In an industry where precision and speed are paramount, angle control has become an indispensable ally for press brakes, meeting the growing need for companies to produce the right part on the first try. If you don't want to read the full article, scroll down and watch the video. How does it work? The system measures the bending angle in real-time using optical or laser sensors. It compares the measured value to the programmed value and, if necessary, makes automatic corrections to the bending process. This ensures precise and repeatable angles, eliminating the need for manual measurements and subsequent corrections. Many companies hesitate to invest in angle control due to the initial cost and fear of slowing down the bending cycle. However, they often underestimate the hidden costs associated with a lack of precision: time wasted on manual measurements, material scrap, and continuous adjustments. If we were to analyze a typical 8-hour work shift, we would notice that half of the time is often dedicated to these manual operations, to the detriment of actual production. An angle control system, on the other hand, drastically reduces this waste, ensuring more efficient and high-quality production. In the long run, therefore, an angle control system is an investment that pays for itself. For this reason, many companies are investing in this type of solution to increase their productivity. Benefits of Angle Control Increased productivity: By reducing inspection times and eliminating manual corrections, angle control significantly increases productivity. Improved quality: By ensuring precise and consistent bend angles, higher quality parts are produced, reducing the number of rejects. Flexibility: Thanks to the ability to work with different materials and thicknesses, angle control adapts to a wide range of applications. Versatility: VICLA has developed an angle control system that allows for two main operating modes, utilizing a material database or operating in free mode. Different Types of Angle Control VICLA offers two angle control solutions, including one integrated into photocells, such as the Iris Plus. This option is particularly suitable for small press brakes, usually up to about 2 meters in length. It works through an image acquisition system: a camera integrated into the photocell takes a series of frames of the profile during bending, correcting in real-time to achieve the desired angle. This solution is ideal for small-scale production. The choice of Iris Plus is advantageous for its ease of use: being integrated into the photocells, it does not require additional installation. Moreover, thanks to its compact size, it does not take up valuable space inside the machine. However, it is important to note that this solution has some limitations. On large machines, it may be difficult to obtain an accurate measurement due to the length of the parts. Additionally, for parts with complex bends, such as multiple or overlapping bends, a different solution is required. A Cutting-edge System for Maximum Quality The second solution offered by VICLA is V-Control, a state-of-the-art angle control system that uses two laser sensors to precisely measure the bending angle during the process. Thanks to its ability to dynamically measure the angle, calculate material springback, and make the necessary corrections in real-time, V-Control guarantees the highest quality results. V-Control can be used with various methodologies Method with preset springback: Used with the values in the database, it is the fastest method that allows real-time control and correction at multiple points on the sheet metal. Method with strain gauges: Perfect for long and thick parts. Through special strain gauges mounted on the shoulders of the machine, it takes measurements at multiple points, detecting deflection and consequently the resulting angle, and automatically correcting it. Real-time measurement method: The most versatile method, which involves measuring at a single point, ideal for short profiles. It allows for real-time angle correction. It is recommended when there is no information in the database (of material and tools), measuring the springback with absolute precision. The great advantage is that it allows companies to build and configure a database with real data. It is important to highlight that all the described methods allow the system to learn the correct angle and automatically apply it to subsequent bends. V-Control: Versatile and Precise The VICLA angle control system stands out for its versatility and precision. Thanks to the ability to work with or without a database of data, it offers maximum flexibility to the operator. When working with new materials or tools, real-time angle control becomes essential. This process, although slightly longer, allows you to precisely determine the material's behavior and compensate for springback. In practice, a pre-bend is performed at an angle slightly higher than the desired one (usually 5°), the elastic deformation is measured, and the final correction is made. This approach guarantees maximum precision even in non-optimal conditions. The VICLA solution stands out from the competition for its flexibility. While other manufacturers impose the use of specific tools and databases, VICLA offers the customer the freedom to work with any type of tool, even worn or special. This means that it is possible to obtain optimal results even in situations where pre-set data is not available. Conclusion VICLA's angle control is a tool that supports and improves the work of operators, regardless of their experience level. Thanks to real-time measurement and automatic correction, V-Control delivers perfect parts from the first bend, reduces scrap, and increases productivity, improving the company's competitiveness.
