Francis Pan

Introduction

A press brake is a type of machine tool used to bend sheet metal, and the “press brake axis” are the core of the machine’s movement, each axis is controlled by a CNC control system and a servo drive at the same time. The more axes there are, the stronger the equipment’s ability to achieve high-precision, high-quality manufacturing of complex parts.

The 6-axis press brake in the shaft press brake is the central equipment of flexible sheet metal manufacturing, with significant characteristics such as high precision, high consistency, low cost, and high efficiency, taking into account the ability to design complex parts and mass production.

This article will focus on the definition, working principle, advantages and disadvantages of 6 axis cnc press brakes, how to choose the right 6 axis cnc press brakes, etc., to help engineers, purchasers or business leaders have a deeper understanding of 6 axis cnc press brakes.

What is a 6 axis press brake?

Definition of 6 axis press brake

As the name suggests, the 6 axis press brake is a CNC press brake that consists of six independent axes to form a set of moving axes, and coordinates processing under the action of these axes to achieve high bending accuracy and high bending efficiency for metal sheets.

Detailed explanation of the 6 axis composition (typical configuration)

  • X-axis: Responsible for controlling the front and rear displacement of the back gauge, which is an axis that directly determines the front and rear positioning of the sheet, and is also related to the position accuracy of the bending line.
  • Y1/Y2 axis: Responsible for controlling the vertical movement of the upper die, realizing the height adjustment of the upper and lower dies, providing deflection compensation for plates with symmetrical or asymmetric loads, and ensuring the accurate angle of bending.
  • R-axis: Adjusts the lifting and lowering of the back gauge, which in turn determines the final height of the material to be supported, and plays an important role in preventing the material from being misaligned and deformed, the bending angle is rough, and the rebound deviation is prevented.
  • Z1/Z2 axis: Z1 and Z2 axes determine the left and right movement of the back gauge. It not only supports the machining of special-shaped or asymmetrical workpieces, but also makes it possible to realize bending tasks that require flexibility and quick changeover.
  • V-axis: As the seventh axis for processing some high-end materials, it determines the width of the tool opening, although it is rarely used in ordinary bending, but its advantage is to adjust the deflection of the workpiece and improve the adaptability of the press brake to different materials and different bending angles.

Differences and advantages between 6 axis cnc press brakes and ordinary CNC press brakes

6 axis cnc press brake is better than ordinary press brakes in the shaft, once it has multi-axis collaboration ability, it has a stronger ability to handle plates, higher precision, and stronger adaptability to multiple bending tasks on the opposite side. 6 axis also has more advantages than ordinary press brakes.

First, it can form complex geometries or asymmetrical sheets in one go, reducing some of the necessary hassles such as flipping and repositioning.

Secondly, the 6 axis press brake has functions such as angle closed loop, angle measurement and deflection compensation that other press brakes do not have, which plays an important role in improving accuracy.

Finally, 6 axis press brakes are equipped with a high degree of automation and integration functions, which occupy a large position in flexible manufacturing.

Electro-Hydraulic Servo CNC Press Brake 6 Axis
Electro-Hydraulic Servo CNC Press Brake 6 Axis

How does a 6 axis cnc press brake work?

