called a groove/concave die)is the bottom tooling in a press brake tooling. It is a hollow tool attached to the lower part of the press brake table, below the workpiece. When the punch presses down, it provides the necessary reaction support and precision to form the metal. Dies come in a variety of shapes and sizes to cope with different types of bending operations, but most have a V-shaped opening, with common V-shaped opening angles ranging from 90°(for stamping)to 30.

Common concave die shapes are:

3.2.1 V-type die

Features: V-type die is the most common type of concave die. The width and depth of the V-shaped groove determine the final bending angle and radius. It is usually part of the four-way wooden block for easy replacement.

In addition, V-type dies are also subdivided into single V, double V and multi-V.

  • 1V die
    1V die
  • 2V die
    2V die
  • 3V 4V die
    3V 4V die
  • Multi-V die
    Multi-V die
  • Single V-type die head: It has a V-shaped cavity and is widely used. It is the most commonly used die in the press brake tooling. The ideal selection of the single V-shaped die opening is based on the 8-fold rule, that is, the length of the V-shaped die opening should be 8 times the material thickness.
  • Bidirectional self-centering V-type die head: This type of die has two parallel V-shaped cavities. Compared with the single V-shaped die, the double V-shaped die head can simplify the bending process. If other bending angles need to be adjusted, they can be operated immediately without reprocessing.
  • Multi-V die head: Multi-V die has multiple V-shaped cavities, and the number of V-shaped cavities can vary from 3 or more. Multi-V die can provide multiple bending options at the same time. You can change the material thickness or bending angle by simply rotating the die.

3.2.2 U-shaped dies

U-shaped dies are designed to create C-shaped or U-shaped bends. They can form bends of 90°to 180°, which is very suitable for creating complex shapes such as channels or deeper bends.

3.2.3 Corrugated dies

Corrugated dies have a corrugated pattern on the bottom of the metal sheet, which can form a corrugated pattern on the metal sheet. They are suitable for bending the outer surface of the metal sheet to form a surface texture with the same pattern in batches.

3.2.4 Flattening dies

Sub-flat dies are used to flatten the bent material to ensure its smooth and flat surface, and finally form a professional appearance of the product surface. For example, flat metal panels are produced for automobile body parts.

Flattening dies are usually used in conjunction with hemming dies.

Hemming set
Hemming set

3.2.5 Hemming dies

Hemming dies are used for hemming or edge folding of metal sheets to enhance the edges of metal sheet parts while ensuring aesthetics. Hemming dies can fold the flat edges of sheet metal workpieces into round or seam shapes for subsequent fine processing.

3.2.6 Channel forming dies

Used to quickly create “U” shaped channels on metal sheets. Compared with the traditional two-forming process of traditional V-shaped dies, channel forming dies only need one forming to complete the operation task.

Z-bending (or step bending) set
Offset dies

3.2.7 Offset dies

Also called “offset dies”, used to create offset bends or Z-shaped, can form two angles at one time. Offset dies can keep the bending operation parallel, thereby improving the accuracy of the workpiece.

3.2.8 Radius dies

Also called “radius dies”, usually used with round punches to form rounded corners, mostly used to create smooth bending contours.

3.2.9 Gooseneck dies

Special shape, mostly used for bending in narrow spaces or existing bends. Gooseneck dies can avoid interference with the workpiece and perform secondary processing on the protruding edges or flanges on the workpiece. They are particularly suitable for bending operations in deep boxes or high flange profiles.

4V Concentric Die
4V Concentric Die

3.2.10 Four-way die

Also called”4V concentric die”, it is the standard configuration when many press brakes are sold. The four-way die has different V-shaped die sizes at each time in a single block. It can complete multiple bending tasks through rapid rotation without reassembly, which greatly improves production efficiency.

3.2.11 Multi-bend die

Multi-bend die can create two or more bend dies in one operation,including special types such as offset die.

3.3 Main classification parameters of upper and lower die tooling

There are many types of upper and lower dies.We can refer to the following parameters for type identification:

  • Product code: The product code is a unique identifier assigned by the manufacturer to each punch or die,usually composed of a number such as the machine name and size information.
  • Degree: Refers to the inclination of the two faces adjacent to the tip radius.This parameter directly determines the maximum bending angle.The most common ones are 90°(specially used for stamping),88°(very suitable for deep drawing),85°,60°,35°and 30°.
  • Radius: Refers to the radius of the V-shaped fillet or the radius of the punch tip.The radius of the Tooling intuitively shows its design purpose.For example:a larger radius represents a film or thicker material with a larger bending radius.
  • Load: Refers to the maximum bending force that the Tooling can withstand.If this limit is exceeded,the Tooling will have irreversible deformation or fracture risks.
  • Height: Refers to the effective bending height of the Tooling,usually calculated according to European standards:effective bending height=total height-30mm of the intermediate connector.
Rolleri Clamping System
Rolleri Clamping System