Cold bending of AISI 304 stainless steel is a fundamental process in the food industry. To achieve precise and durable results, it's essential to understand the principles of bending force and flat pattern development. As detailed in our exploration of materials used in sheet metal fabrication, AISI 304 stainless steel is commonly used in the food industry due to its corrosion resistance and easy cleaning. However, cold bending AISI 304 stainless steel can be challenging due to its high hardness and strength. Stainless steel is tough and tenacious, so you'll need to consider specific technical aspects to achieve the desired outcome. This guide will explain everything you need to know to bend stainless steel correctly, from the force required to bend it to the precision needed for tools that come into contact with food. Determining the Bending Force Bending stainless steel requires a specific amount of force to achieve the desired curve. This force depends on several factors, including the thickness of the sheet, the length of the bend, and the desired radius of the bend. The bending force can be calculated using the following formula: F = K * t * L * (1/R) where: F = bending force (Newtons) K = bending factor (a value that reflects the material's resistance to bending) t = sheet thickness (millimeters) L = bend length (millimeters) R = bend radius (millimeters) The bending factor (K) is a material property that accounts for its resistance to deformation. It varies depending on the type of stainless steel and the specific bending conditions. For AISI 304 stainless steel, a typical value for K is around 1.5. We've written a specific guide that explains step-by-step what the sheet metal K factor is and how to calculate it, along with an automatic calculator. Flat Pattern Development: The Secret to Perfect Shape Imagine you want to create a tin box. To bend the sheet metal and create the side walls, you need to know exactly how much material you need. The flat pattern is precisely that: the length of the sheet metal that, once bent, will create the desired shape. To calculate the development, we use the following formula: Ld = L + 2 * R * sin(α/2) Where: Ld is the flat pattern length L is the bend length R is the bend radius α is the bend angle The sine (sin) is a trigonometric function that helps us calculate the length of the arc of a circle that corresponds to the bend angle. Example: Suppose we want to create a 90° bend on a sheet with a 10mm bend radius. The bend length is 50mm. By calculating the flat pattern, we will obtain the total length of the sheet needed to make this bend. Dimensional Tolerances: Precision Makes the Difference In the food industry, precision is essential. Imagine a gasket that doesn't fit perfectly on a lid: it could cause leaks and contamination. Dimensional tolerances define the range within which a measurement can vary without compromising the component's functionality. For stainless steel bending, tolerances are generally very tight. This is because components for the food industry must be interchangeable and work perfectly with other machine elements. ISO 2768-1 and ISO 2768-2 standards provide precise guidelines on dimensional tolerances for metalworking. These standards ensure that components produced in different parts of the world are compatible with each other.
The press brake operator is a skilled industrial professional responsible for bending and shaping sheet metal into a wide variety of forms using a brake press, such as cnc press brakes or other types of bending brakes. From the sleek curves of automotive components to the sturdy frames of construction materials, press brake operators play a vital role in modern manufacturing. A Day in the Life of a Press Brake Operator A typical workday for a press brake operator involves a dynamic blend of physical and mental exertion. Setup and Operation The day often begins with setting up the press brake machine. This involves selecting and installing the appropriate tools and dies – specialized metalworking tools designed to create specific bends. Operators meticulously adjust machine settings, ensuring optimal performance and precision. Blueprints and Specifications Operators meticulously study blueprints and work orders, translating complex technical drawings into precise machine movements. They must accurately interpret dimensions, angles, and tolerances to achieve the desired shape and size. The Bending Process The bending process itself requires focus and skill. Operators carefully position and secure the sheet metal within the press brake, then initiate the bending cycle. They monitor the process closely, ensuring the metal is bent to the exact specifications. Quality Control Quality control is paramount. Operators utilize a variety of measuring tools, such as calipers and gauges, to meticulously inspect each finished part, ensuring it meets the stringent quality standards set by the manufacturer. Maintenance and Troubleshooting Press brake operators are often responsible for basic machine maintenance, including lubrication and minor repairs. They must possess the ability to troubleshoot minor mechanical issues and quickly resolve any problems that may arise during operation. Safety First Safety is an absolute priority. Operators adhere to strict safety protocols, including wearing appropriate personal protective equipment (PPE) and ensuring the work area is clean and free of hazards. Is a press operator a hard job? As a press operator, you stand for long hours and spend most of the day moving around the production floor. You require physical stamina to stand for long periods and move heavy objects. Aside from physical skills, you require good eyesight and manual dexterity since you work with small objects and use hand tools to carry out maintenance tasks. Moreover, it requires the ability to work with different types of bending brakes, each with its own specifications. For example, CNC press brakes are much more easier to use than manual press brakes, but they require familiarity and confidence in setting up the programs correctly. Essential Skills and Qualifications A strong understanding of mechanical systems is crucial. Operators must be able to troubleshoot basic mechanical problems and understand how the press brake functions. Accurate measurements and calculations are essential, as press brake operators must be able to read and interpret blueprints, perform basic trigonometry, and understand tolerances. In addition, working with metal requires a steady hand and a keen eye for detail. Operators must be able to handle tools with precision and consistently produce high-quality parts. As a press operator, you stand for long hours and spend most of the day moving around the production floor. You require physical stamina to stand for long periods and move heavy objects. Aside from physical skills, you require good eyesight and manual