The press brake is an extremely versatile machine, yet at the same time complex. The technology on which operation is based is only trivial in appearance, however it hides remarkable developments in the mechanical and technological field. In fact, if we compare a modern press brake to one from fifty years ago, on the outside it seems that little has changed. However, the truth is that they are two completely different machines; the external elements may also have remained stationary with the typical design that we all know, but mechanics and electronics have evolved in a silent and inexorable way. Conceptually, between a bending machine from the past and a modern one, there are no changes in the process; both, in fact, share the same purpose: to bring a punch to a matrix up to a certain altitude in the most precise and repeatable way possible. Yet, the modern press brake is the result of constant evolution. Just as happened with cars, which from a simple and almost rudimentary means of transport have become truly high-tech machines, the bending machine is also now a concentration of technological and mechanical innovation. However, both in the case of the car and the press brake, the basic mechanical components have remained the same, but over time they have been improved and refined. To understand the fundamental stages of sheet metal bending and know the best technology that combines efficiency, effectiveness, operating costs and versatility, you need to take a trip back in time and know a little history of press brakes. Among the pioneering countries, there is undoubtedly Italy. In an area surrounding Brianza, businesses have flourished that have enhanced Italian products and continue to do so to this day, within the bending press brake sector. Our country is renowned worldwide for great tradition and quality in the construction of press brakes. Big names like Mariani and many others have literally invented this technology Let’s now take a short journey through the systems that have followed one another, focusing on today’s non plus ultra: the hybrid hydraulic press brake. Press brakes: types and characteristics 1) Mechanical press brakes Mechanical press brakes are still used in many workshops to do marginal work, even if they are now considered to be illegal machines from a safety point of view and, therefore, cannot be used by employees. In the past, the best known mechanical press brakes were Mariani or Omag branded; they were characterised by extremely fast movement and great pressure strength. 2) Promecam RG hydraulic press brakes Originated in France thanks to the intuition of the Italian-French Roger Giordano, RG Promecam hydraulic press brake machines are compact and low. Their most obvious feature is movement of the bench, different from all other press brakes. In fact, if it is usually the upper part - called the beam- that lowers, in this case the bench goes up. Movement is obtained by pushing a central hydraulic system. Simple and very reliable, they have practically made the history of Italian press bending and more besides.To date, they no longer comply with safety regulations as they do not have a speed change point and are not equipped with modern safety systems. They can, therefore, only work if they are adapted with specific kits. They were widespread for quite some time and it is not rare to still find them in many workshops and still operational; in the post-war period they represented a real revolution, as the bench contrasted the natural bending of the beam. The latter, being rather low and compact, allowed large, closed profiles to be obtained, which could embrace the upper part of the machine. 3) Hydraulic press brakes with torsion bar They are the forerunners of the synchronised ones that look very similar in appearance. Movement is via the beam that descends through a pair of hydraulic pistons. They usually have two or three axes: X for the rear carriage; Z for the height of the rear carriage; Y for the descent of the beam. The characteristic of these machines is that the two cylinders are mechanically connected through a bar that couples movement up to the lower dead centre. The latter is regulated through movement of two nuts that lower or lift to adjust the height of the end of stroke of the cylinders and the beam. The machine is controlled by a simple positioner, often without internal memory. 4) Synchronised hydraulic press brakes To date, the synchronised hydraulic press brake is the most widespread modern machine. It includes movement of the upper beam by means of two independent hydraulic cylinders and regulated by appropriate proportional valves. By doing so, the machine is more versatile and allows the operator to work on both cylinders independently to change the descent of the beam and counteract any irregularities of the sheet. It can happen frequently, in fact, that a piece bends more on one side than the other because of the aforementioned variables of the raw material. The numerical control of a synchronised hydraulic press brake is much more advanced than the positioner of the torsion bar press brake. The CNC allows the operator to make many adjustments: from the parking time to the lower dead centre, from the bending speed to decompression. Fig. 4.4 5) Electrical press brakes They represent the latest evolution of press brakes and continue today to be considered a border line solution for some specific needs. They guarantee speed and repeatability, combined with low consumption, however they are less versatile and have much higher costs than synchronised hydraulic press brakes. There are basically two techniques to operate an electrical press brake: with ball screws or by means of special belts. The future of press brakes: the hybrid press brake Synchronised hydraulic press brakes are the breeding ground for technological innovations and improvements with very important results. VICLA has grasped the occasion with much commitment, specialising in hybrid technology. This solution allows the best to be got from the system, combining it and making it into an advanced solution, which is distinguished for: precision; repeatability; energy consumption; quality-price ratio. Millesimal precision VICLA hybrid presses guarantee millesimal positioning of the beam, always ensuring precise and constant bends: all possible irregularities should be exclusively attributed to natural factors due to the variability of the raw material. This surgical precision is possible thanks to use of less oil compared to traditional hydraulic press brakes. Simply think, for example, that a 