The importance of knowing how to assess your perfect press supplier. In an extremely competitive sector such as that of sheet metal machines, it's very easy to come across false legends, old beliefs and complete speculation. It is said that: “all that glisters is not gold”, and nothing is more true. Very often, the market is influenced by misleading news and messages that can lead potential buyers to make sub-optimal or even bad choices. Large renowned brands or those that have simply been on the market for a long time are often chosen “blindly” for the aura of “sacredness” surrounding them. But can we be sure that a significant investment, such as that of a press brake, a long-lasting and demanding asset, does not deserve a more in-depth analysis? The characteristics of the perfect manufacturer A manufacturer that can fully meet the needs of a modern company facing today’s stormy market head-on must be: technological. It must be able to manage, and therefore offer, the best applied technology currently available on the market. Simple and user-friendly numerical controls that allow total, interactive machine management, fast, accurate and green motion systems, as well as state-of-the-art safety systems. It is better to be wary of suppliers who only offer obsolete systems in their catalogues. reliable. Your perfect press supplier does not leave the customer alone under any circumstances. The perfect supplier provides support to clarify all the customer's doubts: support that is ready, available and provided by extremely competent personnel is among the most important ingredients to prevent unnecessary and harmful downtime. This is because even the best machine in the world can have problems, and they are not necessarily related to its quality. Sometimes external factors can also affect press brake operation. available. A manufacturer offering standard machines or machines with few customisation options are rarely able to meet customer needs: even more so in a context like today, in which almost all orders are for special parts, in small batches, of high-quality and with a quick turnaround. It is not acceptable to spend large sums on a standard machine and then realise that it's unable to perform many jobs. You need versatility and flexibility when choosing, designing, and then using. near. Or better: “close”. We do not mean physically close: the closeness of a supplier is measured in its willingness to open its doors and listen to potential customers, and to accompany them through all the stages of making the correct choice. Understanding customers’ core business together, knowing how to explain the solutions that are right for them and how they work: this is closeness, because the perfect supplier cannot take anything for granted. Potential customers, even the most expert, are not press brake manufactures, so they may not be aware of all the aspects to be assessed at the configuration stage. That is why the perfect supplier, besides being able to offer the most suitable technological machine, must also educate customers about it. In short, buying a seemingly banal machine like a press brake is not at all easy. The perfect supplier is one that lets customers make the right choice and offers the best solutions… and know how to explain them!
The k-factor is fundamental in the press-bending sector and is closely linked to the concept of spring back. It is also known as bend allowance and serves to calculate the sheet metal layout. Knowing the k-factor formula is essential in order to bend any kind of sheet metal correctly; in fact, it varies according to the type of material to be deformed. What is the k-factor? The k-factor indicates the behaviour of the material being bent and how it reacts to the applied tensile and compressive stresses. In essence, it's nothing more than the ratio of the sheet metal thickness to the neutral axis, i.e. between t (distance between the inside of the bend and the neutral plane) and T (the workpiece thickness). What is the neutral plane? The neutral plane is the ideal area that does not vary during bending, and neither shortens nor lengthens. Do you want to know more about the neutral plane? We have written an article that goes into this topic in more detail. Broadly speaking, we can say that in the vast majority of cases the neutral plane lies at about 1/3 of the thickness from the inside, so it is 0.33. E.g.: a thickness of 30/10 will have t = 1 mm, so 1/3 = 0.33 = k Nevertheless, there are cases in which the neutral radius tends to shift towards the centre, i.e. when the ratio r/T > 1 Where r is the inside bend radius and T is the thickness. K-factor formula for sheet metal The following formula is used to calculate the sheet metal layout: k = log(r/s)x0.5+0.65 In any case, this table provides a set of values that can be used once you have the right inside bend radius. Sheet metal k-factor table 0,65>r/t<=1 k=0.3 1 k=0.35 1.5 k=0.4 2.4 k=0.45 3.8 k=0.5 What affects the sheet metal layout? The sheet metal layout generally depends on factors such as: the material, thickness and dies used and, to a lesser extent, the punch radius. All of these components affect the inside radius to varying extents. The natural consequence is that, the larger the radius, the smaller the layout, and vice versa. Let’s now look at the main factors that affect the sheet metal layout: 1) The die width: a wider die creates a larger radius than a narrower one. 2) Bend type: another aspect that is often ignored is that the finished workpiece dimensions vary for the same die, material and thickness, depending on whether air bending or bottom bending is used. In fact, the latter creates a smaller radius and therefore requires longer layouts. Special consideration must be given to coining. It is the only method in which the inside radius is the same as the punch radius, so the layout depends on the punch radius alone. 