dexterity since you work with small objects and use hand tools to carry out maintenance tasks. Press brake operators often work closely with other members of the manufacturing team, such as welders and assemblers. Effective communication helps convey information accurately and timely, ensuring seamless operations. Similarly, problem solving and adaptability skills allow operators to handle unexpected issues promptly without major disruptions, contributing to the overall productivity of the team. Safety Considerations Press brake operation presents significant risks, regardless of the machine's age. Operators face dangers at the point of operation, particularly at the front and sides of the machine where access points might be present despite safety guards. While US regulations often place the burden of safeguarding on the end-user, European standards require manufacturers to ship machines with adequate safety features in place. Furthermore, pinch points between moving parts and rapidly moving components like backgauges pose serious hazards. The use of older, refurbished press brakes introduces additional concerns. The condition of the machine, including the integrity of safety systems and the reliability of control systems, may be uncertain. If a company lacks in-house expertise in machine safety, critical safeguards might be overlooked or inadequately maintained. Given the collaborative nature of press brake operation, with multiple personnel often involved, and the inherent unpredictability of machine behavior, it's crucial to designate a single operator as the crew leader. This designated operator is responsible for ensuring coordinated and safe operations for the entire team Career Progression and Salary The role of a press brake operator is a challenging yet rewarding one. It requires a unique blend of skills, including mechanical aptitude, physical stamina, and a strong commitment to safety. For those who possess these qualities and enjoy working with their hands, a career as a press brake operator can be a fulfilling and rewarding path in various ways: Lead Press Brake Operator: Supervise a team of press brake operators, ensuring efficient production and maintaining high-quality standards. Maintenance Technician: Specialize in the maintenance and repair of press brake machines and other related equipment. Tool and Die Maker: Develop and fabricate the specialized tools and dies used in the bending process. Manufacturing Supervisor: Oversee the entire production process, including press brake operations, welding, and assembly. Best practice when operating on a brake press Sheet metal bending often represents a production bottleneck. Issues such as poor organization, lack of historical data, and human error can significantly impact efficiency. The continuous decision-making involved in bending operations can introduce variability and inefficiencies. Without careful analysis, these decisions can lead to non-conformities, material waste, and errors. One of the most effective, yet often overlooked, strategies is regular data collection. By tracking key metrics, you can identify areas for improvement and validate the effectiveness of changes. A Practical Example: Reducing Cycle Time Let's say you want to reduce the cycle time for a repetitive part. Start by analyzing the current state and identifying quick wins. By maintaining the same work pace, you can easily determine if changes have led to improvements in production or quality. Pre-Bending Improvements: Organize materials: Group similar parts together to facilitate easy identification and reduce search time. Consider material orientation: Stack sheets with the same grain direction together to minimize variations in bending behavior. Optimize pallet layoutArrange parts on pallets to minimize handling and maximize efficiency. Designate a specific unloading area: Ensure the unloading area is clear and easily accessible. Implement a structured delivery system: Use carts or racks to deliver materials to the press brake in a predetermined sequence. Ergonomic Considerations Adjust working height: Ensure that parts are easily accessible to reduce strain on the operator. Minimize movement: Organize the workspace to reduce the distance the operator must move to retrieve parts and tools. Improving Your Bending Operation: A Checklist Let's explore seven key procedures that can significantly enhance your bending department: Operator Accountability for Drawing Errors Even if a drawing error causes a problem, the operator should flag it. Common issues include: Incorrect orthographic projections Missing surface finish specifications Omitted threads or chamfers Missing dimensions or tolerances By identifying these errors, operators can prevent mistakes and become more familiar with the part. Verify Part and Drawing Match Ensure that you're working with the correct part and drawing, especially when dealing with similar parts. Even small details can make a big difference. Utilize CNC Program Memory Instead of reprogramming the press brake for each part, save programs for future use. This saves time and reduces errors. Standardize Tool Identification Create a consistent naming system for tooling to avoid confusion. Use a system that clearly identifies the tool's dimensions and characteristics. Verify Bend Angles and Dimensions Always check bend angles and dimensions against the drawing to ensure accuracy. Use appropriate measuring tools like digital calipers and protractors. Invest in Quality Measurement Tools Equip your department with the necessary measuring tools, such as digital calipers, protractors, and electronic levels. The choice of tools will depend on the level of precision required. Save and Update Programs Save all programs using a clear and consistent naming convention that corresponds to the part number. This will make it easy to retrieve programs in the future. Additional Tips for Optimization Continuous Improvement: encourage a culture of continuous improvement by seeking feedback from operators and implementing changes based on data. Operator Training: provide comprehensive training to ensure that operators understand the bending process and quality standards. Preventive Maintenance: regularly maintain your press brake and tooling to ensure optimal performance and minimize downtime. Lean Manufacturing: apply lean principles to identify and eliminate waste in your bending operations. The 5S principle can be applied effectively to the sheet metal manufacturing process as it helps creating a more efficient, productive, and safe work environment – all core tenets of lean manufacturing. If you are curious to learn more on how to create a five-step methodology for organizing and cleaning the workplace, read the case history of VICLA Manufacturer of Sheet Metal Machines. Visual Aids: Use visual aids, such as work instructions and checklists, to support operators and ensure consistency.