110-ton VICLA .SUPERIOR hybrid synchronised hydraulic press has a double tank with just 50 litres per chamber (compared to 200 litres used by a hydraulic press brake). Less oil means fewer ducts, smaller tubing, less heat and expansion and reduced clearance and wear. Two powerful electric motors work exclusively and directly on the minimum quantity of oil necessary. Precise repeatability Repeatability is a direct result of the lesser quantity of oil used. Heating litres of oil that flow within metres of tubing causes considerable side effects, first and foremost, loss of precision. This becomes more and more obvious as the machine is used after numerous work cycles and the inconsistency becomes more visible with each bend. Thanks too to a smaller tank, a compact circuit that allows you to have little oil that changes its volume as the temperature changes, VICLA press brakes maintain bending precision on each work cycle. Repeatability is also guaranteed by precision and the constructive sturdiness par excellence. Without these basic qualities, no electronics or new technology could express its real potential. Energy savings up to 78% If we compare the performance of a hybrid bending machine to a conventional synchronised hydraulic press brake, the results are really impressive: energy savings, in standard conditions, are equal to 55%. But even better limits can be achieved: if the standard hybrid technology achieves 55% energy savings, with the Hybrid Plus option, a sophisticated exclusive hydraulic component, energy savings up to as much as 78% are achieved! This is possible thanks to a simple and effective use philosophy: consume only when the press brake is bending. In a traditional synchronised hydraulic press brake. there is always a large three-phase motor that is never switched off, even while the operator equips the machine, programs the numerical control, organises the pieces near the workstation or, simply, looks at the drawing of the item to work. Instead, the highly coefficient motor of a VICLA hybrid press brake only switches on when the operator activates the machine by pressing the descent pedal. It is a huge advantage in financial terms, even in the short term. In terms of cost, the benefit of hybrid technology is even more obvious. This is because, on comparing the VICLA hybrid system with an electrical press brake that however allows energy savings, the purchase cost is still favourable to hybrid technology. But there’s more: electric hydraulic press brakes, especially if they use a belt system, have a very different structure that makes them generally less versatile. In fact, it is impossible to bend particular parts such as hoppers, tanks of a certain depth or chutes, because their closed structure on the sides and the widespread use of casings creates numerous occasions for collision between the parts and the machine. On the other hand, the hybrid hydraulic press brake allows, like any hydraulics, to work even leaving the machine sideways, with greater use versatility.
A CNC press brake is a modern machine for sheet metal deformation. There are different types on the market: Hydraulic press brakes, hybrid press brakes and electrical press brakes. Modern press brakes are operated and controlled by a computer that helps quickly set the specifications of a job and perform production cycles according to different needs, both short and long term. What is a CNC controller? All mechanical components of the press brakes are integrated with numerical control, which is responsible for setting the bending parameters. The most important parameters in the bending process are: thickness of the sheet; dimensions of the sheet; bending angle; One of the many advantages of numerical control lies in the possibility of implementing bend simulations, during which the machine verifies if there are any collisions or overloads. What are the benefits of using a press brake with numerical control? There are many benefits obtained from numerical control programming on CNC press brakes: Speed Precision Repeatability Adaptation Flexibility Agility The main technologies of ESA numerical control ESA 650 and 660 numerical control This version, with colour graphics and multilingual function, allows the automatic calculation of the PMI according to the type of tool and the required angle, and the automatic calculation of the bending force. Optimisation options include optimal bending sequence, and display of any collisions in the sequence proposed by the operator, also carrying out anti-collision checks between the axes and the matrix in the automatic phase. ESA 675 numerical control It is equipped with an ultra-large 21” LCD HD Multi-touch colour screen and integrated Windows PC, which allows drawings to be opened in PDF format or in another format directly on the machine. Furthermore, it allows optimal management of all Cad-Cam 3D. It is equipped with RAM 8 Gb, 4 USB ports 2.0 + 4 USB ports 3.0. Delem numerical control It is a simple and intuitive Numerical Touch Screen control, with a high level of functionality and a user-friendly and modern graphic environment. It is available with screens of different sizes and features customised to your needs. Press brake programming: management of 3D projects Our modern press brakes can be equipped with programming software for the preparation and processing of 3D projects that guarantees multiple advantages. The programming software available on VICLA machines for sheet metal, for example, guarantee maximum efficiency in tool selection, based on bend radius, maximum force of the press brake, collision control, and the availability of different types of tools and splits. It is also able to recognise and automatically manage the flattened bend thanks to definition of the angles of the pre-bend and the inner counter-bends, calculating the best bending sequence, avoiding collisions and taking into account the availability of splits and skids. Although automatic management almost always finds a solution, the operator also has the possibility to intervene manually and change the data set by the software. For positioning of the stops, the software available on VICLA press brakes provides automatic and manual control options for the back gauge, thanks to the 3D simulation that allows you to view all the moving elements, including the tools, the part to bend and the machine structure. Finally, the software provides the complete tooling report, from the 3D bending sequence, including detailed information bend by bend. The report can be printed or displayed directly on the numerical control.