3.4 Other Tooling components

3.4.1 Tool clamping system

The tool clamping system is used to install the Tooling on the press barke.The mainstream tool clamping systems on the market include Wila hydraulic clamping system,Rolleri clamping system and Wilson pneumatic clamping system,all of which have efficient functions such as fast Tooling change and reduced Tooling vibration.Equipped with a high-quality tool clamping system,it can greatly improve production efficiency and the accuracy of the bending process.

3.4.2 Back gauge

It is used to accurately position the workpiece to ensure accurate bending.The back gauge is accurately calculated by the control system,and the block moves to the specified position through the x-axis to ensure that the workpiece reaches the required bending length.

3.4.3 Crowning system

The crowning system is used to compensate for the deflection caused by the deformation of the slider and worktable caused by the force applied during the bending process.It is particularly suitable for large plate bending operations to compensate for its large deflection.

3.4.4 Press brake safety device

Press brake safety device is an auxiliary tool for press barke operation,and it is standard in most press barkes on the market.Bending machine safety devices are used to ensure the safety of operators,workpieces and the machine itself.Common press barke safety devices are:

  • Laser sentry: The laser sentry will immediately sound an alarm and stop the machine operation once an obstacle such as the operator’s finger is found.
  • Light curtain: The principle of the light curtain is the same as that of the laser sentry,but the difference is that it mainly provides safety protection for the operator.
  • Protective device: The protective device is installed on the side and rear end of the press barke to prevent foreign objects from getting between the Tooling and the punch,especially the operator’s limbs,which greatly ensures the safety of the bending workers.
  • Two-hand control: This type of safety device is outdated and is generally not used by mainstream modern press barke manufacturers on the market. Two-hand control requires the operator to start the press barke cycle with both hands,which ensures that the operator has no chance of getting between the Tooling and the punch, causing personal or machine damage.Although the price is relatively cheaper, it greatly reduces the production speed.

4.Materials of press brake tooling

Common materials of press brake Tooling include low alloy tool steel,carbon tool steel, high carbon high chromium tool steel, high speed steel(HSS), base steel, combination of carbide steel and carbide, new materials, chromium molybdenum steel(Chromoly), special materials and other types. For details, please see: Definition of press brake tooling material

5.How to choose the right press brake tooling

Choosing the right mold is crucial to obtaining the final accurate and efficient bending processing results. The following key factors should be considered during the actual selection:

5.1 Material type

Material type is the main factor affecting mold selection. For example, the strength and ductility of materials such as stainless steel, aluminum, and copper are different, and it is necessary to select mold materials and specifications that meet the strength. For example, some materials with low flexibility and high hardness are difficult to bend, so higher quality molds need to be selected accordingly.

5.2 Material thickness

The thickness of the bending material directly determines the width of the lower die opening(V mold). The classic formula(mm) is:

  • Lower die opening width V≈8×plate thickness T
  • For example, a 2mm steel plate thickness is recommended to use a 16mm lower die V groove

5.3 Bending angle

The bending angle determines the angle of the punch tip and the thickness selection. For example, very sharp angles require an acute offset knife punch and a matching die, while thicker punches can be used when bending metal sheets with larger angles.

In addition, it is actually recommended that the bending angle of the die be slightly larger than the predetermined design angle of the workpiece to avoid the impact of springback.

5.4 Bending radius

High-strength materials require a larger bending radius, so a larger die opening needs to be selected. The selection ratio depends on the type of material used, such as:

Mild carbon steel must keep the bending radius equal to V/8, where V is the die opening width. Materials with higher strength than mild steel require a larger bending radius,so the denominator value will be less than 8.

5.6 Workpiece length

Mainly consider the minimum flange length and maximum flange length of the workpiece,and select a sufficient size to ensure that the workpiece can be fully bent.

5.7 Bending process type

Common bending process types include: air bending,bottom bending and stamping bending.

For example: standard size Tooling are suitable for traditional air bending processes.

5.8 Bending shape

In order to cope with changing market requirements, there are many types of molds.Although many bending shapes can have multiple mold options,suitable bending molds can achieve specific shapes with the least number of processes to ensure maximum production efficiency.

For example: Z-shaped bending requires operation using a V-shaped mold 2 times,while Z-bending can be bent and formed in one time.