Bending steel and high-strength materials requires perfect precision and parallelism, as even the slightest variation can affect the mechanical and aesthetic characteristics of the finished product. The widespread use of these materials in various sectors beyond the more established construction, earthmoving, naval, railway, industrial vehicles, and container industries, has presented new challenges for press brake manufacturers. To meet these demands, it has been necessary to refine multiple aspects, from camber control to force management. Vicla, specializing in the design and construction of press brakes, shears, and automated sheet metal bending solutions, has been able to meet these needs by introducing various innovations and technological advancements over the years. These solutions, explains Marcello Ballacchino, founder and owner of the company along with Corrado Nucci, are the result of a decade-long collaboration and are adopted across our entire range of hybrid press brakes, including those in our top-of-the-line .Superior line. One such installation was recently completed on a 641-ton machine with a 4,600 mm working length – the most powerful ever produced by the company at its plant – commissioned by a major Italian manufacturer of trailers and semi-trailers. The press brake configuration The 641-ton .Superior hybrid press brake is a high-quality, high-performance machine that combines advanced hydraulic technology with optimized electronic management. Compared to conventional hydraulic press brakes, it offers energy efficiency that allows for up to a 55% reduction in electricity consumption, thanks to a hydraulic system designed to ensure low consumption and less oil use. Adaptive crowning is one of the distinctive technical aspects, guaranteeing precise control of the bend over the entire working surface. This technology, says Salvatore Schifano, Vicla's workshop manager, does not require in-depth technical knowledge. The system automatically adjusts the compensation for a linear bend, even on non-uniform materials, such as perforated/slotted elements mixed with solid material. At the customer's request, the .Superior press brake was developed with a rear stroke of 1,500 mm, compared to the more standard measurements of 700 or 1,000 mm. With a power of up to 641 tons over a 4,600 mm working length, the .Superior hybrid press brake produced by Vicla for a manufacturer in the trailer and semi-trailer construction sector stands out for its modularity and capacity for future upgrades. The version produced is already very high-performing and complete, with a cylinder stroke of 500 mm, an opening of up to 800 mm, and a rear stroke of up to 1,500 mm. The equipment, adds Nucci, includes high-load tooling, supplied by one of our qualified partners, and a lower clamp with hydraulic locking for faster die changes. It is possible to mount dies with a 60 or 90-degree base, adapting to even larger sizes. Two sliding, orientable, and height-adjustable front supports, based on the mounted die, faciitate operations, while a real-time angle control system ensures precision.
A renowned Polish manufacturer of high-quality furniture accessories, based in Wąbrzeźno, has partnered with VICLA to elevate their production capabilities. The company, known for its reliability and timely delivery, supplies components to leading furniture brands both domestically and internationally, including kitchen accessories, bedroom furniture accessories, wardrobe components, sliding door systems, furniture legs, bed accessories, table accessories, furniture hinges, aluminum frames, and furniture frames. The Challenge As the company continued to grow, they faced increasing demand, tighter deadlines, and the need for greater efficiency. Their existing machinery was struggling to keep up, leading to production bottlenecks and delays. The Solution: VICLA's 6-Axis CNC Press Brake To address these challenges, the company invested in a state-of-the-art VICLA 6-axis CNC press brake. This advanced machine offers a range of features designed to boost productivity and improve product quality: Precision Bending: Ensures accurate and consistent bends, thanks to advanced angle control technology. Enhanced Efficiency: Reduces energy consumption and minimizes downtime with its efficient design. Versatility: Handles a wide range of materials and complex shapes. Ease of Use: User-friendly interface and intuitive controls. The Results By implementing the VICLA press brake, the company has experienced significant benefits: Increased Productivity: Faster production cycles and reduced setup times. Improved Quality: Consistent and accurate bends, minimizing errors and waste. Enhanced Efficiency: Lower energy consumption and reduced maintenance costs. Greater Flexibility: The ability to handle a wider range of products and materials. This successful partnership between VICLA and the furniture manufacturer demonstrates the power of advanced technology to drive productivity and improve product quality.