The press brake is a simple machine, while at the same time complex because it is linked to the variability of the sheet metal, which requires each machine to be equipped for different sheet metal customisations. This is why it is important to know the characteristics and the elements to consider when configuring a press brake. We discover the fundamental points to consider: Length The length of the press brake depends on the maximum length of the part to work. Furthermore, if bent per stations, it is useful to consider the purchase of a longer press brake, which allows multiple stations to be implemented. For example, for a sheet measuring 1100 x 700 mm, you are advised to choose a press brake measuring 2000 mm long. Tonnage It is intended as the bending force of the machine. In other words, it refers to the capacity to bend of the press brake. Tonnage depends on various factors, first of all the material: a ductile part requires less bending force; on the contrary, a more resistant material such as stainless steel or high strength steel requires greater force. The other factors to consider are: thickness, length and type of work. It is always worth over-dimensioning the press brake by 20%/30% of the theoretical data, thereby avoiding working at the limit of machine capacity. One of the most common misjudgements is to confuse the total force needed to bend a given sheet metal part with the tons per metre for the specific thickness, material and die. Find out more in this guide. Clearance and stroke Clearance is simply the front opening of the press brake A press brake with a larger stroke is a machine equipped with greater intermediates that allow easier extraction of the bent parts. Locks and intermediates Intermediates are adaptors to insert between the beam and the punches and are very useful because they allow deep box structures to be easily made. The tool locking systems are sub-divided into: manual locks; semi-automatic locks: pneumatic blocks; hydraulic locks; The choice of correct locking is fundamental to reduce the work times and correctly manage the work zone. Semi-automatic locks It is a manual semi-automatic lock with rapid front locking-unlocking system of the punch. Operation is very simple and, compared to the traditional manual solution, allows faster and easier re-equipment of the machine. In fact, by moving the locking lever, the punch is released to remove it from the front; while, on closure, the punch is automatically brought to stop and perfectly aligned. Automatic locks The automatic tool locking systems allow equipping of the press brake in complete safety. The tools are automatically aligned, positioned and fastened. This solution drastically reduces the equipping time and considerably increases production. Automatic tool change for press brakes Today, a modern and innovative solution exist that allows automated change of the punches and matrixes. For example, VICLA hybrid press brakes can be connected to an automatic tools warehouse that allows equipping, even on multiple stations, of higher and lower tools. This system is customisable and designed to measure according to client requirements; it reduces setup by 4 or 5 times compared to manual tasks and automatically performs even the most complex equipping, managing 70 mm wide V matrices, rod holding tools and allowing the tool to rotate 180°. Automation covers everything, including upstream operations. One of the more interesting aspects is programming by the technical office: the CAD/CAM system processes the three-dimensional file, creates the best bending cycle and sends the program to the machine that is automatically equipped, referencing the bending sequence directly on the numerical control. All tooling and machining data are automatically saved at the end of the work and exported to management for a 4.0 key data analysis. Back gauge The rear gauge is a motorised structure on which the references are set and can be moved and positioned to allow a variety of complex bends. Movement of the back gauge along the depth of the machine is called axis X. Vertical lifting is called axis R. References It consists of very important and useful tools to support thin sheets. They are equipped with pneumatic operation and a Teflon coating that prevents marks on the material. They can also be activated by numerical control. There are 2 references and they are usually manual, but they can be automated and controlled directly by the CNC; the positioning of the stops is along the Z axis. Independent tower gauge All towers are equipped on VICLA press brakes with a visual LED stop. Switch on of the LED ensures contact of the sheet with the reference. In more accessorised versions, the towers are: Motorised (axes z1- z2) Independent (axes x2 - x3) Anthropomorphic (axes r1 - r2) Bending compensation The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well worked part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. Thanks to special sensors in the beams, crowning enables measurement and compensates deformations in real time. There is no need to set any data; the system actively reacts to changes in characteristics. Each press brake, despite its robustness, is subject to structural bending, during the bending phase, and obviously the deformations are much bigger the greater the effort the machine has to make. The main deformation is crowning, which corresponds to bending of the beam which is pushed into position by the side cylinders; the other (and for many reasons semi-unknown), is called in jargon “yawn” and is the tendency of the frames to open in the throat zone. Thanks to the Flex system the sheet metal press brake dynamically compensates any deformations based on the effort required: the CNC receives the data from the pressure sensors of the cylinders, which are interpolated in real time