6 axis cnc press brake workflow step by step

  • Feeding: Before loading, the X-axis will give the line datum, the Z-axis will provide the precise positioning position, the R-axis will set the support height, and after all the data is accurately calculated, the press brake operator will place the plate.
  • Programming: The CNC system will comprehensively combine the data of the plate and the angle of the required bend, and design the bending trajectory, what kind of tool to use, how big the V-port width and the punch radius will be programmed by the internal computer.
  • Trial folding: After all the work is ready, the press brake operator can perform the first trial folding, the purpose is to verify whether the parameters of the first design can perfectly manufacture the required product, if not, then slowly adjust the press brake radius, angle, etc.
  • Bending: After passing the trial fold, the enterprise should carry out large-scale production. The 6 axis work together to execute the bending sequence, and each independent axis is responsible for its own steps to ensure the accurate landing point and angle of the bending line.
  • Testing: The product is inevitably composed of several unqualified parameters, and the press brake operator has to test a series of parameters such as angle and radius online. The unqualified ones are extracted and subsequent corrections are made.
  • Calibration: The wrong parameters of unqualified products in large quantities are corrected, and then the depth of the Y axis and the opening width of the V axis are updated and compensated in real time to adapt to the subsequent material processing.
  • Batch: The press brake operator combines the previous trial and correction data to finalize the parameters of mass production and execute the production process, continuously collects data during the process, traces the quality, and applies the process library to quickly reproduce different batches.

How to work together with 6 axis

  • Rapid positioning of back support material: The positioning of the back gauge mainly relies on the X-axis, R-axis and Z-axis. The X-axis provides a polyline reference, the R-axis and Z-axis determine the distance and vertical height of the back gauge, and the rapid positioning of the back gauge plays a great role in improving the speed of the changeover and the accuracy of repeated positioning.
  • Asymmetric parts support: Support asymmetrical parts, mainly used in Z1/Z2 axes and Y1/Y2 axes. The Z1/Z2 axis independently positions the left and right unequal edges, while the Y1/Y2 adjusts the plate thickness and the angular difference caused by bias load, so that asymmetrical parts can also be formed with high precision.
  • Optimization of complex folding: During the programming phase, press brake operators can use 3D simulation and collision detection systems to optimize folding sequences to optimize path screening while reducing the risk of flipping, handling, and pinching.

Sensors, compensation and software

  • Angle measurement: The angle measurement device is generally a laser angle sensor or a grating ruler and other angle sensors, their role is to detect the bending angle in real time, and then feed back the data to the CNC system, the CNC system will automatically adjust the bending parameters to improve the bending accuracy and stability.
  • Deflection compensation: The deflection compensation is carried out on the V-axis, specifically to offset the deflection of the small deflection between the bed and the slider with a reverse compensation curve, reduce the angular deviation to the target tolerance, improve the consistency between the bending end and the middle of the long part, and reduce the subsequent shaping.
  • Material database and simulation: The database generally includes the yield strength, elastic modulus, thickness, etc. of the material, and then combined with 3D simulation software to optimize the bending program, reduce testing and rework, and improve the process quality.

The main characteristics and technical points of the 6 axis cnc press brake

High precision independent Y1/Y2 control and synchronization accuracy

The independent Y1/Y2 provides control of the depth of the downforce for symmetrical or asymmetrical workpieces. The synchronization accuracy system can adjust the errors of the original algorithm and reduce the shortcomings of the algorithm.

These two make the angular tolerance and verticality of long parts, thin plates and complex contours significantly improved, reduce subsequent shaping and rework, and improve the qualification rate of products.

Multi-station capability brought by multi-axis back gauge system

The X-axis is responsible for the front and rear positioning of the back gauge, the R-axis adjusts the height of the back gauge, and the Z1/Z2 axis realizes independent movement and multi-station arrangement.

These axes support multi-station parallel bending and quick die change, significantly reducing machining time and improving productivity.

At the same time, they enhance the optimization performance of asymmetrical parts, bifold sequences and complex bending paths, avoiding some manual errors and repetitive processes.

Automatic deflection compensation and angle closed-loop control

The V-axis corrects the deflection between the table and the slider to ensure the angular consistency of the entire bending line. The angle closed-loop is usually combined with the angle sensor and the feedforward rebound model for real-time fine-tuning, which significantly improves the angular consistency and pass rate of the plate.

Quick tool change, tool library, program library and 3D bending simulation

Quick tool change can significantly improve production efficiency, and tool libraries and program libraries can realize rapid data identification and operation. 3D bending simulation can complete the inspection and optimization of the bending sequence in the offline stage, reducing the cost of trial and error.