5.9 Tooling brand and budget

Reliable Tooling brands have taken into account problems such as dents and deformation when producing Tooling, so they have higher honing performance and durability, which can greatly increase the service life and reduce the frequency and budget of Tooling replacement.

5.10 Production volume

For high-frequency production, it is recommended to use molds made of high-strength alloy or carbide materials;

For small batch and single-piece production,standard Tooling can be used to save costs.

5.11 Press brake compatibility

Due to the wide variety of press brake Tooling,please choose a design and style that is compatible with your press brake.For details,please refer to the press brake manufacturer’s manual,or directly consult your equipment manufacturer to find the right mold that best suits your machine.

6.Press brake mold parameters and setting methods

Understanding the various mold parameters of the press brake is a necessary skill for the operator before performing bending operations. The specific key parameters and formulas are as follows:

6.1 Bending force

The bending force is the approximate force required to bend the sheet metal material.

The calculation formula is: F=K x W x T x UTS

(F is the bending force, K is the K factor,W is the material width, T is the material thickness, and UTS is the ultimate tensile strength)

6.2 K factor

The K factor refers to the tensile capacity of the workpiece material. There is no calculation formula for this property value, which is usually explained in the specific workpiece material reference icon.

6.3 Minimum flange length

Minimum flange length value=8 x T ( material thickness )

6.4 Inner bend radius

Inner plate radius=mold width – (T/2)calculation ( where T is material thickness)

7.Press brake Tooling maintenance and storage method

Good storage methods and regular maintenance work can increase the service life of the press brake Tooling, so what specific things should be done? The following is a detailed description:

7.1 Daily cleaning

The most important thing is to develop the habit of wiping and cleaning the press brake Tooling after work every day.It is recommended to use the cleaning agent recommended by the mold manufacturer.If the dirt, grease and other contaminants generated by the mold during operation are not removed in time and stored properly, the mold will also increase wear and even cause corrosion.

7.2 Timely knife grinding

The sharpness of the Tooling has a great influence on the accuracy of the bending operation, but it is well known that even the sharpest Tooling will become slightly or even significantly blunt after a period of use.Therefore, the operator needs to sharpen and correct the Tooling regularly to avoid blunting the Tooling into the bending operation.

7.3 Reasonable lubrication

In order to reduce unnecessary friction between parts, it is recommended to refer to the Tooling manufacturer’s guide to select the lubricant suitable for your own Tooling, and apply lubricant to the Tooling before each operation.

7.4 Rated limit

It means to ensure that the Tooling operates under the tonnage pressure within the rated limit range to avoid damage to the Tooling or even the machine caused by overpressure, which is not worth the loss.

7.5 Good storage environment

It is recommended to store Toolings in an environment that is isolated from moisture and chemical pollutants.Some press brakes are equipped with Tooling storage cabinets when they are produced.If your current press brake does not have one, it is also recommended to equip an additional dedicated Tooling cabinet and place it near the machine to ensure smooth workflow and good storage effect.

7.6 Regular Tooling replacement

The operator needs to regularly check the integrity and good condition of the Toolings.If any damage, cracks or severe wear and tear is found in the Toolings, the Toolings need to be replaced before the operation to avoid poor bending quality during the operation, which is not worth the loss.

8.Where can I buy press brake tooling?

8.1 Find equipment suppliers directly

If you already have one or more press brakes,it is recommended to ask your press brake manufacturer directly to buy molds.Professional press brake manufacturers usually equip their own brand of various models of equipment with matching press brake tooling.

8.2 Find a well-known brand press brake tooling company

Well-known brands on the market include WILA(Netherlands), Trumpf(Germany), Wilson tool(USA), RAYMAX(China), etc. These brands have been developing and producing press brake tooling for many years.The product quality is high and the variety is rich,and the after-sales guarantee is also comprehensive.

8.3 Contact us directly

RAYMAX is a leading press brake tooling manufacturer in the Chinese market.Whether it is for basic models or high-end press brakes, RAYMAX not only customizes various press brake tooling while selling equipment, but also provides separate press brake tooling technology free guidance and sales services. If you happen to have the purchase demand of press brake tooling, but are troubled by the difficulty of selection, please contact us directly. Our technicians are online 7*24 hours to provide you with free guidance!

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Hello, Customers!

Francis

Author introduction

My name is Francis Pan, I’m the foreign trade manager of RAYMAX. I have been engaged in the fields of metal manufacturing and numerical control machinery for more than 10 years. Welcome to contact us. I am more than willing to provide you with the best service and products.

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