A renowned Polish manufacturer of high-quality furniture accessories, based in Gdów, has partnered with VICLA to enhance their production capabilities. The company, known for its reliability and timely delivery, supplies components to leading furniture brands both domestically and internationally, including kitchen accessories, bedroom furniture accessories, wardrobe components, sliding door systems, furniture legs, bed accessories, table accessories, furniture hinges, aluminum frames, and furniture frames. The Challenge As the company continued to grow, they faced increasing demand for their products, tighter deadlines, and the need for greater efficiency. Their existing machinery was struggling to keep up, leading to production bottlenecks and delays. The Solution: VICLA's Hybrid Press Brake To address these challenges, the company invested in a state-of-the-art VICLA hybrid press brake. This advanced machine offers a range of features designed to boost productivity and improve product quality: Real-time angle control: Ensures precise bending angles, reducing the need for manual adjustments and improving accuracy. Adaptive bending system: Automatically adjusts to material variations, delivering consistent bend quality. High-speed performance: Enables faster production cycles and increased output. Energy efficiency: Reduces energy consumption, lowering operational costs. Customizable configuration: Can be tailored to specific production needs. The Results By implementing the VICLA press brake, the company has experienced significant benefits: Increased productivity: Faster production cycles and reduced setup times. Improved quality: Consistent and accurate bends, minimizing errors and waste. Enhanced efficiency: Optimized energy consumption and reduced maintenance requirements. Greater flexibility: The ability to handle a wider range of materials and product designs. This successful partnership between VICLA and the furniture manufacturer demonstrates the power of advanced technology to drive productivity and improve product quality.
This renowned company in Czersk, specializing in supplying metal components for the furniture industry, has chosen Vicla, a manufacturer of sheet metal machinery, to boost the productivity of its processes. This strategy has materialized in the installation of a 40-ton, 1250 mm bending press. Why Purchase a New Press Brake? Based in Czersk, the company is a major supplier of furniture components to the largest European multinationals. Employing 70 people today, it's a third-party metalworking center specializing in producing items such as lift supports, brackets, bases for chairs, tables, beds, armchairs, and various types of hinges. The increasing demand for small-batch, custom parts prompted the company to invest in a new, small-sized bending press that was both incredibly fast and precise. A crucial prerequisite was the desire to find a reliable partner capable of producing a high-quality sheet metal machine. VICLA, a manufacturer of sheet metal machinery, was selected as the trusted partner to undertake this special project. The Bending Press A custom-made 40-ton bending press, with a 40-ton capacity and a 1250mm working plane length, 7 axes, and preparation for a bending robot. It is equipped with angle control photocells and a quick pneumatic lower tool clamping system. Angle Control Photocells By reducing the speed change point to 0mm, eliminating unnecessary slow speed travel, it guarantees time savings of up to 3 seconds per cycle. These photocells incorporate an integrated real-time image processor with real-time angle measurement data that includes the inside and outside angles of the material, average angle, material warp angle, material spring back angle for various material types, thickness, and grain direction, plus end of relaxation angle. The Results Thanks to this new sheet metal machine, the company is now able to complete orders more quickly, manage order peaks, and increase the productivity of its bending department.