Safety system and ergonomics (light curtain, foot pedal, two-hand control)

Some press brake safety devices such as light curtains, foot pedals, and two-hand controls can effectively protect the safety of operators, avoid dangerous accidents, and provide guarantee for the long-term orderly production of the factory. Ergonomics can help operators work, reduce worker fatigue and improve operational consistency.

35-ton x 4-foot 6 axis electric press brakes suppliers full servo electric press brake for sale
35-ton x 4-foot 6 axis electric press brakes suppliers full servo electric press brake for sale

The advantages of six-axis bending machines

Precision and consistency

  • Repeatability: The 6 axis press brake can adjust the wrong parameters at any time through the coordination between the six independent drive shafts and the real-time data monitoring and feedback system, achieving repeatable positioning accuracy with a low error level and ensuring the stability of the quality of batch parts.
  • Angle control: The 6 axis press brake has a large number of angle sensors, which upload the monitored irrational data to the CNC system in real time, which can automatically correct the bending angle, minimize the material rebound error, and improve the qualified rate of the finished product.
  • Material rebound compensation: With a built-in material database, the system automatically adjusts the bending parameters according to the characteristics of different metal materials, effectively compensates for material rebound, and ensures accurate angles.

Reduce costs

  • Reduce rework and scrap: High-precision control and automatic compensation provide the basis for reducing rework and scrap, which greatly reduces the chance of rework and material waste through a single forming operation.
  • Shorten the adjustment time: The 6 axis cnc press brake is equipped with the function of rapid die change, and integrates multi-station, tool library, simulation and process library, significantly shortening the adjustment cycle and improving equipment utilization.
  • Optimize labor: The degree of automation is high, and it is more accurate, which greatly reduces the dependence on the technical level of operators, reduces human operation errors, and reduces labor costs.

Improve processing efficiency and automation

The 6 axis cnc press brake has a multi-axis linkage system, has a certain automation foundation, and is equipped with automatic loading and unloading and robotic arm and other automation equipment, then the efficiency of the production line for handling complex workpieces will be greatly improved, and the level of automation will rise.

Adapt to the bending needs of complex workpieces

With a multi-axis independent control system and a highly flexible back gauge system, the 6 axis cnc press brake can support the processing of special-shaped, asymmetrical, and multi-fold complex parts to meet the diverse needs of modern sheet metal fabrication.

Comparison of improvement points of 4 axis press brakes

Compared with 4 axis press brake, the 6 axis model has more mature one-time tooling technology, which can effectively reduce subsequent corrections, and under the Y1/Y2 independent control and deflection compensation technology, it greatly improves accuracy and consistency, and at the same time has significantly better flexibility.

Typical applications of 6 axis cnc press brakes

Automobiles and commercial vehicles

The field of 6 axis cnc press brake is mainly engaged in the manufacture of some parts for daily use of automobiles, including anti-collision beam reinforcement plates, seat slide brackets, wiring harness fixing frames, power battery box frames, wiper motor brackets, etc. It can improve the manufacturing strength of these parts and provide better quality automotive parts for automotive consumers.

Aerospace and rail transit

Devices in the aerospace field, such as aviation interior fixtures, equipment brackets, electrical hatch reinforcements, and rail transit fairing skeletons, will have high precision requirements, and 6 axis cnc press brakes can reduce the rework situation during the bending process and increase the accuracy and consistency of aerospace devices.

Chassis cabinets, electrical and electronics

6 axis cnc press brakes are used to manufacture high-precision thin plates in the fields of machinery and electronics, and through the precise positioning of the 6 axis and precise angle adjustment, these thin plates can not only bear the firmness of the box cabinet, but also use more high-end electronic inventions.

custom 125 ton x 10 ft 6 axis CNC servo hydraulic metal sheet press brake machine for sale
custom 125 ton x 10 ft 6 axis CNC servo hydraulic metal sheet press brake machine for sale

How to choose the right 6 axis cnc press brake for your business

tonnage

When choosing press brake tonnage, it is necessary to consider the material, thickness, and maximum bending length of the material to be processed.