to establish the correction to implement. Energy saving systems It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. The results in numbers of this technological innovation are significant, as seen on the graph. Angle control systems L.A.C. VICLA angle control L.A.C. angle control consists of two laser sensors mounted on linear guides that slide to the rear and front of the press brake bench taking the measurement in one or three points depending on the length of the piece. Located on the sides of the matrixes, they have the purpose of reading, through a system of lasers and cameras, the inclination of the edges of the bends during deformation. It is the most complete and performing solution for automatic angle measurement and control. Angle reading takes place in 3 phases: A laser beam is projected on the sheet metal surface The camera detects the elastic recovery of the material The CNC automatically sets the correction suitable to obtain the system desired angle that we use on our VICLA press brakes and is the best you can find on the market. The guaranteed precision is very high and in the order of fractions of a degree. The system is also able to historicize the elastic recovery of the sheets, ensuring a constant and specific self-learning of the press based on the real situation of the company. Obviously the angle control system guarantees the best performance if it is supported by solid and precise mechanics and perfect integration with numerical control. With the latter, there is a continuous data exchange dialogue that allows perfect application with each item being processed. If, for example, for volume issues, a specific bend cannot be measured by the angle control system, it can be linked to the previous reading made on another flap of the same piece. Vicla optical angle control is a safe investment and surprisingly quick return as it makes continuous measurement operations by the operator completely unnecessary with an exponential increase in productivity and quality. Probe angle control There are essentially three types: inserts in the punch, hosted in the matrixes or applied to parallel sliding trolleys the exact same as those of the optical systems and placed on the sides of the bench. On first examination, it could appear a definitive solution, however these are also not without limitations which, in practice, only appear during their real use. The first is without doubt the installation difficulty. This is the typical limit of the controls inserted in the tools that include use of special punches and matrixes equipped with sophisticated, sensor-based strips. Such angle control systems have very poor versatility when you consider they are not usable by changing tool set-ups. Another limitation is their characteristic fragility. Being small and very sophisticated mechanical elements, they are easily subject to failure caused by accidental impacts or malfunctions due to the accumulation of dust and dirt. O.A.C. (Optical Angle Control) Optical control is directly assembled on photocells to capture images of the profile detecting, calculating and correcting the bending angle. One of the most sophisticated optical controls is the IRIS PLUS system. Although it is part of the optical angle control unit, IRIS plus is an alternative solution because it can perform an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. This eliminates any interference between the parts and the angle control devices and achieves totally versatile use. The system, in fact, allows very interesting accuracy and reliability if the emitter and the receiver are not beyond a certain distance. After approximately 2.5 metres, in fact, there is a natural increase in the phenomenon of refraction of light rays that reach the control system which are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not ensuring the same accuracy in the reading of the bend. Optionals and accessories on the press brakes Bending flattening table The bottom bed has a bending/flattening table in order to perform flat hem bends without the need for a dedicated die. Its versatility makes it the ideal solution for companies that carry out many flat hem bends. The option is built directly into the die holder, and therefore can be used in conjunction with any other die that has a standard connection without the need to disassemble the table. Front sheet metal supports These front supports have a linear guide that extends beyond the bottom beam. Their height can be adjusted and they also slide sideways and rotate. A practical clamp-release system makes them very easy to mount and remove quickly. Metal sheet bending followers They can lift weights up to 380kg. Use of the metal sheet bending followers offers an important advantage to reduce risks for the operator and increase the quality of the bent parts: it was designed to avoid counter-bend effects and reduce the need for other operators. It can also be easily removed from the front and placed on another bending machine. Side parking An extension of the linear guides, extending beyond the bench. This solution is used to park the sheet metal supports when not in use. Wireless 2-pedal foot switch It is powered by an integrated solar panel that allows you to get up to 20% more autonomy from battery life; it does not require connection, nor cable laying. The ultrasonic sensors are located on either side of the lower bench to transmit and receive data wirelessly. Tool locator The system indicates via the incorporated LED the right locking position of the equipment during tool configuration and indicates the position of the active tool in production mode. It is a real and proper visual aid immediately available to the operator who, by doing so, does not waste time measuring and understanding where to position the tool and can dedicate his time to other operations.