Those who work in sheet metal fabrication know that shaping metal, even on an industrial scale, is a true art. When discussing sheet metal deformation, it's essential to understand the different bending techniques, as each influences the final product's design and functionality. A solid grasp of press brake operation, combined with a strong foundation in design principles, can significantly enhance the quality of the finished piece. Types of Sheet Metal Bending Sheet metal bending is a cold working process that permanently deforms the material by applying force through a punch. There are several bending techniques, each suited to different desired outcomes. Three-Point Bending This category includes air bending, bottoming, and coining. Air Bending In air bending, the sheet is suspended in air and the punch presses down on it, creating a bend. This method is versatile and allows for a wide range of bend angles. Bottoming Bottoming involves the punch fully contacting the bottom of the die, resulting in a more defined and consistent bend. In contrast with air bending, the principal point here is that the workpiece touches the walls of the die while being bent, forcing sheet metal into precise forms. Coining Coining is a high-force process that compresses the material between the punch and die, producing a very sharp bend. Coning is implemented in any case when a manufacturer needs a sheet metal to be stamped. It causes permanent deformation of the workpiece into the shape required. At the same time, it makes a workpiece to take the form engraved on the surface of the bottom die, if necessary. Hemming or Flattening The hemming technique, which requires specific tooling, is used for example to create edges that are safe to handle, or to reinforce thin sheet metal. It is usually performed in a two-step process: pre-bending creating an angle ranging from 35° to 26° (according to the sheet metal thickness) obtained with air bending process flattening process where the bend is completely or partially closed (hem). Tangential Bending This method uses a tangential punch to create bends where access is limited. Folding Metal folding involves a specialized automatic sheet metal folding machine where the sheet metal is clamped securely, and a folding beam moves up or down around a pivot point to create the bends. Unlike bending, which is often limited to single-axis deformation, folding allows for multiple bends in a single operation. This technique is well-suited for creating complex, three-dimensional shapes with interconnected bends, enhancing design flexibility and efficiency. Factors Affecting Bend Quality Material Properties: as explained in detail in this dedicated article, the type of metal, its thickness, and its hardness all affect the bending process. Tooling: the design of the punch and die, as well as their material, play a crucial role in achieving the desired bend. Read this guide and learn which are the most comming tooling in a press brake. Machine Setup: proper machine setup, including bed height, backgauge position, and tonnage, ensures accurate and repeatable bends; this is why we create a comprehensive guide which explains every single component of a press brake. Bending Technique: the chosen bending technique, whether it's air bending, bottoming, or coining, will impact the final result. Benefits of Sheet Metal Bending Versatility: Sheet metal bending can be used to create a wide variety of shapes and components. Precision: Modern press brakes and tooling enable highly accurate and repeatable bends. Efficiency: Automation and CNC controls have significantly increased the speed and efficiency of sheet metal bending. Cost-Effectiveness: Sheet metal bending is a cost-effective way to produce custom metal parts. Conclusion Sheet metal bending is a complex process that requires a deep understanding of materials, tooling, and machine operation. By carefully selecting the appropriate bending technique and equipment, manufacturers can produce high-quality components that meet the demands of various industries.
EVB Metalwork Fabrication, specializing in contract machining, has consistently prioritized machinery innovation to fuel its growth and evolution. One such example is their partnership with VICLA, which introduced the .Superior hybrid press brake to their workshop – a machine renowned for its ease of use and exceptional precision, perfectly suited for EVB's complex machining operations. EVB's history is a testament to its growth from a small, family-owned workshop in the 1960s to a respected player in the sheet metal working sector. Marco Butti, the company's current owner and grandson of the founder, shared insights into this journey, the challenges faced, and the pivotal role of technology, particularly the collaboration with VICLA, which marked a new era of success and innovation for the company. EVB Metalwork Fabrication was established in the 1960s and primarily focused on third-party metalwork services, including laser cutting, bending, and part assembly, explained Marco Butti. Initially focused on repairs and small jobs, the company has successfully adapted to market demands, technological advancements, and expanded its service offerings. We have always strived to evolve our metalwork products, emphasizing quality over quantity. The diversity of work EVB handles is a testament to its strength, ranging from small 1 kg parts to 25-meter-long plinths. This flexibility enables the company to consistently meet customer needs and maintain high productivity. Investing in Technology for Efficiency: Hybrid Press Brake Butti also highlighted a common challenge in the manufacturing sector: the shortage of skilled workers. Jobs are becoming increasingly complex, and there's a dwindling pool of skilled workers, he observed. In response, EVB has invested in new technologies and modern machinery to ensure efficiency and quality in their work. Over the years, we've consistently updated our equipment, he confirmed. A significant milestone in EVB's modernization was the collaboration with VICLA, a machine tool manufacturer. VICLA's .Superior hybrid press brake has elevated EVB's production standards. Butti noted, The .Superior, being a highly innovative machine, is remarkably intuitive and fast, even for those with limited bending experience. This insight translated into a noticeable improvement in productivity. The need to modernize their equipment became even more apparent when the operator of their previous bending machine retired. The old machine was barely usable, admitted