Shaft configuration and selection

When selecting axes, the general configuration is Y1/Y2, X, R, Z1, Z2 and 6 axis, if it cannot meet the machining needs, you can add a V axis. In terms of configuration, it must have an angle monitoring system such as laser angle measurement, and if possible, a quick clamping system and a tool system can be introduced to improve the speed and accuracy of processing.

Control system and software

3D bending simulation and collision check, automatic folding sequence, database are the most commonly used functions of 6 axis cnc press brakes, they can provide the perfect bowl solution, and can also automatically perform bending correction, providing strong support for automated intelligent production.

Accuracy and consistency indicators

Deflection compensation, angular tolerance and other systems are two important tools for a 6 axis cnc press brake to achieve perfect accuracy, and they play an important role in handling some angles with rebound and large deviations.

Maintenance and after-sales

Good product quality is the guarantee to reduce the frequency of maintenance after purchase, and the maintenance cost after failure should be considered before buying. High-end after-sales service is equally important, which determines whether customers can effectively get started quickly and solve related problems.

Budget and TCO

The budget includes equipment procurement, tool maintenance, energy consumption, lubrication treatment, labor costs, etc., which should be calculated in detail and considered clearly before purchasing. Enterprises can improve production efficiency through process library integration and automation, reduce unit cost and labor cost, thereby reducing TCO.

6 axis press brake price

Key factors affecting prices

Generally speaking, tonnage determines the specifications and costs of structural parts such as frames, hydraulic systems, and tool bases. The larger the press brake tonnage, the higher the price. The length affects the size of the body, the straightness control and the deflection compensation ability, and the longer the length of the countertop, the more expensive it is.

Brands in Europe, America, Japan and other countries have serious premiums and heavy tariffs, and no Chinese brand has higher cost performance and more flexible local services. The control system is the soul of the press brake, and the higher the control system, although the higher the product quality, the more expensive it is.

Reference for typical price range and configuration differences

Some basic models are priced at $100000 to $200000, with the core 6 axis, but they are not so good in terms of angle closed loop, manual or basic deflection compensation, standard back block and ordinary clamping, etc., and are only suitable for conventional materials and bending lengths.

On the basis of the typical basic model, hydraulic/electric deflection compensation, fast clamping, enhanced back stop (material database/3D simulation and other functions) are added, with a price range of 250000 to 400000 US dollars, suitable for multi-variety small and medium-sized batches.

The high-end model combines laser angle measurement closed-loop Delta X、 High end features such as automatic follow-up feeding, robot interface, and safety linkage, priced at approximately $350000 to $700000 or more, are suitable for long piece, exterior piece, and rhythm production.

On-demand configuration and phased upgrade strategy

The first stage is to strengthen the ability of the core 6 axis to ensure that the 6 axis cnc press brake has a stable angle closed-loop and basic automation capabilities, and quickly improve the efficiency pass rate of the production line.

In the second stage, we can try to introduce more advanced sensing and measurement, offline programming and 3D simulation systems to improve the performance of the 6 axis cnc press brake. The third stage can be equipped with full automation integration to become a top-of-the-line 6 axis cnc press brake.

Conclusion

6 axis cnc press brakes not only have high precision and high consistency, but also have great advantages in shortening processing time and reducing labor input costs.

With its own excellent strength and many use scenarios, the 6 axis cnc press brake has become an important machine in the modern sheet metal industry, suitable for the design and processing of more complex workpieces with high precision and consistency requirements, as well as the production environment of device manufacturing in some top fields.

Relying on stable manufacturing and application engineering capabilities, Raymax Tech provides customers with cost-effective 6 axis bending options and configuration solutions, while attaching importance to localized services, after-sales technical guidance, and Q&A, to help customers achieve mass production targets faster.