The VICLA is not just synonymous with efficiency and accuracy in the sheet metal processing world. Another real strength is our ability to design ergonomic machines with a simple, user-friendly interface. We have studied these features to make them easier to use. Discover our video tutorial to learn how to power a VICLA machine up and
VICLA has been working on systems to help fabricators reduce setup time and minimize production time through stage bending. VICLA Automatic Tool Changer provides the ability to produce multiple bending stations that require various tooling types with only one setup. The demand for smaller, more complex and heterogeneous batches requires finding solutions to shorten production times and lower costs. The smaller the batch, the more the setup times impact on the productivity of the machine and on the production cost. VICLA ATC system - Single or Twin – is designed to automate and speed-up the setups for efficiently producing small batch sizes. The system combines one or two hybrid press brakes with an automatic tool changer, allowing for multiple tooling setups, reducing setup times by 4 or 5 times compared to the ordinary manual operation. The main element of the system is a compact shuttle that serves as robotic tool changer that places the tool sets, up to 1-3/4” V opening, in the clamping systems of the upper and lower beams. This shuttle retrieves and replaces tools in the tool magazine, which can store up to 197 ft. of dies and punches. The tooling can be used in manual or robotic setups. The upper tools can also be rotated 180 degrees. A modular and custom-made solution One of the many other advantages of the VICLA automatic tool changer is the offline programming capability. The CAD / CAM system processes the three-dimensional file, creates the best bending sequence and sends the program to the machine, which is automatically equipped, and calls-up the bending sequence directly on the numerical control screen. All tooling and processing data are automatically saved at the end of the job and exported to the management system for data analysis. About VICLA Sheet Metal Machineries VICLA is an Italian manufacturer specialized in the design and engineering of high performance and customizable bending press brakes, shears and robotic cells. Each machine is tailored to the needs of the individual customer and designed based on its specific production needs. As a result, there is no VICLA machine equal to the other and each of its products excel in terms of production performance and productivity. Thanks to detailed attention, continuous research of high quality, and cutting edge technologies, VICLA has what it takes to provide its customers with the most innovative, robust and reliable technology on the market. This is the company mission since 2008 which has brought VICLA to steadily grow as a machine manufacturer and increase its market shares in Italy, Europe and North America. VICLA official USA Dealer: Comeq Inc., +1 410-933-8500, vicla.eu VICLA Headquarters (Italy): +39 031-622-065, vicla.eu
Sheet metal fabrication is the process of cutting, bending, punching, and assembling flat sheets of various types of metal into desired structures or products. Sheet metal fabrication is now widely used in industries such as agricultural, aircraft, automotive, energy, robotics, and more to manufacture industrial and consumer equipment. Fabrication shops are businesses that specialize in sheet metal fabrication and employ a variety of personnel to handle the difficult process. Design, cutting, punching, bending, assembly, quality check, and packing are the main steps. The creation of a design for the final product is the first step in the sheet metal production process. CAD engineering is the starting point for the route from sheet metal to metal products. The procedure comprises specific data, including dimensions, material qualities, and tolerances that thoroughly outline how to turn a bespoke design into a tangible product. Engineers, architects, designers, and many other experts came up with concepts using schematics and blueprints before the widespread adoption of CAD models in many industries. However, all of that changed thanks to computer-aided design (CAD) models. Modern metal fabricators may use CAD software to create bespoke designs that are accurate and repeatable and can then be scaled up to mass manufacturing. If you're interested in learning about the many ways CAD aids in sheet metal fabrication, here are five of them. 1. Streamlined design process When working with CAD, a designer can take advantage of the software's ability to smooth out bumps in the sheet metal design process. CAD software aids designers in the process of synthesizing, analyzing, and documenting their designs. These factors contribute to the designer's productivity, which translates into faster design, lower design costs, and shorter project completion times. Furthermore, the amount of effort required to design the various models has been significantly reduced because the software automates the majority of the task. Designers can experiment with concepts and save draughts digitally thanks to computer software. You'll be pleased with the results of having your designers work in CAD. Furthermore, because the designer is using CAD, every step of the design process will be documented, allowing everyone to synthesize and analyze the process. 2. Better quality design CAD systems are extremely accurate, allowing error figures to drop dramatically and, as a result, improving design quality. Traditionally, if a design did not work as expected, the team would have to start over. CAD design teams, on the other hand, are better equipped to control the quality of the final engineered product. With CAD software, designers have access to a plethora of tools that aid in conducting a thorough engineering analysis of the proposed design. The low-risk virtual investigation, for example, enables organizations to improve manufacturing speeds and reduce resource waste caused by flawed designs. For starters, CAD reduces the possibility of human error significantly, allowing machinery to craft an item seamlessly while avoiding resource waste. Furthermore, the CAD design process results in fewer draught productions and wastes, resulting in a cheaper and faster production process. 3. Simplified information sharing Creating design documentation is one of the most important aspects of designing when using CAD software. In fact, CAD software aids in better design documentation. Next, all design data can be easily saved and used for future reference, reducing the need for excessive communication. These documents and files can be easily shared among partners and reviewed by teams to ensure that all details are correct. This allows for a more thorough internal understanding of the vision and the work that must be done. CAD software, especially if you're part of a large team, makes it simple to collaborate with team members. Furthermore, due to the integrity of these documents, team members on the ground can be directly allotted information about critical design features, allowing for faster development while reducing assembly errors. 4. Better visualization Visualization is an important tool in Computer-Aided Design because it allows you to effectively and efficiently design, debug, validate, market, maintain, repair, update, and recycle products. The unrivaled visualization capability of CAD software is due to higher levels of sophistication achieved with graphics and visualization techniques, which allow for the creation of images of stunning quality and realism. This is how CAD enables you to create and visualize 2D or 3D objects, as well as make as many changes as you need with less effort than drawing them on paper with a pencil. Architects, engineers, and designers can now use CAD visualizations to create 3D versions of their plans to test how well the design works before spending any money. Furthermore, a completed design will boost their confidence when selling their work to clients. 5. Speed and versatility Speed and versatility are two important aspects of CAD systems that have helped them become an important part of sheet metal fabrication and encourage us to come up with new ways to build things. Designers can use CAD software to visualize their designs and test them against real-world variables. They can easily change the same file if something needs to be changed. Before CAD, people had to do things the old-fashioned way, with paper, pencils, and rulers. They would have to redo the entire design if they wanted to change it. However, CAD eliminates the need for physical prototyping by allowing the designer to simulate all necessary testing in the program virtually. Furthermore, CAD software allows users to use various effects, typography, shapes, and backgrounds to help with artwork and creativity. Final words CAD may be the most significant innovation for metal fabrication and other industrial needs. CAD modeling enables the development of a specification for a custom metal part that is easily understood and actionable by all parties involved in the design and manufacture of the part. When you embrace the benefits of CAD, your designers, prototyping team, and project managers will all be pleased. Furthermore, increased productivity will result from improved quality and reduced waste.
The angle control is a high-tech accessory that allows the achievement of a very important consistency of the bend angle values. Over the years, manufacturers have developed many solutions to address variations in raw material properties before bending. An angle control is able to detect the deformation of the material dynamically during machining. Obviously, not all angle control systems are the same and to better understand their characteristics and peculiarities it is necessary to take an in-depth study. Below is an overview of the existing systems on the market today. O.A.C. (Optical Angle Control) optical controls Although it is part of the group of optical angle controls, IRIS plus is a solution capable of taking an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. IRIS plus does not set any space limits because it is a system housed directly inside the Lazersafe safety devices. This eliminates any interference between the workpieces and the angle control devices and achieves total versatility of use. With IRIS plus, control is perfect but non-invasive, leaving full freedom to the operator while working and always guaranteeing excellent results with all tools and materials. VICLA adopts the IRIS Plus angle control system precisely where it can guarantee the best performance: on small press brakes. The system, in fact, allows a very interesting precision and reliability if the emitter and receiver are not beyond a certain distance. In fact, when approximately 2.5 meters are exceeded, there is a natural increase in the phenomenon of refraction of light rays that reach the control system that are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not guaranteeing the same accuracy in reading the lean angles. Laser Angle Control The DATA M angle control system is one of the most effective and high-performance solutions for automatic angle measurement and control. The DATA M control is a type of laser angle control; it consists of two laser sensors mounted on linear guides that slide at the back and front of the press brake table. Compared to other types, the Data M is one of the most effective and high-performance solutions for automatic angle measurement and control: This device measures and corrects the bend angle in a few ways: • Performs a dynamic measurement while the workpiece is bent • Extrapolate the springback and calculate the correction on the numerical control • Bends based on the previously calculated correction Requirements: • Requires a minimum reading edge of 20 mm out of slot • We recommend that you use a T-matrix • It involves the installation of two linear guides on the machine bench When to buy an angle control system? Often those who have to buy a new bending machine find themselves in doubt whether to also install an angle control system. Assessing the need for angle control is a complex issue and there is no single answer for each case, because it depends a lot on the type of machining and the needs of the individual workshop. Benefits of Angle Control Systems? If you are looking for a new press brake, you must carefully evaluate all the technical aspects of the machine. Before you even choose your brand, it's important to consider what your needs are. Very often we let ourselves be enchanted by the big brand names, but there is no worse mistake than letting yourself be guided in the choice only by the notoriety of the brand or by the price; often we end up neglecting the technical aspect. It is far more important, therefore, to be clear about your company's production needs. Even when choosing whether or not to buy angle control, it's important to ask yourself at least two questions: What kind of work do you do? What is your goal? For example, if you work with small, custom batches, or you make prototypes with fine materials, or you do machining that requires extreme bending precision, you should consider equipping the bending machine with an angle control system. This device is not only an optional extra, but it is a real indispensable ally for certain processes, especially if the material is valuable and a mistake on the corner means having to throw away the piece (and your money!). Many business owners are hesitant about the idea of using angle control, for two reasons: 1. The prejudice on the initial investment, judged by many to be too high 2. The misconception that angle control slows down the work too much Are these legitimate doubts, or are they the result of errors of initial assessment? Let's try to answer them. Angle control costs too much Angle control systems are very advanced instruments, equipped with various measurement methods that facilitate the bending process. It is normal, therefore, that the initial investment reflects the complexity of the option. However, in the face of an initial investment that may seem high, the price of angle control is a completely subjective parameter and is affected by many considerations. For example, have you ever tried to quantify the cost of material thrown away due to errors and waste? You should also include the economic impact of all delivery delays and staff hours lost due to bad work in your calculation. If you haven't already, you'll be amazed to find out how a significant amount of moneyare wasted to rework due to errors, distractions, and waste! If, on the other hand, you already know the costs that are weighing on your company, you are certainly able to more correctly assess the amount of the investment of an angle control. Think about it: does the value of angle control outweigh all the money you've thrown away so far due to mistakes and material waste? Angle control slows down work Some people might wonder that angle control slows down the bending process. Of course, the measurement process takes time, which varies depending on the measurement method used and the complexity of the part to be performed. For those who do precision machining, prototyping, or using fine materials, for example, getting the part right the first time means lowering costs, increasing production quality, and reducing risk. Another important aspect to consider is that, nowadays, modern angle controls are equipped with different methods of use that allow you to choose the most suitable function depending on the type of processing. For example, if you need to make bends that have the same angle, you can set the measurement method to correct all equal angles based on the measurements made on the first bend. In the same way, if you have already derived the springback of that batch of sheets, you can use a particular function, similar to the Real Time control, but much faster. In summary, instead of thinking about how much angle control slows down your work, wouldn't it be more useful to consider how much productivity can increase?
Nowadays it’s possible to have both speed and accuracy when bending sheet metal, you just have to know how to choose: in fact, to create this apparently impossible marriage, you need a press brake that provides real added value to the production chain. Today we will find out what are the most important – and often overlooked – things to consider to finally have speed and accuracy in your company at the same time. Sheet meal bending brings with it physiological issues, first of all from a number of environmental and material variability factors. The production line of a sheet metal workpiece is similar to a chain, which begins with an idea developed in a technical office, which is subsequently roughed during the cutting phase, to then be “brought to life” and given form by the press brake. If every link in the chain is not high quality and well lubricated, your company's movement risks jamming or working badly, resulting in unacceptable speed and efficiency losses. That is why it’s counter-productive to invest inconsistently in the technologies you need. For example: it’s unreasonable to think of reducing waste sufficiently by purchasing a laser cutting machine of the latest generation, a champion of speed, if you then accompany it with an obsolete or low-cost press brake. So here are some tips to avoid having to choose between speed and accuracy. 1) Choose a robust, well-built machine Being able to count on machines designed specifically and manufactured with care and quality is a key factor in ensuring speed and accuracy at the same time. In this sense, made in Italy is in itself a great business card, especially considering experience, professionalism, capability and general quality. Contrary to any false stereotypes, Italy is one of the top five countries in machine tool production, and it’s no coincidence that the sector worldwide has always recognized Italian manufacturing as offering great added value. 2) Choose a manufacturer that listens to you This is a much undervalued issue, but several sources confirm that choosing a good machine without having the same good support can turn out to be completely counter-productive. For example, relying on a manufacturer that is smaller in size but large in service gives a huge competitive advantage that is hard to quantify. What you need is a partner that is willing to let you visit its site, talk to its owners and employees and, of course, directly to its service department for any need. Because speed and accuracy must also go together in support. 3) Choose a manufacturer that focuses on your needs If you need a particular component or accessory in order to work with speed and accuracy, it's good if the manufacturer has it in its catalogue and, above all, that it can advise which one is best for you with transparency and expertise. Sheet metal bending supports, hybrid technology, multi-axis backguages, quick tool connections, etc. All devices that should never be considered a running cost, but a real investment to improve process quality and effectiveness. Therefore, bending speed and accuracy can only coexist if you have a high-quality machine made by a professional manufacturer that is willing to listen to your needs. These have become essential conditions in order to ensure that your work provides added value. None of your customers will ever be willing to pay a premium for waste because your machine is slow and inaccurate, especially in an extremely competitive market like ours.
The art of press brake bending is sometimes unjustifiably underestimated. Companies, sometimes unconsciously, tend to concentrate their economic commitments in other parts of the production chain. For example, technical offices are often state-of-the-art and equipped with the latest tools, while the press brakes used are old and hyper-economical. Sheet metal is a living material that presents a range of objective difficulties during the bending process: underestimating it is an own goal for the company and can become very expensive in the long term. Fortunately, technology has made huge strides, allowing some manufacturers to make the best use of it and develop efficient equipment. If press brakes can now be considered mature machines from an operational and structural perspective, we cannot say the same of the equipment used to enhance them and increase their performance. So, what equipment is essential in a press brake? A hybrid system that makes it accurate and green For most processing, a hybrid system of the latest generation guarantees an indisputable energy saving and can position the top beam with an accuracy in the order of thousandths of a millimetre. These are all benefits that bring great economic savings for the company. Active crowning As is known, press brakes are subject to natural structural deformation during processing. Bending of the top beam is the most obvious. An automatic system with special sensors located in strategic areas of the press to ensure that the punches and dies are the right distance apart along the whole length of the working area is undoubtedly an invaluable benefit. This ensures that a bent workpiece will have the same desired angle in the middle as at the ends. A multi-axis backgauge Having backgauges that can be positioned quickly and accurately almost anywhere has become a must. In fact, the market increasingly demands production of high-quality complex workpieces in small batches: tapered bends, edges that are not parallel to the deformation line, processing stations and so on. With multi-axis backgauges, these and many other complex processes can be carried out more easily. Off-line programming On other words: standardisation. Being strictly linked to the human factor, bending efficiency depends on the skill and experience of the operator, as well as the quality of the machine used. Where the company has a high personnel turn-over or a growth in volumes that must also be supported by an increase in personnel, the use of CAM can be extremely useful in bending. In fact, in this case the know-how and experience of an expert can be “spread” over the new recruits in a short time, bringing great benefits to production. User-friendly numerical control In any case, even if there is no off-line programming, numerical control is the main tool that allows even unskilled press brake operators to interface effectively with their machines in a short time through a clear, simple and complete interface. When the start-up time of a new machine is longer than expected, the problem is often due to difficulty in understanding and controlling an unclear system, which can create problems for operators, regardless of whether they are expert or inexperienced.
A press built to the highest standards, with numerous process parameter checks and alarms to warn when any of them drifts is able to maintain a consistent level of bend quality, but there is much more to be considered. The spring back variable Let’s look at sheet metal bending: it’s a material with many variables: bending response to laser cutting, plasma cutting, size tolerances and so on. Whenever you have to tackle a different workpiece, you also have to think about aesthetics if you are dealing with materials such as pre-painted sheets and steel. For those working with the press brake, everything has to do with the ever-present forming variable: spring back. This is a variable that occurs when the material attempts to return angularly to its original shape after being bent. Tensile strength, material thickness, tool and press brake type naturally all affect spring back. It is essential to predict and evaluate spring back effectively, especially when working with tight bends, as well as with thick, high-strength materials. Laying out workpieces for bending The material normally deforms during bending. The length of the workpiece to be bent is naturally not the same as that of the axis of the bent workpiece. The axis that retains its original line (known as the neutral axis) shifts towards the inside of the bend, and its position depends on various factors such as the sheet metal thickness, bend radius and material quality. These are the factors that can be used to establish the layout of the workpiece to be bent. The tools Many types of press brake tools are available, such as radial, gooseneck and bending/flattening tools, for which the load limit becomes a decisive factor. There are two limits to consider: the limit that the tool itself can withstand, and the load limit at the centre line of the press brake. When it comes to tools, take great care to choose the correct tool and consider the load that the tool can withstand. Work is often carried out at the tool load limit, which risks damaging the punch and die. To avoid damaging tools or even worse the press brake, always observe the load limits. Cleaning Dirt particles can enter the hydraulic circuit if it's not sealed properly, so make sure that the tank cover and breather seals are in good condition. The breathers are fitted on the tank cover, and allow air to flow into the tank to avoid creating a vacuum inside when oil is pumped into the cylinders. Dirt in the oil can result in malfunctions and faults in the pump and valves. Most hydraulic circuit problems are related to contaminated oil, which can cause the valves to stick in the “on or off” position. This means that tool cleaning is very important: dust, oil, debris, chips and other material that builds up over time can scratch the workpiece surfaces.