3) Punch radius: as already seen, the punch radius in standard conditions (therefore not with special bends that require the use of tools with very large radii) should be about 2/3 of the inside bend radius. This is because, to a lesser extent, this component also tends to create differences in the dimensions of finished workpieces. Bending medium thicknesses with a punch radius that is too small (e.g. r of 0.8 on a thickness of 50/10) not only creates unsightly grooves on the inside, but also causes more material stress and an unnatural curvature. Sheet metal k-factor: how to lay out a metal sheet Workshops use various techniques to find the layout. There is now a tendency to rely on the many software packages on the market, but the corrections made may still be based on empirical methods developed within companies. Now let us look at some of the methods used by operators. Experience-based tables: these are obtained by noting the compensation added to layouts in practical trials. Compensation values: this involves adding compensation values corresponding to a percentage of the thickness to the inside bend measurements. DIN tables: these are tables that provide values to be subtracted from the outside dimensions of the bent workpieces. Geometric calculations: by applying the k-factors obtained from the formula seen above or by using the example grid values based on r/t. Forcing the radius and changing the k-factor: this is an approach used by designers and draughtsmen who use 3D modelling software. Percentage method: this is a widely used system. It involves initially simplifying the inside radius of the alloy based on the die and material, and then entering the k-factor from the table. Now that you know what the k-factor is in detail and how to calculate it, you can accurately determine the layout of the sheet metal to be bent.
Just saying 4.0 is not enough to have “the” press Some manufacturers try to anticipate the changes, exploiting the fact that press brakes already have certain characteristics that take them in the direction of Industry 4.0 parameters, but they clash with the discordant opinions of others who say that “Speaking of Industry 4.0 in this sector is undoubtedly more difficult if we compare it with laser cutting, punching and panelling.” So let’s look at what characteristics make a 4.0 press: CNC directly connected to the company network with programming from the office; high level of safety equipment; remote support; direct connection with the company ERP. Press brake and tools When it comes to bending sheet metal to give it a custom finished shape for the specific application, the accuracy of the finished bend is essential: if the bends are not made accurately, then the final product will simply not be correct to the drawing. This is a particularly relevant scenario for users that bend complex parts, in which even small inconsistencies during the bending process can ruin a whole batch of parts. When it comes to tools, it's very important to choose the correct punch and die combination, and to assess the bending radii and capacity of the tools. However, numerical control can check the choices made and warn if they are inappropriate, as it's already configured with the specifications of the main tool manufacturers. The force of sheet metal An excellent bending result without wasting material, however, does not depend on the press alone. Industry 4.0 standards or not, it's necessary to consider that steel is a living material, which bends in a specific direction but requires special attention to its spring back and, consequently, to the force used during bending. For those using the press, spring back is a variable that occurs when the material attempts to return angularly to its original shape after bending. However, spring back can increase very significantly as the inside bend radius increases in relation to the material thickness. New high-strength steels, for example, exhibit greater spring back than basic mild steels, some stainless steels and many types of aluminium. Cutting costs and increasing accuracy of the press brake In addition to the ecological and energy-saving aspects, the most obvious benefit of using 4.0 press brakes is that they can be integrated into factory IT systems in order to manage the entire production process in a modern and increasingly automated way. Electric press brakes eliminate the need for hydraulic oil and can reduce energy costs. Greater efficiency has helped to stimulate manufacturers’ interest in electrical and hybrid designs. For many of them, peace of mind comes from knowing that their press brakes will produce bends to precise specifications without the need to adjust for changes in oil temperature, which is more than enough reason to switch to an electric or hybrid system. For others, the frustrations they have endured due to imprecise bends, such as unnecessary costs and stress, are a reason for pushing toward Industry 4.0. In simpler terms, hybrid and electric bending presses can help manufacturers dramatically simplify downstream operations, saving time and money while increasing customer satisfaction. Accuracy and energy savings are therefore driving manufacturers to invest in hybrid press brakes, which require much less maintenance because they use significantly fewer valves and less oil, or electrical press brakes, which are completely oil-free. Choose your next press carefully: rely on the experts!