Butti. To assess the new technology, EVB brought their own test parts to VICLA. They provided us with the .Superior press, we brought our own equipment, and spent half a day producing at VICLA, said Butti, describing a fruitful collaborative experience. The results were impressive: We noticed a completely different way of working: machining was done with greater productivity, he added. The new machine enabled EVB to tackle previously complex workpieces with ease, even empowering less experienced employees to work efficiently. The operator only needs to know how to use a smartphone to start bending with the VICLA press. Marco Butti emphasized that the new technology has made it possible to produce parts that previously required significant operator expertise. Now we can make them with much less hassle and time wasted on checking each individual part, he said. The VICLA press brake, in particular, has been instrumental in solving critical bending operations for paint plant conveyor tracks. These tracks demand precise tolerances and are complex to bend, being 1.5 to 3 meters long with narrow bends. Thanks to the precision of the VICLA machine, EVB has achieved higher output than before. The machine has simplified work not only in terms of time but also in terms of physical effort for operators. The attendant can follow the bending process step-by-step, ensuring greater accuracy and reducing operator strain. Hybrid Technology for Maximum Precision The VICLA .Superior hybrid press brake is designed to meet the precision and versatility requirements of modern production environments. Its robust and technologically advanced design ensures high performance and exceptional bending quality. One of its distinctive features is its hybrid configuration, which combines energy efficiency with superior performance. The electric drive system reduces energy consumption and promotes environmental sustainability, a crucial factor in today's industrial landscape. The .Superior is equipped with an advanced numerical control system for intuitive programming and easy operation. Operators benefit from a user-friendly interface that facilitates the input of machining parameters and the management of bending programs. This aspect has been highly appreciated by EVB and is a key strength of VICLA technology for Italian metalwork fabrication companies. Additionally, the machine integrates with CAD/CAM systems for seamless project management and production continuity. Other notable features of the .Superior include an automatic bending angle correction system, which guarantees accurate and repeatable results. This technology optimizes production processes, increases efficiency, and minimizes scrap. The .Superior bending brake is also designed to handle a wide range of materials and thicknesses, making it suitable for various industrial applications. This versatility is particularly valuable for subcontractors like EVB, who prioritize flexibility in their offerings. The machine's compact and versatile design also optimizes workspace, a significant advantage in the Italian industrial landscape where space is often limited and expensive. VICLA Bending Machines: A Partnership for Innovation Looking ahead, Butti confirmed that EVB continues to explore new investment opportunities in technology and strategic partnerships. While they considered acquiring a smaller press brake, personnel limitations presented a challenge. Despite these hurdles, their commitment to growth and innovation remains steadfast. The next purchase in this sector will still be VICLA, said Butti, highlighting the fruitful partnership that has laid the foundation for future success. EVB Metalwork Fabrication's experience and collaboration with VICLA exemplify the importance of investing in technology and innovation to maintain competitiveness in today's market. With a focus on the future and a strong commitment to quality and efficiency, EVB continues to be a model of how tradition can evolve to meet the new challenges of the modern industrial world.
Press brake tooling consists of punches and dies that are used to shape sheet metal into desired forms. The punch is the top tool that presses down on the material, while the die is the bottom tool that supports the material during the bending process. What is a press brake? A press brake is a machine used to bend sheet metal into various shapes. It consists of a top beam (punch) that moves vertically and a bottom beam (die) that remains stationary. The sheet metal is placed between the two beams, and the punch is pressed down to bend the material. There are several types of press brakes: mechanical press brakes, hydraulic press brakes, hybrid press brakes, CNC press brakes, Rotary press brakes. Read our comprehensive guide which explains each type of press brake. Choosing the Right Press Brake Tooling Selecting the appropriate tooling for your press brake is crucial for achieving accurate and efficient results. Here are some key factors to consider: Material Type: the thickness, strength, and ductility of the material will determine the best tooling options. Bend Angle: the desired bend angle will influence the choice of punch and die shapes. Bend Radius: the radius of the bend will impact the tooling requirements. Tooling Configuration: consider factors like V-die openings, punch profiles, and tooling materials. Press Brake Capacity: ensure your tooling is compatible with the tonnage capacity of your press brake. What material is used for press brake tooling? Press brake tooling is typically made from hardened tool steels or carbide materials. These materials offer excellent wear resistance, durability, and heat resistance, making them suitable for demanding bending applications. Setting Up Press Brake Tooling Proper setup of press brake tooling is essential for accurate and safe operation. Follow these general guidelines: Cleanliness: ensure the tooling and press brake bed are clean to prevent scratches and debris from affecting the bending process. Alignment: carefully align the punch and die to ensure proper contact with the material. Clamping: secure the tooling in place using the appropriate clamping mechanisms. Tonnage Adjustment: set the press brake tonnage to match the requirements of the material and bend. Safety Checks: conduct safety checks before operating the press brake to ensure proper setup and prevent accidents. Additional Consideration It is important to carry out a correct tool maintenance: regular maintenance, including cleaning, lubrication, and inspection, is essential for prolonging