Frequently asked questions about 6 axis cnc press brakes

The 6 axis cnc press brake is a press brake with six independent CNC axes, the typical combination is Y1, Y2, X, R, Z1, Z2, and if it is more high-end, you can also choose the V-axis for deflection compensation. The six independent axes are each responsible for their own plates and operate in a coordinated manner to achieve high-precision, high-symmetry bending of plates and forming of complex geometric workpieces.

Compared with the 4-axis press brake, the 6 axis press brake has more Z1/Z2 axes responsible for controlling the front and backward movement of the back gauge, and more Z1/Z2 axes and R-axis to adjust the vertical height of the back gauge compared to the 3-axis. It not only supports fast switching between asymmetrical parts and multi-station, but also enables high-precision angle-to-high flexibility machining of complex workpieces.

Due to the different manufacturers of 6 axis press brakes, their price is greatly affected by factors such as maximum tonnage, machine configuration, brand awareness of 6 axis cnc press brake manufacturer, and whether it is in an economically developed area. It is generally believed that a 6 axis press brake ranges from hundreds of thousands to millions of yuan. It is recommended that enterprises purchase according to the materials they need to process.

6 +1 axis refers to the addition of a V axis that affects the width of the tool on the basis of 6 axis. The “6+1 axis” is usually found on 6 axis press brakes with high-end configurations, and the extra V-axis can compensate for the deflection that occurs in the bending of long or thick plates, further improving the accuracy of the angle and the consistency of mass production.

Y1 and Y2 are independent lifting shafts on both sides of the upper die, which control the depth of the punch and achieve accuracy and consistency in the bending angle. Z1 and Z2 are responsible for the left and right movement of the back gauge, which provides the possibility of multi-station or asymmetrical positioning of workpieces.

The R-axis controls the vertical height of the back gauge and thus determines the final height of the material. It not only reduces the probability of common problems such as sagging or secondary clamping of the sheet, but also adjusts the amount of rebound, which plays an important role in improving the accuracy and quality of the final product.

The X-axis is the axis that coordinates the movement of the back gauge forward and backward, which is mainly used to provide the reference distance of the polyline and is the choice of most standard bends. As an independent left and right front and rear axis X1/X2 axis, it is a shaft that realizes differential control, which is suitable for conical bending, asymmetrical parts and other working conditions. To sum up, the use of the X-axis is generally sufficient, and if the part complexity or accuracy requirements are very high, consider using the X1/X2 axis.

For standard or relatively simple bending and low frequency of change, the four-axis can be competent and more economical. For scenarios with multiple varieties of small and medium-sized batches, asymmetrical parts, and scenarios that require rapid switching of multiple stations or higher consistency of long parts, priority is given to 6 axis.

The minimum requirement for complex parts is 4 axes to start, and it is recommended to use 6 axis to reduce the probability of flipping and secondary clamping, achieve more folding sequences in one clamping, and improve the product qualification rate and production efficiency. For more extreme and complex working conditions, higher-level configurations such as “6 1” axes can be considered.

Brands that support multi-axis and 3D programming functions in the industry include Delem, ESA, Cybelec, etc., which have multi-axis collaboration, 3D graphical programming, collision simulation, material database, and the ability to network with production systems. The specific compatibility should be based on the official specifications of the selected model and control system.

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One response to “What is a 6 Axis Press Brake? Working Principles, Advantages, Applications, and Buying Guide”

  1. TUĞBA Avatar
    TUĞBA

    I appreciate you sharing this blog post. Thanks Again. Cool.

One response to “What is a 6 Axis Press Brake? Working Principles, Advantages, Applications, and Buying Guide”

  1. TUĞBA Avatar
    TUĞBA

    I appreciate you sharing this blog post. Thanks Again. Cool.

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Hello, Customers!

Francis

Author introduction

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

Email：   [email protected]  | Wechat：  13645551070

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