There is one thing in VICLA that nothing could break or bend. It is our system of values based on the principles of maximum efficiency and utmost attention to detail. Each machine leaving the factory is in fact manufactured by merging all the creative capacity and typical innovation of Made in Italy with top sector professionals and engineering skills. This results in extremely strong, stable, ergonomic and precise products. Starting with the VICLA flagship product and technological and innovative gem, the hybrid press brake .SUPERIOR or .FIRST compact bending press for small and medium-sized bends, up to the .DIAMOND guillotine shears manufactured to guarantee extremely precise cuts. Use of the best Italian and European parts completes the circle of our inspirational philosophy to obtain maximum quality and efficiency. This is why our company has a long-standing collaboration with the Swiss Hoerbiger Group, a world leader in the production of parts for sheet metal machining and in the sectors of compression and drive technologies, production of hydraulic systems and numerous mechanical engineering applications. A partnership for our clients that guarantees utmost levels of reliability and state-of-the-art technical equipment. State-of-the-art technology used by VICLA Hybrid System as standard on the .SUPERIOR press brake: this technology is offered without additional costs compared to traditional machinery, and ensures considerable energy savings (55%), and a significant reduction in oil consumption, risk of leaks (70%) and pollutants. Qualities that make the entire production system highly efficient and increases productivity by 20%. This is just one of many examples of the style and philosophy behind the VICLA brand, a way of working that has proudly brought us satisfaction and recognition. Last but not least is the great commercial and marketing acclaim received at the prestigious Euroblech 2016 international fair in Hanover: the world's number one event in the field of sheet metal processing, where we were the protagonists. In terms of turn-out, image and gratification. Find out how to choose your next press: rely on the experts!
Software 4.0 integrated into VICLA press brakes can increase company performance by at least 20%. The world of press brake bending is moving increasingly towards interconnected and automated production processes, and Industry 4.0 is certainly changing the way we work. That is why VICLA press brakes come with software to help collect, analyse and improve the performance of your company. We have always focussed on innovation, and this led us to integrate advanced solutions for the smart factory when developing our range of press brakes. Let's look at the solutions. Why choose a 4.0 press brake Press brakes have undergone an incredible evolution in recent years, transforming them from simple bending machines into truly technologically advanced and complex systems. And, while this has allowed the most modern companies to equip themselves with efficient, high-performance press brakes that improve production, more traditional entrepreneurs, accustomed to old press brakes that are no longer fully functional, continue to mistrust and fear innovation 4.0. Let’s take a brief look at how a 4.0 press brake can significantly improve production in your company and why: A 4.0 press brake is a smart machine: it can store and use huge amounts of data to continuously improve production. The CNC is connected directly to the company network and programmed by the technical office: the benefit of remote programming is that it considerably reduces downtime and guarantees full control of bending collisions. The high level of safety equipment: a 4.0 press brake is equipped with technologies and devices that reduce variability and dependence on the human factor, as well as the risk of accidents. The devices installed on our press brakes protect operators without limiting the working speed. Later we will see how our press brakes combined with software 4.0 can help you increase your industrial production by at least 20%. Data Rec and Track Prod software: software 4.0 for VICLA sheet metal press brakes Our press brakes all come with software 4.0. Already mechanically robust and tested, all VICLA machines come with our software 4.0 to communicate with the company management software in order to provide data that can be used to optimise the entire production process. We have already seen what a 4.0 press brake is; now we will see how our software increases company performance by at least 20%. The first of the two tools is Software Data Rec It features functions to: acquire data from the machine and enter it into an SQL or Access database; provide detailed information for job scheduling: e.g. workpiece production times with manual, semi-automatic or automatic processing; access time data related to programming, tooling, testing the first workpiece, workpiece processing. The second is Software Track Prod This software can: Monitor, display and trace data in the company management software and enhance the entire production cycle. Acquire information, analyses and reports in order to optimise machine use Identify critical conditions: an Alarm History provides a report of the messages sent by the machine. These two programs can then analyse the production flow in real time and detect any critical conditions so that you can act in real time to correct, reduce and eliminate errors. The great benefit of this software is that it promotes an approach based on data analysis by operators and the company organisation, which can lead to significant production performance improvements. In fact, our customers can testify that their company performance has been improved significantly by optimising production processes and reducing waste.
If there is a versatile machine in the workshop, it's the press brake. There are hundreds of variants with different performance capabilities, but all have a recognisable architecture. It might seem to be a simple machine made up of relatively few parts, which performs a simple, even trivial, process. Nothing could be further from the truth! A good press brake in the hands of a great operator can create real works of art. In the hands of an inexpert operator, on the other hand, it risks becoming the root of big problems. However, it should be noted that experience alone will not prevent mistakes. Often, even experienced operators can have bad habits or insufficient awareness, or can underestimate risks, resulting in damage of various kinds. In practice, here are five mistakes to avoid with your press brake: 1) Neglecting cleaning What many consider to be a mere waste of time is actually one of the primary procedures to be carried out as standard practice. A clean machine is also a monitored machine, because damage or small oil leaks can appear at any point. 2) Not carrying out maintenance Operators must not only be able to bend, but also to take care of those aspects of their machines for which they are responsible. No company expects press brake operators to know how to disassemble and reassemble a press brake. However, operators should be responsible for all aspects of normal lubrication, proper cleaning of moving parts, and reporting any anomalies, even the smallest. 3) Attempting to bypass safety systems A rather burning topic, also because those who violate the minimum safety rules usually have a wide range of excuses to justify their actions. In reality, today's safety systems, such as the widely used multi-beam photocells, can be considered quite mature. There are no longer any excuses: the systems anchored to the machine beam no longer impede the process, unless they are not set up correctly. What’s more, nowadays modern systems are difficult to bypass. If an operator must raise a photocell because of some workpiece with a complex shape that cannot be made in any other way, they must be aware that the working speed cannot exceed 10 mm/s by law. 4) Concentrating forces in small areas One of the most common misjudgements is to confuse the total force needed to bend a given workpiece with the tons per meter for the specific thickness, material and die. When, for example, bending a 15 mm stainless steel bracket that is 100 mm wide using a die with V = 100 mm, the total force required would be about 26 tons. However, even though the machine has a much higher capacity, a similar force concentrated in a small area can not only ruin the tools, but even deform the machine structure. That is why the force to be assessed in order to establish whether the processing is feasible must always be expressed in Tons/m! 5) Using the machine improperly It will seem obvious to most, but the press brake is made for bending. In addition to the problems already mentioned, which can result from underestimating the tonnage per metre, there are those that arise when operators use the press brake improperly. For example, using the bed as if it were an anvil for fixing badly-made workpieces or for processing other than bending that involves excessive stresses, such as straightening, drawing with home-made dies, etc. Problems can arise even when urethane dies are used brutally, expecting them to perform a 90° bend in one stroke, dangerously stressing the proportional valves as they rise and wearing the tools out quickly. To these we could add many other misuses that, besides damaging the machine, can also cause serious injuries to the operators. So, press brakes are among the machine tools that are most subject to interpretation during use, leaving room for the imagination. It is up to operators to respect them and take care of them in order to extend their life and efficiency.
The importance of having the right equipment to achieve great results is often mentioned. In this case, it is not just the quality of what you have that is important, but how you use and look after it is also essential. In fact, improper use and poor maintenance are factors that will demolish even the best equipment over time. That is why, when it comes to press brake bending, you have to remember that a machine is to the operator what a winning horse is to the jockey. Looking after your press brake is a duty that, however, makes it a pleasure to work with! But what are the best practices for looking after your machine properly? 1) Know your machine technically Managing your press brake properly and taking care of it is undoubtedly the first step in making it last a long time. 2) Lubricate the machine correctly and consistently The press brake is an orchestra of moving mechanical parts conducted by electrical and electronic systems. It is extremely important to follow the manufacturer's specifications carefully regarding lubrication frequency and the location of the lubrication points. Proper lubrication also means using high-quality greases and oils, chosen exclusively on the basis of the manufacturer's specifications. The points that require lubrication include: the beam sliding points, the rear carriage and any bending supports. If there is a centralised lubrication system, check it methodically. 3) Clean the machine A clean press brake is not just beautiful to look at, but is also efficient! Usually, you can only see oil leaks if the machine is perfectly clean, even small ones such as seepage from the cylinders, or abnormal drips in the backgauge area or on the floor inside the machine. Proper cleaning means following the manufacturer’s specifications and not using aggressive detergents or other unsuitable products. In addition to this, take great care to avoid cleaning the optical scales improperly! If in doubt, contact the manufacturer. 4) Generally check correct operation and settings A press brake is composed of many moving parts, including some large ones. These large masses are actuated repeatedly for millions of cycles in a year, with extremely tight tolerances. Just think of a beam that weighs thousands of kilograms: during each cycle it is “dropped” and then braked to slow it down in just a few tenths of a millimetre. It is taken to bottom dead centre (BDC) with an accuracy in the order of hundredths of a millimetre, and is then raised for the next bend. Inertia, vibration and continuous stress can wear out some susceptible components over time. Operators who work diligently must also be diligent in relation to their machines, and immediately report any kind of anomaly, even the smallest. Only they can recognise the signs of potentially much larger problems that will harm the machine and production. For example, small gaps in the backgauge or poor positioning accuracy. Obviously, the first step is to choose a manufacturer that is able to make high-quality press brakes in order to eliminate almost all of these kinds of problem. 5) Keep the tools and bed clean Keep the mating surfaces between the dies, punches and machine clean. In fact, when bending materials such as carbon steel, or when stainless steel has small slag balls in the corners of the holes and edges caused by an imperfect laser cut, these residues often end up on the press bed. If they are not removed, they can score the supporting bases, which may compromise optimal bending over the years.
VICLA press brakes are made based on strong features: frame sturdiness, maximum efficiency, and outstanding bending accuracy. For top quality that is also expressed through the most advanced and innovative technical solutions. An example of such a solution is 3D PROV, programming software for preparing and processing 3D products that offers multiple benefits. Such as the use of automated systems that can speed up the management times of the entire process (from design to finished product), minimum downtimes thanks to the offline programming feature, fewer discarded pieces thanks to collision control during bending sequence, tool library compatibility that allows for checking the availability of the tools required for production. Some of the main features of the 3D PROV are: Direct import from SolidWorks, Solid Edge and Inventor; Import and development of 3D parts in IGES and STEP formats; Automated and manual setup based on the type of material, machine and tool properties; Automated and manual bending sequence with collision control; Automated and manual calculation of retainer position and ledge with interactive graphical control on all axes; Automated calculation of retainer retraction; 3D simulation of the bending process with collision control; Detailed report on machine setup stations, also including bending sequences, used tools, graphical information, and bending specifications. The 3D PROV programming software ensures maximum efficiency in tool selection, based on bend radius, maximum press brake force, collision control, and the availability of different tool types and splits. To make the machine even more efficient, you can have full control over the hemming process, because the software allows you to set the default tools for automatic recognition as well as the pre-bending angle (default and editable value). 3D PROV can also calculate the bending parameters automatically to avoid any collisions, taking account of the availability of tool splits, horn tools and inward back-bending. Full manual control with split of complete bends into partial bends and the option to set the pre-bending angle and interactive change of the bending sequence order. For retainer positioning, 3D PROV offers automatic and manual backgauge control options with automatic 3D simulation (retainers, tools, piece to bend, machine frame) and collision control with all parts in motion. The software also provides a full setup report, from bending sequence instructions to charts containing detailed information for each bend.
A modern CNC press brake can cut down on maintenance costs while improving the production performances. Over the years, manufacturers have been developing different solutions to improve the performance of their products. Through tools, functionalities and technological innovations sheet metal press brakes have evolved starting from mechanical presses to hybrid cnc press brakes. Recently we have produced two hybrid cnc press brakes to a Russian company specialized in metal and alloy processing for the design and furniture sectors. The need to reduce production costs, create many product prototypes and complete orders in a short time, were the reasons that convinced the company to buy our cnc hybrid press brakes. Scroll at the bottom to read the technical specs of these two industrial press brakes. Let's now have a closer look at the real benefits of a hybrid sheet metal press brake. Hybrid cnc press brake: less consumption and environmental impact In a traditional hydraulic press, a big pump is constantly active, whether the machine is working or not. In this way there is high and useless energy and heat dissipation. VICLA's hybrid system allows the machine to consume energy only when the pedal is activated. This means that the consumption of the press brake is minimum when tools are changed and, in general, during those steps in which the crosspiece is not involved. Low oil consumption is another key point. The quantity of oil used in our bending machines is dramatically low compared to traditional hydraulic press. Small oil tanks translate into many advantages, such as: more savings less environmental impact less maintenance costs A quicker production The brushless engines are directly connected to two small oil tanks. The advantage is that the cnc press brake is more precise and is not affected by temperature variation, as opposed to traditional machines. Moreover, such as in the case of hybrid press brakes that we have recently sent to Russia, the addition of high-tech devices to perfectly control both the bending precision and the structural flexions of frames, allow to achieve unrivaled performances. CNC press brakes: special configuration We recently produced two hybrid sheet metal press brakes for a client based in Russia and specialized in the processing of high-end furnitures. The company requirements in terms of adds-on and personalization included the choice of adding two special devices that control the bending precision and the structural flexions of the frames. See below the detailed configuration of each hybrid cnc press brake. Hybrid CNC sheet metal press brake VICLA .SUPERIOR 50/20 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Hydraulic crowning system managed by CNC Optical scales and high speed photocellls IRIS LazerSafe Tooling set for punches and dies Main power 5,5kW Oil capacity 80l Hybrid CNC sheet metal press brake VICLA .SUPERIOR 110/31 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Dynamic hydraulic crowning system managed by CNC (Clever Crowning) Management of the structural flexions of the frames (Flex System) Optical scales photocells with double optical path Lazersafe Manual quick system clamping of the punches Tooling set for punches and dies Main power: 11kW Oil capacity 50l + 50l Call us or contact us for more information Now that you now exactly how a hybrid cnc press brake can improve your production, you may want to receive a personalized quotation. Use our online configurator or contact us by filling out this form. Our international team will be more than happy to provide you with all the necessary information you need.
Superior in every aspect, even in terms of power saving, low consumption and environment protection. .SUPERIOR is a sheet metal press brake made by VICLA, able to bend and cut the costs of the entire manufacturing cycle, reducing them to a minimum, while speeding up the production times to maximum velocity. Hybrid System The standard version is equipped with an innovative hybrid system and comes at the same price as a traditional machine, ensuring exceptional power savings and a massive reduction in oil consumption thanks to the use of the double tank. The results in numbers of this technological innovation are: power savings of up to 55%, significant oil consumption reduction (e.g.: 2X40 litres – press of 110 t), output increased by 20%, 20% decrease in fast-up limit, 50% decrease in oil temperature, risk of leakages reduced by 70%, tank volume reduced by 50%, and 50% faster and easier installation. With VICLA Hybrid System, the piping system is reduced by up to 60%. Hybrid System Plus All these advantages translate into greater performance of the manufacturing system and perfect finished products. In one word: quality. Not only in terms of stability of the frame and the bending precision, but also with regard to power saving and environment protection. The Hybrid System is a standard feature included in the standard version of the .SUPERIOR press brake, but the system is however extremely versatile: optional features and accessories or custom-made solutions are also available, depending on every production requirement. Hybrid System Plus: the system that cuts down consumption to 78% compared to traditional machines and to 23% compared to the standard Hybrid System. This is VICLA’s pursuit to ensure absolute quality. Daily investments in research and development, entrusted to highly skilled engineers and staff with top qualification and skills in metal working. Ongoing efforts that show the first evidence of achievement of new and important goals. First of all, an innovative system for automated die change will be shortly completed.