tool life and ensuring optimal performance. If your are interested in the topics, we have created a guideline for proper maintenance of the press brake. Top Tooling Types: Punches Punches are tools fixed to the ram by various fastening systems. Punches are essentially the blades that descend from above onto the sheet metal during bending, tracing the bend line and thus determining the subsequent height of the flange. They can be classified based on their characteristics, which will then tell us whether or not a tool is suitable for performing a bend. The mechanical and dimensional characteristics are always found in the catalog and are often stamped on the front of the punch. Product code: the name assigned by the manufacturer; it consists of a series of numbers that provide mechanical and dimensional information about the punch. Degrees: the inclination between the faces immediately adjacent to the tip radius. Visually, they already show whether a punch is designed to be able to make bends closer than 90°. Among the most common are those at 90° (specific for coining), 88° (excellent for deep drawing), 85°, 60°, 35°, 30°. These last ones are often called needle tools to emphasize their very pointed shape. They are used for common air bends and for performing the bend-squeeze operation. Height: the useful height which in the European standard is equal to the total height minus the 30 mm of the attachment to the intermediate. Tools with a greater height allow for good use in the creation of deep boxes. Radius: the radius of the punch tip and visually shows us what type of use it was designed for. Generally, a larger radius suggests use for thicker materials or for bending thin sheet metal but with very large-radius bends. Some tools have a flat tip and have specific uses, for example, if the flat vertex segment is quite long, in hemmed bends (calendering) of large thicknesses. Load: the maximum bending force that the punches can be subjected to, the limit beyond which the risk of irreversible deformations or breakage begins. Those known as swan neck, mostly suitable for tight and consecutive bends, can rarely have maximum loads comparable to those of straight tools, for a simple geometric reason. How to select a punch for your press brake There are many types of punches available for different jobs. The punch selection should be made only after knowing the basics of each type of press brake punches. These different punches are: Standard Punch The standard punch is the most common press brake tool. Its thick body and narrow tip generate high tonnage, suitable for bending thicker materials. The inward side has a slight concave curve with flat outsides, allowing for shorter flange folding. Acute Angle Punch Use acute angle punches for very short bends, typically 30° or less. They can also handle larger angles like 60°. These punches have a sharp tip and a generally bulky body. Narrow Punch Narrow punches are uniformly thin throughout. They fit in tight spaces where other punches might not. They're also known as sword punches. A common application is closing square or box profiles. Sash Punch Sash punches have a narrow body and an angled tip that bends inward. They're ideal for creating bends around corners, like door jambs and sashes. Swan Neck Punch Swan neck punches are used for marking applications and creating U-shaped profiles. Their unique shape prevents workpiece legs from colliding with the tooling. Gooseneck punches are similar but weaker due to the unsupported line of force. Joggle Punch Joggle punches are specialized tools for making bends around corners. Their thinner profile is ideal for creating S-shaped bends. They're less common and used for niche applications. Radius Top Punch Radius top punches have a rounded tip instead of a sharp one. This creates a U-shaped bend instead of a sharp V-shape. They're often used with a U-shaped die for rounded corners. Bottom Press Brake Tools: Dies Dies are the lower tools attached to the press brake table. They come in various shapes and sizes, but most have a V-shaped opening. Common V-opening angles range from 90° (for coining) to 30°. Multiple dies offer versatility, allowing you to bend different thicknesses without changing tools. However, they can be limited in height, especially for Z-shaped pieces with tight bends. T-dies are another option. They have a single V-opening but offer more flexibility in terms of dimensions. With a bit of experience, you can visually assess the suitability of a die for a particular bending application. Dies can be classified based on: Product code: a unique identifier for each die, assigned by the manufacturer. Degrees: the angle of the V-shaped opening in the die, determining the maximum bend angle. Radius: the radius of the rounded corners of the V, affecting the quality of the bend. Single V Die A single V die features a V-shaped cavity. They're the most common press brake die due to their versatility. The V-die opening should ideally be eight times the material thickness. Two-Way Self-Centering V Dies These dies have two parallel V-shaped cavities, streamlining the bending process. You can change bend angles without retooling. Multi V Die Multi V dies have multiple V cavities, offering various bending options. Rotating the die allows you to change bend angles or material thickness. Corrugating Dies Corrugating dies create a corrugated pattern on the sheet metal. They're used for specific applications requiring a textured surface. Flattening & Hemming Dies These dies fold and flatten the entire flange length in an acute angle bend. They come in sprung-loaded and U-section styles. Channel Forming Dies Channel forming dies create a U-shaped channel in one pass, instead of the traditional two-pass process using V dies. Tool clamping systems When selecting press brake tooling, it's essential to consider the clamping system. The clamping system significantly affects machine setup time. We've summarized 7 tips to optimize your press brake setup. Clamping System Types Tool clamping systems can be classified by their attachment type, like Promecam (European) or WILA. Upper and lower tool clamps can also vary by fastening technology: manual, semi-automatic, hydraulic, or pneumatic. Press brake tool storage Loading and unloading press brake tools is time-consuming. VICLA's automatic tool changer reduces setup time by up to five times. Learn all about automatic tool changers: what they are, how they work, and their benefits. Watch the video on how does an automatic press brake tooling storage works: