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 Tooling Types: 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.
One of the primary challenges faced by the sheet metal working industry is minimizing downtime between completing one batch of parts and starting the next. VICLA has addressed this issue by developing an innovative tool storage solution tailored to press brake tooling: ATC Automatic Tool Changer. VICLA ATC Tool Changer: Efficient Tool Storage, Loading, and Unloading Designed to streamline the interface between the press brakes and the storage system, the VICLA Automatic Tool Changer ensures quick, effortless, and safe storage, loading, and unloading of all sizes of punches and dies. Key Features of the Automatic Tool Changer Modular Design: Easily customizable to fit any press brake configuration and usage requirements. Scalability: Expand storage capacity by adding additional modules as needed. Versatile Options: Available in double input models and XXL sizes for large and heavy-duty press brakes. Comprehensive Tool Management: Efficiently store and manage not only punches and dies but also special tools like hemming tables. Key aspects of automatic load and unload of punches and dies This system is customisable and designed to measure according to client requirements; it reduces setup by 4 or 5 times compared to the ordinary manual operation and it automatically performs even the most complex equipment, managing tool sets up to 1-3/4” V opening and rod holding tools. The upper tools can also be rotated 180 degrees. It also allows the use of Promecam or WILA clamping systems. 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, recalling 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. Advantages: Reduction of set-up times Increase of productivity Customizable configuration Versatile and automated programming Simple and intuitive use Handling of complex setting Setup two press brakes at the same time 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. Offline programming One of the many 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. Need More Information? Whether you're seeking to optimize your press brake tool management or have specific questions, don't hesitate to contact us. Download our brochure or submit an online request for a quotation.
Springback is a frequent challenge encountered in sheet metal bending: it occurs when a bent piece of metal partially returns to its original shape after the bending force is released. This phenomenon is a result of the material's inherent elasticity. Why Does Springback Happen? Internal Stress: When a material is bent, its internal structure is stressed. Some parts of the material are compressed, while others are stretched. Elastic Recovery: When the bending force is removed, the compressed and stretched areas try to return to their original state, causing the material to partially straighten What's happening inside a bend When you bend a piece of metal, the outer part stretches (tensile stress), while the inner part compresses. There's a neutral layer where there's neither tension nor compression. The fibers in the outer stretched layers tend to pull the bend back towards its original shape, causing springback. Tensile Test To understand this better, scientists do a tensile test. They pull a piece of material until it breaks. This test shows how the material stretches and at what point it breaks. The tensile test, although simple, provides fundamental data for understanding the mechanical characteristics offered by a given material. To perform the test, a special hydraulic machine is used that has housings or clamps in which the ends of the specimen are inserted, which can have different shapes and sections but are standardized. This kind of reverse press has the characteristic of exerting a tensile stress, rather than a compressive one, and causes a tension in the specimen until the material yields and subsequently breaks. The entire test cycle is not random, but is carried out slowly and gradually, recording two fundamental quantities: the amount of pressure exerted; the percentage elongation of the specimen. These two measurements are translated into a graph that traces the progress of the deformation and rupture of the specimen in real time. What the stress-strain curve tells us: Elastic region (A-B): the material can return to its original shape if the load is removed. Yield point (B): the material starts to deform permanently. Plastic region (B-D): the material is permanently deformed. Fracture point (D): the material breaks What does it have to do with springback in metal bending? Returning to bending, we can understand that the zone around the neutral plane is the one that has undergone the least stress and has therefore remained in the elastic condition of the material: it is exactly where the fibers directly responsible for elastic recovery reside. The peripheral zones, on the other hand, are irreparably yielded and contribute to the stability of the deformation. We will see later the strong connection that exists between the neutral plane and the issue of sheet metal developments. Calculating Springback Accurately calculating springback requires understanding several factors: Modulus of Elasticity (MOE): Also known as Young's modulus, it measures a material's stiffness and resistance to deformation. Yield Strength: The point at which a material begins to deform plastically. K-factor: A multiplier that determines the neutral axis location within a bend. Read our full guide and use our online calculator for k-factor Inside Bend Radius: The radius of the inner curve of the bend. Material Thickness: The thickness of the sheet metal. Bend Angle: The desired angle of the bend. Luckly, modern press brakes, such as VICLA bending brakes, uses NC to predict and compensate for springback. Some advanced machines produced by VICLA provide devices that compensate for springback in real time. Factors Affecting Springback in metal bending: Yield Strength: Stronger materials exhibit more springback. Bend Radius: Sharper radii generally lead to less springback. Die Opening: Wider die openings in air forming can increase springback. Material Thickness: The relationship between bend radius and thickness impacts springback. Overcome Springback Springback depends on many variables related to the sheet metal, and each material reacts differently. In some high-strength steels, the springback is so pronounced that special equipment is required. So how do you compensate for springback? While coining was once a common method to address springback, it's generally not considered the most effective or efficient option today due to potential drawbacks. Bottom bending offers greater control over the bend angle compared to other methods, but it can be challenging due to the high tonnage requirements. Air forming, especially when paired with a modern CNC press brake, is a relatively stable process. However, variations within the same batch of sheet metal can still impact springback. Factors like thickness, grain direction, and tensile strength play a significant role. Achieving Perfect Bends For precise bending in applications where springback is critical, angle compensation feedback mechanisms can be employed. These systems utilize sensors, cameras, or lasers to monitor springback during the bending process and make real-time adjustments to ensure accurate results. Angle Control for Managing Springback Angle control systems are essential for effectively managing springback in sheet metal bending. These advanced technologies accurately measure and correct deviations in bend angles, ensuring precise and consistent results. By continuously monitoring the bending process, angle control systems can detect and compensate for springback in real-time. This eliminates the need for manual adjustments and reduces the risk of errors. Additionally, these systems can store historical data on springback behavior, allowing for optimized process settings and improved part quality. VICLA's angle control system is a state-of-the-art technology designed to deliver exceptional precision and performance in sheet metal bending. With its advanced capabilities, VICLA's system ensures consistent bend angles and minimizes the effects of springback. One of the key advantages of VICLA's angle control is its ability to learn and adapt. The system stores historical data on springback behavior, allowing it to continually refine its adjustments and optimize the bending process for specific materials and applications. Conclusion By understanding and addressing the factors that contribute to springback, you can significantly improve the accuracy and efficiency of your sheet metal bending processes. Implementing strategies like overbending, angle compensation, and proper tooling selection will help you achieve consistent results and minimize waste.
Hydraulic press brakes, known for their precision and power, utilize oil cylinders to control the bending process. While offering superior performance, they can be complex to maintain and may have higher operating costs. CNC hydraulic press brakes automate many functions, improving efficiency and accuracy. Synchronized hydraulic press brakes, a more advanced version such as VICLA .Smart model, use two independent cylinders for precise control and greater versatility. Components of an hydraulic press brake Hydraulic cylinders: these are the muscles of the machine. They generate the necessary force to push the bending ram down onto the metal sheet, creating the desired shape. Operator controls: think of these as the machine's steering wheel. They allow the operator to fine-tune the bending process by adjusting settings like the angle and pressure. Hydraulic fluid: this fluid acts as the machine's lifeblood, transmitting pressure from the cylinders to the bending ram. Die set: the die and punch are the tools that shape the metal. They're like cookie cutters, determining the final form of the bent piece. How Hydraulic Press Brakes Work The hydraulic press brake operates by harnessing the force of hydraulic fluid, which is controlled by modern computer technology. When the operator initiates the bending process, hydraulic pumps generate pressure. This pressure is transmitted through the hydraulic system, causing the ram to move vertically. The ram then applies force to the metal sheet, pressing it against the die to create the desired bend. The operator controls the ram's speed, position, and force using CNC machines or computer controls. This allows for precise adjustments and ensures high-quality bends. Hydraulic press brake in action: what happens during the bending phase When an operator activates the foot pedal to make a bend, the ram descends to a predetermined point. In reality, the bending cycle consists of several distinct phases, each with its specific function and name. Operator Input The operator sets the desired bending parameters, such as the angle, depth, and material type. Ram Descent The machine's ram moves downward towards the sheet metal. Bending As the ram descends, it presses the metal against the die, forming the desired shape. Dwell Time The ram remains in position for a brief period to ensure the bend is complete. Ram Ascent The ram moves back up to its starting position. Are hydraulic press brakes accurate? Hydraulic centering, also known as automatic crowning, is a system used to maintain consistent bend angles across the entire length of a workpiece. It compensates for the natural deflection of the press brake bed, ensuring precise and uniform bends. How does hydraulic crowning system work? Hydraulic centering is a system that uses high-pressure cylinders strategically placed within the press brake bed. These cylinders counteract the bed's natural deflection during bending, ensuring a consistent and parallel alignment between the punch and die. This, in turn, results in a workpiece with a uniform bend from center to side. The numerical control system can accurately predict the necessary force to apply to the hydraulic cylinders based on factors like the workpiece's dimensions, material, and the press brake's structure. This ensures optimal performance and precise bending results. Evolution of cnc hydraulic press brake Hybrid press brakes represent the pinnacle of press brake technology, offering significant advancements over traditional synchronized hydraulic press brakes. This innovative approach combines the best aspects of different systems, delivering exceptional results in terms of precision, repeatability, energy efficiency, and cost-effectiveness. Key benefits of hybrid press brakes include: Microscopic precision: ensures consistent and accurate bends. Energy efficiency: up to 78% energy savings compared to traditional hydraulic press brakes. Versatility: handles a wider range of applications than electric press brakes. Hybrid press brakes demonstrate the evolution of press brake technology, offering superior performance and efficiency while maintaining the versatility of traditional hydraulic press brakes. What can you create with an hydraulic press brake? Hydraulic press brakes are versatile tools used across numerous industries to transform sheet metal into various forms. Their precision, efficiency, and power make them indispensable in shaping components for everything from automobiles to buildings. The Automotive Industry Body panels: hydraulic press brakes form the intricate curves of car and truck bodies. Chassis components: frames, brackets, and other structural elements are shaped using these machines. Internal structures: dashboards, consoles, and other interior components are also formed with hydraulic press brakes. The Aerospace Industry Aircraft parts: wings, fuselages, and landing gear are shaped with precision using hydraulic press brakes. Structural components: internal frames and supports are fabricated to exacting standards. The Construction Industry Structural elements: beams, columns, and other components for buildings and bridges are formed using hydraulic press brakes. Metal roofing and wall panels: these machines create the intricate shapes needed for modern construction. HVAC components: ducts, vents, and other parts are fabricated using hydraulic press brakes. The Shipbuilding Industry Hull formation: large sheets of metal are bent and shaped to create the hull of ships. Internal structures: hydraulic press brakes form various internal components for ships. Tips for Choosing the Right Hydraulic Press Brake A common mistake when purchasing a hydraulic press brake is to focus solely on the brand name before considering your specific needs. While well-known brands often have a good reputation, it's crucial to prioritize your production requirements. Here are some key factors to consider. If you are interested in this topic, don't miss to read our utlimate guide on choosing the right press brake Workpiece Dimensions Length and Thickness Determine the maximum length and thickness of the material you'll be bending. For instance, if you're primarily working with 3mm thick carbon steel sheets up to 2500mm long, an 80-ton press brake is sufficient. Material Type Consider the different types of metals you'll be working with. Stainless steel, for example, requires significantly more bending force compared to carbon steel. Production Needs Batch Size If you have large production runs, a more powerful press brake might be necessary. For smaller batches, a smaller, more compact machine could be more suitable. Complexity of Bends The complexity of the bends you need to produce will also influence your choice. Features and Options Automation Consider the level of automation you require. Some press brakes offer features like automatic tool changing, which can increase productivity. VICLA's ATC Automatic Tool Changer reduces setup times compared to manual labor. It can manages multiple stations, different tools and can automatically setup up to two press brakes at the same time. Control System The control system should be user-friendly and offer the necessary programming capabilities for your specific applications. Read our guide which explains the different type of cnc press brakes and how they work. Hydraulic Press Break Cost and Budget The cost of a press brake is a significant factor to consider. However, it's essential to evaluate the machine's capabilities and features in relation to its price. A higher investment may be justified if it leads to increased productivity, improved accuracy, or reduced operating costs over time. Ask yourself: does the machine's cost align with its features and capabilities? Will the machine provide a positive return on investment through increased efficiency or cost savings? Vendor Support and Warranty Consider the vendor's after-sales support and warranty. A reputable vendor offers installation, training, and maintenance. A solid warranty provides peace of mind. VICLA is an Italian leading hydraulic press brake manufacturer known for quality and innovation. Our customizable CNC hydraulic press brakes offer a wide range of sizes and configurations. Contact us!
Sheet metal bending, a pivotal process in metal forming that dates back to ancient times, involves manipulating sheet metal into desired shapes through the application of force. This technique has evolved significantly with technological advancements, encompassing a range of methods like air bending, V bending, and U bending, each suited to specific applications. Metal bending is a complex process that requires careful consideration of various factors, including material properties, press brakes, tooling, and process parameters. The ability to consistently achieve accurate and high-quality bends is crucial in many industries. Today, commonly used machines for sheet metal bending include press brakes, rotary bending tools, and roll bending equipment, showcasing the versatility and adaptability of this process. These machines have evolved to offer greater precision, efficiency, and automation, allowing for the production of complex components in large volumes. Table of Contents History of Sheet Metal Bending Types of Sheet Metal Bending Importance of Sheet Metal Bending in Manufacturing Sheet Metal Bending Process, Design and Planning Common Materials Used in Sheet Metal Bending Sheet Metal Bending Machines Understanding Sheet Metal Bend Allowance and K-Factor Challenges and Solutions in Sheet Metal Bending Evolution of sheet metal forming Today's modern press brakes are equipped with sophisticated CNC systems, offering enhanced precision and efficiency. While the basic mechanical concept remains the same – bringing a punch to a matrix – the internal mechanisms and electronics have undergone substantial advancements. This evolution has transformed press brakes into high-tech machines capable of producing complex bends with greater accuracy and repeatability. Why Is Sheet Metal Bending Essential in Manufacturing? Sheet metal bending is a cornerstone of manufacturing, transforming flat metal sheets into essential components across various industries. From automotive and aerospace to consumer electronics and construction, its versatility and importance are undeniable. Material selection is crucial in sheet metal fabrication, as it directly impacts the strength, durability, workability, and appearance of the final product. Understanding the composition, characteristics, and interactions of various materials with the press brake is essential for accurate project calculations. Beyond Steel: Exploring Diverse Sheet Metal Options Here's a list of common materials used in sheet metal bending: Steel: The most widely used material due to its strength, durability, and versatility. Aluminum: Lightweight, corrosion-resistant, and easy to work with. Stainless steel: Offers excellent corrosion resistance and formability. Copper: Known for its electrical and thermal conductivity, often used in decorative applications. Brass: A copper-zinc alloy with a golden appearance and good workability. Titanium: Highly durable and lightweight, often used in aerospace and medical applications. Cor-Ten steel: A weathering steel with self-protecting properties. The choice of material depends on factors such as the required mechanical properties, corrosion resistance, cost, and the specific application. Material Composition Key Characteristics Common Applications Steel Iron and carbon alloys High strength, durability, versatility, cost-effective Automotive, construction, appliances Unalloyed Steels Iron and carbon Varying levels of hardness based on carbon content General-purpose applications Alloyed Steels Iron, carbon, and other elements Enhanced properties like corrosion resistance, heat resistance, and specific mechanical characteristics Stainless steel, Cor-Ten steel Stainless Steel Chromium, nickel, and often molybdenum Excellent corrosion resistance, formability, durability Food processing, marine, medical, architectural 300 Series Stainless Steel 304 (18/10), 316 High corrosion resistance, formability Commercial kitchens, appliances, food processing 400 Series Stainless Steel 430, 410 Good corrosion resistance, mechanical properties Appliance panels, cutting tools, industrial equipment Cor-Ten Steel Weathering steel Self-protecting from corrosion, high tensile strength Outdoor structures, architectural elements Aluminum Lightweight, corrosion-resistant, easily processed Aerospace, automotive, consumer electronics Copper High electrical and thermal conductivity, corrosion resistance Electrical wiring, heat exchangers, decorative elements Brass Copper and zinc Malleable, corrosion-resistant, attractive appearance Decorative components, musical instruments, plumbing fixtures Titanium Lightweight, highly durable, corrosion-resistant Aerospace, medical, military Want to learn more about sheet metal materials and their applications? Read our comprehensive guide on how to choose the right material for the bending process Principle of Sheet metal Bending Process Sheet metal bending involves a series of steps, beginning with design and planning. Factors such as material type, thickness, and desired bend angles are considered to select the appropriate sheet metal and bending method. The process then involves material preparation, alignment, and the actual bending operation. Finally, the finished product is inspected and verified to ensure it meets the design specifications. Types of sheet metal bending methods A deformation process is a technological process that involves modifying the dimensions of a material through the application of controlled external stresses. In the case of sheet metal, deformation processes can be divided into five main groups. Air bending It is the typical deformation of press brakes. It represents the most versatile processing and involves the use of a die with a V-shaped groove and a punch. The points of contact with the sheet metal are three: 1) vertex of the punch; 2) left vertex of the die; 3) right vertex of the die. The versatility of three-point bending lies in the possibility of working on small and discontinuous batches together with large productions with a practically infinite range of thicknesses; in fact, conceptually, there is no actual limit to the thickness in bending. In fact, assuming that it is possible to have a machine with adequate performance and by widening the size of the die, it is possible to bend any thickness of sheet metal. Sheet metal bending is carried out by vertically approaching the tools up to the desired height and identified by the numerical control of the machine. Behind this simple concept, many technological and design solutions have been developed by manufacturers over time. Some of these are now completely outdated in favor of others that guarantee greater precision, speed, safety and lower environmental impact. Pros Versatility: Suitable for various metal types and thicknesses. Reduced tool wear: Less contact with the die reduces wear and extends tool life. Flexibility: Allows for a wide range of bend angles with a single set of tools Cons Less precision: The bend angle can be influenced by the material’s springback. Dependence on material properties: Variations in metal thickness or strength can affect bend consistency. Forming or coining Through a wide range of possibilities (such as deep drawing, hydroforming, etc.), this type of processing involves the use of dies that give a specific shape to the sheet metal and are designed exclusively for this purpose. It is a process that is not particularly versatile but that guarantees great repeatability. Forming is in fact the most adopted solution by companies that need to produce large volumes. Pros: High Precision: Yields exact bend angles with minimal springback. Consistent Results: Ideal for repetitive, high-volume production with uniform quality. Clean Edges: Produces sharp, well-defined bends. Cons: Tool Stress: Exerts significant pressure on tools, leading to potential wear. Material Limitation: Less effective for very thick or hard materials. Higher Cost: Often more expensive due to increased tooling demands. Folding It involves the deformation of long strips of sheet metal through their forced passage through a long series of rollers that gradually modify their shape. Folding requires a dedicated system, such as folding machines, often of large dimensions, but allows obtaining complex profiles thanks to the possibility of adding further processing during the process, such as cutting, punching, welding, threading and much more. Panel bending It is carried out by applying a lateral force through a moving blade, which deforms the panel until the desired shape is reached. Its use is dedicated to thin thicknesses, typically up to a maximum of 3 mm. Panel benders are very complex machines and relatively recent, having been born around the 1970s; they guarantee high productivity and versatility in the face of a high initial investment. What is the desired outcome of this bending operation? When we ask, 'What am I trying to achieve with this bend?', we're diving into the heart of sheet metal forming: managing variables. Several factors influence a metal’s ability to bend without breaking or losing its structural integrity Every bend has specific requirements, including desired angle, radius, and surface finish. These requirements, combined with the properties of the sheet metal itself, the tooling used, and the machine settings, all contribute to the final outcome. Understanding these variables is essential for producing consistent, high-quality bends. Here a list of the 5 most important factors that determine the bendability of metal. For the full list, please refer to this table. Material Composition and Finishings Any type of surface treatment or pattern on the sheet metal can make bending more challenging. Perforations or raised patterns on the sheet metal can make bending even more difficult. The uneven distribution of material along the bend line (i.e., the area that will be deformed) creates asymmetrical stresses that cause the part to slip during the bending process, making it particularly difficult to achieve a correct flange length. The same inconsistency is also reflected in the bend angles, which vary continuously, making it difficult to standardize the process. This means that when the material has an uneven surface (like perforations or textures), it causes uneven forces during bending. This can make the part slip, leading to inaccurate bend angles and inconsistent flange lengths. How to solve it One possible way to counteract this problem to a significant extent is to install a wider die. Bending with wider dies means that the deformation occurs over a larger area and is therefore gentler. However, such a measure is not always sufficient and is completely useless in ensuring consistent flange lengths. Using a wider die can help distribute the forces more evenly, but it won't solve the problem completely, especially when there are significant differences in the material thickness on either side of the bend line. Unfortunately, in the presence of holes, raised patterns, or other functional features, there are asymmetries between one side and the other side of the bend line that make the use of a wider die useless. Features like holes or raised patterns create uneven stresses that can overcome the holding force of the die, causing the part to slip. These asymmetries during deformation create asymmetrical stresses, often greater than the clamping force. This causes the sheets to slide in search of an equilibrium, and the most evident consequence of this variability factor is inconsistent and varying flange lengths. The uneven stresses caused by the features on the material can lead to the sheet metal sliding during bending, resulting in inconsistent flange lengths. Thickness Variation Thickness variation is generally the most common variable in bending operations and is also quite common in plain, unfinished sheet metal. Why? Simply put, the processes used to produce sheet metal, especially for thicker gauges, cannot guarantee absolute precision. In fact, each sheet exhibits dimensional deviations, which, although within the expected tolerances at the time of purchase, impact the consistency of angles during bending. The thicker the material, the more noticeable the problem becomes. A decrease in the actual thickness of the workpiece leads to an increase in the angle α. The reason for this annoying issue is purely geometric and, unlike other variable factors, it doesn't affect the earlier stages of the production process. The maximum downward travel of the upper beam coincides with the lowest point reached by the punch inside the die and is called the 'Lower Dead Point' (LDP). The CNC controls identify the LDP using an internal algorithm that calculates it based on the following data: sheet thickness, material, tool height, and desired angle (angle α). The CNC machine converts the desired bend angle into a specific movement of the punch. The accuracy of this conversion depends on how advanced the machine's software is and the overall quality of the machine. Even a small difference in thickness can cause a significant change in the bend angle, especially for angles close to 90 degrees. These variations might seem insignificant in earlier stages like cutting or nesting, but can have a big impact on the final bend angle. Grain Direction The orientation of the metal’s grain can significantly impact its bendability. This variable is also known as anisotropy, and it is a physical property that affects how sheet metal behaves when bent in the longitudinal or transverse direction. This characteristic is imparted to the raw material during the rolling process, particularly in cold rolling. The rolling process causes three dimensional changes in the starting semi-finished product according to the following proportions: Along the length, very significantly; Along the width, to a medium-low extent; Along the thickness, very slightly and gradually. This means that the internal fibers of the material are forced to follow the direction of the most modified dimension and, therefore, are arranged perpendicular to the rolling mill rollers. This causes the sheet metal to respond differently to bending when done transversely or parallel to the rolling direction. An anisotropic material, in fact, has different mechanical strengths depending on the orientation. For example, alloys like AISI 430 stainless steel and aluminum exhibit significant anisotropy. This variable affects the consistency of bend angles and, in some cases, even the developments. The bend radius, in fact, is the element that most affects standardization: the stronger a material is, the larger the naturally occurring inner radius will be. The more yielding a material is, that is, the less resistant, the smaller the bend radius will be. For this reason, the same sheet, which guarantees its maximum mechanical performance when bent transversely to the rolling direction, generates two different radii. Temperature The sole environmental variable that significantly influences the sheet metal bending process is temperature. While temperature fluctuations are often overlooked in controlled environments, they can have a noticeable impact on both the bending machine and the sheet metal itself. For example, extreme temperature changes, such as those experienced on very hot or cold days, can affect the machine's hydraulic system and the material's properties. Similarly, when working with freshly cut metal that is still at a different temperature than the ambient environment, temperature variations can introduce inconsistencies in the bending process. Even in highly automated production lines, temperature remains a critical factor to consider. In bending machines, temperature fluctuations can affect the machine's performance from the moment it is turned on to after numerous bending cycles. What are Critical Design Considerations for Sheet Metal Bending? Effective sheet metal bending requires careful design considerations. To achieve the desired outcome without compromising the material's integrity, it's essential to focus on the following key aspects: Material Selection: choose a material that suits the project's functional and aesthetic requirements, considering its bendability. Bend Radius: ensure the bend radius is appropriate for the material thickness to prevent cracking or deformation. Grain Direction: align the bend line with the metal grain to reduce the risk of cracking. Bend Angle Accuracy: consider the material's springback characteristics to achieve the desired bend angle. Hole Placement: avoid placing holes near the bend line to prevent distortion or weakening. Edge Condition: ensure smooth edges on the sheet metal to avoid irregularities in the bend. Calculating Bend Allowance and K-factor The K factor is a crucial parameter in sheet metal bending, but it can be tricky to determine, as it depends on factors like material, thickness, inner radius, and bend angle. The k-factor is fundamental to designing precise sheet metal products. It allows you to anticipate the bend deduction for a large variety of angles without having to rely on a chart. There are numerous ways to explain it, but let's just say the k-factor is the percentage that reflects how the neutral axis move toward the inside surface during the bending process. In other words, the k-factor is nothing more than a multiplier that can give you an accurate value for the relocated neutral axis. And if you know the bend allowance, you can extract the k-factor from it. Once you know the k-factor, you can use it to predict the bend allowance for various angles. Read our guide to understand more about k-factor. What is sheet metal bend allowance? Bend allowance is a critical value in sheet metal fabrication. It refers to the additional length of material required to account for the stretching that occurs when a sheet metal part is bent. Essentially, it's the extra length you need to add to a flat sheet to achieve the desired bend angle. The neutral fiber is an imaginary line within the material that experiences neither tension nor compression during bending. It's along this line that the material neither stretches nor compresses. Bend allowance is the extra length you need to account for when bending a piece of metal, to ensure that the final part is the correct size. Why is bend allowance important? Accurate dimensions: without the correct bend allowance, your finished part will be too short. Consistent results: a well-calculated bend allowance ensures that all parts are identical. Reduced waste: by accurately calculating the bend allowance, you can minimize material waste. Using Software for Calculations of Bend Allowance and K-Factor You can use our online calculator to accurately calculating k factor and sheet metal bend allowance. Troubleshooting Common Sheet Metal Bending Issues Understanding and addressing common sheet metal bending problems can significantly improve the quality and efficiency of the fabrication process. Here are some frequent issues and potential solutions: Springback: to prevent the material from returning to its original shape after bending, slightly overbend or use a material with a lower yield strength. Cracking: avoid bending the metal beyond its elastic limit. Using a proper bend radius and annealing the material can help prevent cracking. Warping: to avoid uneven stresses and prevent warping, ensure uniform thickness and use symmetric bending techniques. This can include punctures and vent curls. If you eager to learn how to avoid them, read our dedicated guide on how to deal with puntures and vent curls in sheet metal bending. Scratches or Surface Marks: protect the material with films and maintain clean tooling to prevent surface damage. Inaccurate Bend Angles: regular maintenance and calibration of the bending machine are crucial to ensure accurate angles.
The choice of the right material is fundamental for any sheet metal fabrication project. Understanding the composition and characteristics of these materials, how they interact with the press brake, and the variables of the sheet metal itself, is essential for accurate development calculations. Different materials offer unique characteristics that can significantly influence the strength, durability, workability, and aesthetic appearance of the final product. Steel Throughout history, steel has always been employed in a highly versatile manner. This material has been indispensable for technological innovation worldwide. In fact, without its availability and low cost, the Industrial Revolution would not have been possible. Over time, steel production techniques have been perfected. When discussing steel, it's useful to distinguish between two main families: Unalloyed steels: Composed of iron and carbon alloys. Alloyed steels: Alloys containing elements in addition to iron and carbon. Beyond the presence of elements, there are different types of steel based on the percentage of carbon present. In general, the higher the carbon content, the greater the hardness. When referring to mild or hard steels, we're talking about the carbon concentration. Generally, steel can be classified into these categories: Extra mild: 0.5-0.25% carbon Mild: 0.15 – 0.25% carbon Semi-mild: 0.25 – 0.40% carbon Semi-hard: 0.40 – 0.60% carbon Hard: 0.60% - 0.70% carbon Very hard: 0.70% - 0.80% carbon Extra hard: 0.80 – 0.85% carbon Alloyed Steels We've mentioned that alloyed steels are metals that mix other elements besides iron and carbon. One of the most famous is undoubtedly stainless steel. Stainless Steel Stainless steel is composed of a high percentage of chromium, which makes the material highly resistant to corrosion and temperature; chromium also provides great malleability, making stainless steel a material used in countless applications. In press braking, various types of stainless steel are used, each with specific characteristics that make them suitable for particular applications. The most commonly used types of stainless steel are: 300 Series Stainless Steel Stainless Steel 304: This is the most common and versatile type of stainless steel and is also known as 18/10 stainless steel due to the percentages of chromium and nickel present in the alloy. It's known for its excellent corrosion resistance and formability. This material is often used in applications requiring high corrosion resistance, such as commercial kitchens, appliances, and food processing equipment. Stainless Steel 316: In addition to nickel and chromium, it also contains molybdenum, which further improves corrosion resistance, particularly against saline and chemical environments. It's widely used in marine, chemical, pharmaceutical, and medical applications where the environment is particularly aggressive. 400 Series Stainless Steel Stainless Steel 430: This is a type of ferritic steel with good corrosion resistance and good mechanical properties. It's often used for internal applications such as appliance panels and architectural cladding. However, compared to the 300 series, it has lower corrosion resistance and lower malleability. Stainless Steel 410: It offers a good balance between corrosion resistance and hardness. It's used for applications requiring high wear resistance and moderate corrosion resistance, such as cutting tools, blades, and industrial equipment. Cor-Ten Steel Cor-Ten steel, also known as weathering steel, is a special alloy with a brownish-red color. The name COR-TEN comes from the combination of corrosion resistance and tensile strength, highlighting its main characteristics of corrosion resistance and tensile strength. The primary property of Cor-Ten steel is its rare and unique ability to self-protect naturally from corrosion, an oxidative reaction that responds to environmental stresses and leads to the development of a surface oxide patina that, if scratched or removed, constantly regenerates over time. Aluminum Aluminum is another highly popular material in sheet metal fabrication due to its lightweight nature, corrosion resistance, and ease of processing. It finds applications across a broad spectrum, from aerospace to automotive and even household appliances. Aluminum can be anodized to further enhance its corrosion resistance and aesthetic appeal. Copper Copper is renowned for its exceptional electrical and thermal conductivity, making it perfect for electrical and heating applications. It also exhibits good corrosion resistance and can develop a protective patina, lending it a unique and appealing appearance. However, copper is relatively expensive and often used in specialized applications. Brass Brass, an alloy of copper and zinc, is valued for its ease of processing, corrosion resistance, and golden appearance. It's widely used in decorative components, musical instruments, and plumbing fixtures. Its malleability allows for the creation of intricate and precise details, making it ideal for precision work. Titanium Titanium is a highly durable and lightweight material known for its exceptional corrosion resistance and ability to maintain its structural integrity even at high temperatures. It's employed in industries demanding superior performance, such as aerospace, medical, and military. The downside is that titanium is expensive and requires specialized processing techniques. The choice of material for sheet metal fabrication depends on a variety of factors, including the desired mechanical properties, corrosion resistance, cost, and the specific application. Each material offers unique advantages and can significantly influence the production process and the performance of the final product. Understanding the characteristics and interactions of these materials is essential for successful sheet metal fabrication projects.
Stainless steel's unique properties, such as its corrosion resistance, which we explain in detail in this guide to materials in sheet metal working, make it a popular choice. Stainless steel is used in industries ranging from food processing to construction and medical equipment. However, working with stainless steel in the sheet metal bending process presents a number of unique challenges. To understand these challenges and how companies are overcoming them, we interviewed two specialists in stainless steel fabrication. The Challenges of Bending Stainless Steel Stainless steel parts are prized for their high resistance to corrosion, hygiene, and visually appealing finishes. However, these same qualities can create problems during processing, particularly bending. Stainless steel sheets aren't your typical flat sheet, says Davide Chinellato, Production Manager at Inox Piave di San Fior. They often undergo various processes that can lead to deformation and thickness variations. The key is achieving consistent, uniform bends along the entire length of the piece. Beyond bend quality, processing speed is crucial. Today's press brakes need to be extremely fast while maintaining safety compliance, Chinellato adds. This was a challenge in the past, as safety features often slowed production. VICLA machines, however, deliver complete safety without sacrificing performance. Stainless steel's properties necessitate meticulous handling to avoid visible defects in the finished product. Marco Nervi, owner of C.L.A. LAVORAZIONE INOX, a company specializing in raw stainless steel machining, emphasizes this point: For instance, bending requires a perfectly straight and continuous bend throughout the entire piece. If the bending machine's force isn't consistent, you might end up with a slightly open or closed bend. Choosing the Right Bending Machine Selecting the right press brake is critical for achieving flawless parts on the first try. Companies managing numerous orders with departments working in sync require machinery that guarantees precision, repeatability, and reliability. Inox Piave, for example, opted for a unique press brake configuration to handle their one-of-a-kind parts. The machine, developed over a year, features a special backguage explains Chinellato. Essentially, it has a single crossbeam for general movement of the stops, plus four independent stops for customized adjustments. The Advantages of Hybrid Bending Machines Both companies chose a hybrid press brake due to its numerous benefits. Firstly, it offers consistent repeatability thanks to a compact system with reduced piping and a direct drive connection between the pump and motor. Secondly, there's speed. Hybrid press brakes leverage cutting-edge technology to deliver high thrust. The system combines an electric axis with a hydraulic clutch and a brushless electric motor, providing both high force and fast travel speeds. Finally, hybrid machines offer greater versatility compared to all-electric models. As Chinellato explains, For the bending we do, an all-electric option wouldn't deliver the necessary performance. That's another reason we chose VICLA's hybrid technology. Selecting the Right Tools Cost is another crucial factor when working with stainless steel, as Nervi explains: Material costs have risen in recent years, especially in the first half of 2022 when finding materials was difficult. This, combined with the material's delicate nature, makes waste reduction essential. Even minor marks can render a stainless steel component unusable, particularly in applications like furniture where aesthetics are paramount. Materials like AISI 304 stainless steel, iron, galvanized steel, copper, brass, aluminum (including diamond plate and painted varieties) all require meticulous handling to avoid visible defects. Choosing the right bending machine is crucial, but so is using tools that won't damage the material, such as protective films placed between the sheet metal and the die. We have written a guide that illustrates the main types of dies and punches most used in bending. The K-Factor in Sheet Metal Bending The K-factor is a critical aspect in sheet metal processing, including stainless steel. It's essential for achieving accurate bends. The K-factor represents the ratio of the material thickness to the neutral radius, directly impacting the final bend result. For a deeper dive into the K-factor and its influence on stainless steel processing, please refer to our article on the sheet metal K-factor.
When we talk about tandem press brakes, we refer to a particular configuration that involves the connection of two machines into one, but there are also solutions that combine three bending machines (tridem) or 4 bending machines (quadrem). In this type of configuration, the machines can have the same length and the same nominal bending power or different lengths and nominal bending powers can be provided. What are the characteristics to consider when choosing a tandem configuration? Let's find out together in this complete guide. What are tandem press brakes? When two press brakes are used in tandem, a single CNC controls both machines. However, each machine can also be used independently for added flexibility. What are tandem bending machines used for? To bend long profiles, it is not necessary to have a large bending machine. Sometimes it is enough - and much more beneficial - to choose a tandem configuration, because it allows for greater versatility and productivity. Specifically, tandem bending machines can be used in synchronised or single mode. In the first case, both machines can be programmed by the numerical control of the master machine, which sends the signals to the secondary machine, allowing synchronized management with a single CNC. It is crucial that both machines are perfectly calibrated, as any problem on one machine will affect the operation of both. In any case, machine builders already prepare the optimal configuration of the machines during assembly, so if the operator follows all the instructions given during installation, it is very difficult for problems to arise in the future. In the case of separate use of the machines, each machine is independent, equipped with its own photocells and a safety guard. With this solution it is possible to carry out different processes in each machine, with the advantage of optimizing production in the best possible way. In fact, many metalwork fabrication, in addition to the bending of heavy and long profiles, supports the bending of shorter pieces. Moving a huge machine to bend smaller profiles would be costly in terms of time, energy and productivity. With a tandem setup, however, you can easily switch to single mode and operate each machine completely autonomously. So that's one of the great advantages of the tandem setup! We'll talk about the other benefits - and limitations - in a moment, but first we'll focus on some equally important aspects. What processes can be done? Most of the bending that requires a tandem configuration concerns long sheets that require high powers. The processed products belong to the most varied sectors, including: industrial bodywork, trailers, agricultural equipment, aircraft parts, modular spaces and storage solutions. Most tandem bending machines have deeper recess dimensions (e.g. around 1000 mm) in order to allow more agile bending of wide profiles. To enable this, machine tool manufacturers such as VICLA design a larger, thicker and more solid structure that can compensate for the increased stresses that result from having a larger groove. Another interesting aspect is that, compared to a large bending machine, tandem bending machines generally do not need a pit for the lower bench housing What are the characteristics to consider when choosing a tandem? When choosing a tandem configuration, it is important to consider the bending force: it is widely believed that using two bending machines in combination allows you to double the bending force at every point of the machine, but this is a mistake. The total force, given by the combination of the force of each machine, applies only in the case of bending along the entire length. Let's take a concrete example. Let's take two bending machines of 4 meters and 250 tons each. In a tandem configuration, the total force is equal to 500 tons, but only if you are working on a profile that requires the entire length. On the other hand, in the case of a shorter profile, for example less than 4 meters, the total power will be 250 tons! Another aspect to evaluate is the configuration: tandem bending machines allow you to have almost the same customizations as a single bending machine, with one caveat: while, for example, it is possible to have a different number of axes for each machine, the configuration of the stomp and the bench, for obvious reasons, will necessarily have to be identical in both machines. Here is a list of the customizations you can do: Oversized recess Increased stroke Larger opening Intermediate heights Clamps for all types of tools Sheet metal escorts Motorized front supports What are the advantages of tandem compared to using a single machine with the same length and power? When choosing whether to have a tandem, it is important to consider the following advantages: Flexibility: we have repeatedly specified the great versatility of a tandem, but it is worth repeating it once again. Such a configuration allows two machines to be used together or separately, with the great advantage that a workshop does not need to equip itself with additional machines. It also allows you to adapt to business changes effectively, always ensuring future business options. Last, but not least, is the speed of execution: thanks to the reduced size, the bending machines configured in tandem are more streamlined in movements than a larger bending machine and this allows to obtain a fast work cycle. Lower risks: buying a tandem allows you to halve the risks compared to buying a large bending machine, which will be more exposed to the risk of production stoppages. In a tandem, on the other hand, it will still be possible to produce parts on the working machine. Lower ancillary costs: Before purchasing, it is always important to evaluate all the costs related to the new project. How do transportation costs differ for one large machine compared to two smaller machines? Will special permits be required? Will additional foundation preparation work be required for one type of configuration over another? Understanding all the associated costs is the only way to accurately calculate your return on investment. What are the limitations of a tandem? We often talk about the benefits, but little about the limitations. Let's look at some factors that can influence the decision to buy a tandem: We have already said that the versatility of tandems consists in being able to bend long pieces without having to equip themselves with imposing machines that require more space and additional bending at the foundations. However, it's worth noting that a tandem setup still has limitations. One of them is related to the recess: although it is possible to increase the depth, it could still interfere with the bending of certain parts. Another consideration is the cost of the machine. Depending on the case, buying a large car can prove to be more expensive than choosing a tandem, however, the opposite is also true. In fact, a tandem consists of two machines and therefore each component is doubled (two CNCs, 4 cylinders, etc.). This does not mean that a tandem is less convenient than a single car, but it is certainly one of the many aspects to consider when buying. Now let's see what the other criteria are to consider before buying a machine. What criteria should be adopted when purchasing a new machine? Before proceeding with the purchase of a tandem or a large bending machine, it is essential to consider all the variables at play, first and foremost your production needs. What are the processes you need to do? How much do they cost you? What is the level of sustainability in continuing to process the parts through the current production process? These are fundamental questions to pay close attention to. How to achieve higher productivity and save costs? What are the markets that offer the latest products? What are the changes in the production field in recent years? Buying tandems seems like a serious financial solution. Start with a clear estimate of the status of your work and get the answers to questions about how to increase the productivity of your operations and get the most profit possible. Our consultants at your disposal Would you like personalized advice to find the right machine for you? Contact us now.
The ever-increasing demand for skilled pressbrake operators, who possess both practical know-how and a deep understanding of the theoretical aspects of bending, has solidified our commitment to providing comprehensive training opportunities. In collaboration with an Italian school, we are proud to offer a unique theoretical/practical BENDING CLASS. The program attracted a diverse group of participants, including experienced, as well as young PB operators eager to learn, and drawing department personnel seeking to enhance their knowledge. The enthusiasm for learning and the need for technical expertise were palpable throughout the course. Many companies have recognized the importance of investing in training to unlock the full potential of their workforce and technology. By empowering their employees with the necessary skills and knowledge, they can achieve a significant competitive advantage. The ongoing industrial change requires making the production cycle increasingly efficient, keeping production costs low without compromising quality and safety. Factors such as the growing demand for product customization, on one hand, and the difficulty of finding qualified labor, on the other, are pushing companies to reorganize their production departments to remain competitive. One of the fundamental elements on which companies are trying to act to contrast the shortage of labor is to enhance internal resources by training, stimulating, and retaining them. Training plays a key role because it allows us to acquire an awareness of the difficulties and the most practical aspects of bending thanks to which it is possible to make the process more streamlined and solve many problems upstream of production. A highly skilled press brake operator or fabricator who possesses a deep understanding of both the practical and theoretical aspects of sheet metal working is an invaluable asset to any company. In fact, a qualified and adequately trained operator will play a key role in making the production cycle increasingly efficient, contributing to increasing the quality level in the repetitiveness of the processing processes. A second interesting aspect related to personnel training is its flexibility. Companies are increasingly aware that to improve the efficiency of the production chain, synergy is needed between the technical office and the production department. In fact, the technical office must have precise information on the characteristics and limits of press brakes in order to design and draw efficiently, avoiding errors and waste. It happens too often, in fact, that the technical office develops developments with tolerances that are too hard, if not impossible to achieve considering the equipment (press brake and tools) in the bending department. Knowing the theoretical bases behind the sheet metal forming process can help designers and draftsmen to have a complete overview of all the necessary elements in the design and drawing of parts. It is precisely to encourage the sharing of knowledge that at VICLA we have chosen to move in two directions: on the one hand, by organizing training days, full of detailed diagrams and valuable insights that stimulate lively debates; on the other hand, by creating a bending manual – as for now, available only in Italian - which summarizes the theoretical and operational bases of sheet metal working. The manual contains numerous tips and practical advice to take press bending to its maximum possible performance, as well as an in-depth overview of the evolution of press brakes and new technological solutions to improve the quality of finished products. For 10 years now, the machine tool industry has been witnessing an incredible revolution, says Marcello Ballacchino, owner of VICLA together with his partner Corrado Nucci. I am referring to the automation of processes, the advent of robotics and the development of machines with a high energy coefficient. And then we must not forget the great theme of the Digital Factory. This new way of conceiving production is projecting the entire sector into the future. Hence, VICLA's mission to continue to look ahead, to anticipate requests and meet the needs of customers. The Bending Day was a valuable opportunity to share our passion for sheet metal working and to forge stronger relationships with our customers We can't wait to replicate this experience!
Sheet metal bending often represents the bottleneck of the entire production process, because sheet metal, which is a living material, can take on infinite shapes and sizes and this, sometimes, is the cause of little-known and complex problems to solve. It must be said that, sometimes, problems do not arise in front of the machine, but very often are caused by an upstream error in the technical office. It is for this reason that you should learn to identify sources of error early on and correct them upstream, when it is still possible to intervene in the entire bending process. What are the most common problems when bending sheet metal? Simplifying, we can distinguish between two categories: punctures and vent curls. For each, there are different approaches you can take to eliminate or limit the problem. Here's a summary of what we'll be talking about: Punctures near the bend line Partial punctures Pre-drilling with smaller diameter Vent Cuts Reducing the width of the matrix Changing the Folding Mode Using tangential bend dies Vent Curls Vent Cuts Bending Mode Changes Tangential bend dies A book would not be enough to describe in detail every single point and the possibilities of solution. Today we will limit ourselves to talking about sheet metal drilling and what are the first two solutions you can adopt. We'll be delving into the rest of the game in the coming weeks. Drilling near the bend line Punctures in the vicinity of the bend line are an extremely common problem. The presence of holes near the bend axis can create a deformation that changes the shape and position of the hole. The best solution would certainly be to avoid designing bent sheet metal elements with holes too close to the bend lines. However, if you do not have this possibility, there are several strategies that can be adopted both by the technical department of the company that physically makes the piece, and by the operators. Partial drilling Mainly used in heavy metalwork fabrication, partial drilling involves not completing the entire shape of the hole. This makes it possible to preserve a surface useful to be supported by the matrix during deformation with the consequent stability of the perforated shape. The hole will be completed by further processing, such as with a hand plasma. As you can imagine, this technique is best used in the presence of high thicknesses and small quantities of pieces. Pre-drilling with smaller diameter All in all, similar to partial drilling, pre-drilling with a smaller diameter involves a non-complete drilling of the template to be removed during cutting. In this case, a small hole is drilled and sufficient to avoid any deformation during bending. Unlike the partial drilling technique, pre-drilling with a smaller diameter is faster and suitable for even medium-thin thicknesses and medium-large batches. In the next article, we'll continue to dive deeper into the approaches you can use to handle holes near bend lines. If you haven't already done so, we recommend subscribing to the VICLA newsletter!
Two weeks ago we discussed how important it is to know the recurring problems of sheet metal bending and we saw what the first two cases are, i.e. partial drilling and pre-drilling with a smaller diameter. Today we are going to delve a little deeper into the theme of drilling, introducing vent cuts and we will end by talking about the use of tangential bend dies. Are you ready? Tagli di sfogo It consists of providing a cut at the bend line that allows the flap to be bent up to the apex of the notch. The cut can then be restored by welding or left open depending on the end use of the piece. This method, where permitted, also guarantees absolutely outstanding results. It consists of making cut strokes or real windows that interrupt the bend line at the holes. In the presence of a high thickness, simple cuts cause tears on the ends of the bend line break. This phenomenon may not be a problem, even more so if the external radius is restored through welding and grinding. However, in the presence of elements subject to fatigue and high loads, it is advisable to operate in a different way, for example as in this image, where, thanks to an H-shaped cut, tears and potential crack triggers are completely avoided. Die width reduction The reduction of the width of the matrix is a technique that finds its best application when it is already provided for in the technical office. At the drawing or planning stage, if there is the appropriate knowledge, it is already possible to understand whether the deformation of the holes can be avoided with this system and whether the workshop has the right tooling for the purpose. If so, the technical department will necessarily have to generate a development suitable for the new condition. This also means that it is a good rule of thumb to state on the drawing which is the die to be used in production to obtain the correct part. Reducing the width of a die, as already described, causes a smaller bending radius in the sheet metal with the consequence of obtaining a part with a smaller finished size than desired. Changing the bending mode As already discussed in this volume, there are three folding methods, each with its own peculiarities: air folding, matrix bottom and coining. Depending on which mode it is adopted, there is a different constancy in the shape of the holes during bending. Working in air, in fact, the sheet metal is totally free and suspended on the die and this approach is the least favorable condition to preserve the holes from deformation. For this reason, it is more suitable to use an 88° homologated matrix for hollow bottom mode. In this case, the internal faces of the die, coming into contact with the sheet metal, reaffirm the deformations bringing the holes back to their initial shape. If high precision is required, it is advisable to consider the use of this technique already when determining the development of a part. Using tangential bend dies For several years now, special dies have been offered on the market equipped with milled semi-rollers and housed on special seats. The position of these rollers is maintained by springs that allow them to move and return to their initial horizontal position. Tangential or oscillating bend dies have many advantages in the face of a rather high purchase cost and a wider width than traditional dies that makes it more complex to make closely spaced Z folds. In the next article we will complete the topic of the most common problems by talking about venting curls. If you haven't already done so, we recommend subscribing to the VICLA newsletter! Is this your first time reading this blog? Download our press bending manual and subscribe to the newsletter!
During the bending process, the machine is subjected to a tension that causes a deformation of the structure and, consequently, also of the sheet metal; to compensate for this kind of stress, the crowning system comes into play. When we bend the sheet metal with a press brake, the upper crossbar always tends to curve upwards. The crowning system lifts the die to maintain a constant distance between punch and die. Without it, the result of the bending angle would be irregular. To put it in a nutshell, in a press brake with incorrect crowning or without crowning, the bending result will have a more open or closed bending angle. For this reason, it is of fundamental importance to choose the correct crowning system for your press brake. What are the main crowning systems? There are several crowning systems, some of which are exclusive patents of very few manufacturers such as VICLA. Today you will discover the three main systems and which, among them, really helps you to achieve perfect folds without having to waste material and money on tests and verifications of the part. If you want to read immediately what it is, you can go directly to the paragraph where it talks about active hydraulic crowning. Wedge-style crowning system The wedge-style crowning system is an adjustment that takes place beforehand and can be modified on the basis of the characteristics of the sheet metal. It consists of two rows of wedges across the length of the bed; one row is fixed and the other is movable; moreover, it involves a series of profiles with different inclinations, characterized by a stronger marking in the center and less on the sides. The wedge in the middle of the bed has a higher slope than the wedges under the pistons, and the angle of the slope decreases toward the ram from the middle of the bed. On one of the sides of the machine there is a gear motor: when activated, the movable wedge creates a curve with the high point at the center of the bed and the low points at either end of the bed below the pistons to create a spline curve in the table. The wedge bench always requires an intervention by the operator; In fact, the profiles, when viewed from the side, show an oblique contact plane that allows the expert bender to adjust the rib and make it localized. This system, while very useful, has one major drawback. With the wedge table, changes to the linearity of the bench cannot take place during bending, but must necessarily be made beforehand. In fact, this crowning system is also called pre-crowning, precisely because the adjustment takes place before starting to bend the sheet metal. Sheet metal bending and crowning: how much do you need to compensate? Compensation is one of the crimper's big pet peeves. While it is true that there are theoretical tables and formulas to calculate compensation, it is equally true that sheet metal is an unpredictable material. It happens very frequently that the theory clashes with the variable behavior of sheet metal. What can be done in these cases? Surely the first step to take is to know all the factors that determine the behavior of the sheet metal. It will help you understand how to compensate for them and not waste time and material on tests and verifications. Sometimes, however, even knowing the material is not enough and the company could run into many problems deriving from non-uniform parts: material cost, late deliveries, high waste. Getting the result right the first time becomes essential for companies that want to remain competitive in the market. Crowning systems: hydraulic crowning Hydraulic crowning is a system historically used by many manufacturers. Inside the bench, in the table that bears the stress and supports the dies, high-pressure and low-flow cylinders are inserted. Like real hydraulic jacks, they push the center of the bench upwards, thus compensating for the deformation of the stomp. The effect you get is the perfect parallelism between the punch line and the die line. With hydraulic crowning, you get a workpiece with a constant bend between the center and the sides. Even in this case, however, it may happen that, due to the variability factors of the sheet metal, the system returns a value that is not optimal. In fact, the numerical control calculates the compensation on the basis of the description of the piece to be produced and on the calculation calibrated to the structure of the sheet metal machine. Linear bends of sheet metal at the first attempt: active hydraulic crowning The only way to successfully manage crowning is to use technology that measures the actual deformation and corrects it in real-time. VICLA, for this reason, can guarantee active crowning, which, in fact, represents the evolution of the system and the ultimate in terms of repeatability and precision. With VICLA's Clever Crowning active crowning system, you can be sure that no matter how different the material is, you will always achieve a perfectly linear crease. How does the active crowning system work? VICLA's Clever Crowning active crowning is a sophisticated and extremely intelligent system that provides for a modification of the linearity of the bench, calculated exactly on the basis of the real need. The press brake, in fact, thanks to special sensors inserted at the strategic bending points, is able to understand exactly how many hundredths of a millimeter the extent of the crossbar bending is. It is no longer a parametric calculation, but a real value that establishes the exact pressure that the cylinders must use to compensate for the bench and achieve the perfect bends along the entire length of the profile. This solution does not require corrections because it is positioned completely automatically, always guaranteeing excellent results. In short, it is a real revolution in the bending process that improves work in the workshop in many ways: you get excellent results even with inexperienced staff, as the system calculates everything automatically; reduce material waste, as the system applies the exact compensation in real time; reduce production times because you no longer need pre-crowning and part checks. All the systems currently offered on the market, hydraulic or mechanical wedge, require corrective intervention by the operator. They are therefore semi-automatic systems, in which the positioning is theoretically determined by the NC but is subsequently corrected by the operator. With VICLA's Clever Crowning active crowning system, on the other hand, the NC measures the changes to be made in real time without you having to intervene with subsequent adjustments. This option is available on the hybrid press brake. SUPERIOR and allows you to achieve exceptional performance. Now that you know how to achieve perfect folds without wasting time and material, discover the other benefits of VICLA press brakes.
During the last 10 years, industries across all sectors have actively participated in a significant shift towards automation, with solutions for every aspect of production, from automated warehouse management lines to robotic bending cells. Robot integration revolutionized the sheet metal bending process on press brakes. Automated press brakes represent for sure an advanced solution for industrial automation, increasing the quality and efficiency of work. Thanks to the advantages of state-of-the-art programming, press brake bending cell can work continuously, providing constant, repeatable and high-quality results, without the variability associated to human operators. How does a bending cell work? A robotic bending cell is an integrated system that combines a robot and a press brake. This solution allows to automate the entire bending cycle. In particular, automation includes: Part picking by the robot, which is equipped with suction cups or magnets Thickness control and centering plate Bending phase (includes performming of re-grips or turnovers) Palletizing Faster production cycles thanks to robotic bending The lack of qualified staff has developed an increased need of automated production. Without any doubt, the scarcity of qualified labor can be considered one of the main factors that has required this change in the workshop organization. Robotic bending cells are designed to perform a variety of operations. The use of automated solutions allow companies to make the production cycle more efficient, while keeping production costs low, without compromising quality. The robotic bending cell automates the entire bending cycle, from part picking to final palletization, ensuring high-quality and consistent results. Let's take a real example: the bending department of a company can organize the work on a continuous cycle. You might optimise effectively the work by using the robotic cell during the night to perform all the simplest and repetitive processes, while operators can focus exclusively on the most complex and challenging phases of processing, especially those in which a robot cannot compete with the creativity and added value of an experienced bender. The operator, released from doing repetitive tasks, can put its attention on other activities, such as preparing for the next processing phases, or can be trained on machine maintenance. With this kind of organization the company can fully exploit the potential of automation for the simplest working phases, where the human contribution is less appreciated. On the other hand, companies can employ human capital on more remunerative tasks, fostering the development of new skills and creating the conditions to retain the most valuable resources. MATRIX: robotized cells without limits To meet these needs, VICLA has designed MATRIX, the fully customizable robotic cell that perfectly meets the real needs of customers. It is a highly performing integrated system, easy to program and designed to meet the needs of the individual customer. VICLA stands out for the high level of customization of both the robot and the press brake, which can be configured in terms of power and length, while the integration with the robot is designed according to the customer's needs. The cell configuration is highly versatile and allows to easily switch from automatic to standalone mode when needed. The design is compact and can be configured according to the space available. The robot can pick a wide variety of sizes, even the smallest, thanks to different gripper options. It is possible to equip the robotic cell with a mobile or press brake-integrated (ATC) tool changer and obtain a fully automated bending system. The high-tech sensors ensure a consistently accurate bending angle. The angle control, the adaptive crowning system, and the Flex device ensure perfect linearity even on non-uniform materials. Matrix offers a suite that combines bending software and robot programming in a single environment, also allowing to import drawings, collect real-time data, monitoring production. These features make the Matrix bending cell particularly reliable and productive, thus helping to meet the shortage of skilled labor. Due to the fact that it is fully customizable, VICLA offers various custom-designed configurations. The customer can therefore choose a solution with a gantry robot, a rail robot or a fixed platform robot. Let's see together the advantages of each type. Robotized cell .Matrix Baseline Integrated robotic cell that combines a press brake and a floor-mounted robot. The robot can be configured to move on a rail, thus obtaining a seventh axis, or it can be positioned on a fixed support platform. A bending cell with a rail robot offers a lot of advantages; let's see some of them: Increased flexibility: if the robot is equipped with a seventh axis on a rail, it can serve multiple workstations, allowing for different operations without the need for operator supervision on the machine and the execution of tasks at different points in the production line. Downtime reduction: thanks to the ability to move along the rails, robots can reduce downtime associated with the movement of materials or components within the work area, improving overall production efficiency. Increased productivity: robots moving on rails can avoid the downtime typical of production, optimizing cycle times during the day and the night by serving production lines 24/7, saving time increasing productivity. Better use of space: thanks to their mobility, rail robots can be used more efficiently because they work in a larger space, allowing for better organization of the production area and a strong reduction in the footprint of the machines. First piece right: each process is first designed remotely and feasibility is checked using specific software. The robot checks and positions the part exactly where it needs to be bent, and specific devices are used to verify the position and material, which ensures the right first piece from the beginning. Matrix Skyline: for a more efficient use of space Integrated robotic solution that combines a press brake and a robot mounted on a gantry. This configuration is the best solution when it would not be possible to install a rail-mounted robot due to space limitations. Thanks to the use of an overhead gantry for the robot, the working area is free of obstacles, allowing for greater flexibility and versatility. Unlike the version with a floor-mounted robot, this system does not require to place the bending brake on lifting blocks, making it a more versatile solution even when used in standalone mode. Robotized bending with automatic tool changer Robotic bending can be integrated with an automatic tool changer that automatically performs even the most complex setups, handles dies up to 70 mm V width, round tools and also allows 180° rotation of the tool. VICLA ATC - Single or Twin - can reduce setup times by 4 or 5 times compared to manual operations. This system, combined with a bending robot, is the most suitable solution for saving time in the bending cycle, combined with flexibility and production speed. Robotised solutions from laser to bending Matrix Tailor is an innovative system that enables the complete automation of laser cutting and metal bending. Its uniqueness lies in the use of two or more 8-axis gantry robots, where the eighth axis is dedicated to bending. This solution allows the robots to be used not only for bending, but also for sorting and palletizing the laser cut parts. The automation covers several aspects, including: automatic sorting, part transportation from laser machine to bending machine using by AGV (Automated guided vehicles) robots and bending phase. The flexibility and versatility of this solution become even more evident when considering that the system can be designed for 24/7 production. During the day, production can be managed by operators and/or robots, while at night the system can operate automatically. In this way, robots can work with or without human intervention, even carrying out entire shifts fully automatically.
A robotic bending cell is a system that integrates a robot and a bending press, designed to perform operations of picking, bending, and depositing metal sheet profiles. It is a solution born out of the need for companies to make the production cycle more efficient while keeping production costs low without compromising quality. The modern era of mechanical processes is characterized by a common thread: an increase in the level of quality in the repeatability of machining processes. In the field of sheet metal processing, continually improving productivity is one of the current major challenges, especially considering the growing variability in shapes, sizes, and quantities of pieces demanded by the market. What are the possible solutions? As always, there is no one-size-fits-all formula, but there are options that better suit each individual company. Today, we will talk about robotic bending and how it can enhance corporate productivity. Robots and Innovations in Industrial Bending: Latest Developments Bending automation has made significant strides compared to a few years ago, considering collaborative robots (cobots) or automated tool changer. Before the advent of cobots and anthropomorphic robots, a Cartesian robot was used. This is a robotic arm that moves along a large steel frame positioned in front of the bending press. Technological evolution in recent years has allowed freeing the robot from the elevated horizontal sliding beam, giving rise to the anthropomorphic bending robot. Automation of Bending The sheet metal processing sector is experiencing remarkable technological evolution, especially in the field of press bending. Traditionally, the bending phase has always been considered the bottleneck of the entire process because it is where the most significant waste occurs, both in terms of material and time. Automated solutions act on two fronts: speeding up the bending cycle and reducing human error. The automated bending cell relieves operators from strenuous, repetitive, and unstimulating work, allowing them to focus on other tasks. VICLA automatic tool changer allows machine setup without operator intervention. Programmable remotely or on the machine, it accelerates the bending cycle. Advantages of Robotic Bending In the new smart factory, the programming phase of different processing stages is managed by the technical office, which becomes the true operational center of the workshop. With everything controlled from a single location, the bad habit of having programs in the machine more accurate than the technical drawings or relying solely on the notes of the benders ceases. Reduces Costs By reducing the discretion of the human factor, costs can be reduced. Positive impacts include a reduction in material waste and a decrease in the production cycle (operators can focus on optimizing other production cycles). Additionally, the work of people involved in other areas is expedited. Lifts operators from repetitive, strenuous, and risky activities Another aspect not to be overlooked is the safeguarding of the health of operators who, freed from taxing and dangerous activities, can engage in other tasks. Operators can cease manual handling of large sheets, eliminate the risk of finger crushing during the bending phase, especially for very small pieces, and reduce risks and fatigue from manual tool changes. Improves Job Estimation Automation allows precise measurement of the time, material, and energy required to produce a piece. This enables more accurate quotations and eliminates the discretion of the human factor. How often does one base the price on skilled operators who are not always the same ones producing the piece? Additionally, knowing in advance the timing, energy, and material, the company can make accurate forecasts of costs and revenues for the current year, improving the overall management of cash flows. Robotic Bending vs. Manual Work It is a common misconception to believe that automated bending will lead to the end of thousands of jobs. The same was said of the advent of the PC, but facts have shown that the introduction of new technology tends to have more positive than negative effects. Bending automation will drive the development of human skills. New skills will range from machine maintenance to programming. Thanks to the time saved, versatile figures capable of performing multiple tasks could emerge— for example, a laser cutter or a welder could learn to manage a robotic bending station much more quickly than a manual machine. So, will benders lose their jobs? Absolutely not! A robot can never replace the work of a highly skilled bender, also because not everything can be automated. There are indeed processes so complex that they must necessarily be carried out by the human hand. Control Systems in Robotic Bending: Optimization and Precision As advanced as bending robots may be, they cannot understand if they are working correctly and if the piece is successful. To avoid unpleasant situations where the system worked all night and one ends up with a series of pieces that have errors and inconsistencies, it is necessary to equip oneself with sensors and bending control systems. The first is angle control. It consists of a system of laser readers running parallel to the bending bench. This solution guarantees the set angle without any additional correction. Another useful precaution that ensures the correct positioning of components is the rear register sensor system. Other very useful devices are inserted inside the bending bench and serve to detect and compensate for natural flexions due to the bending effort. Adaptive bending device (VICLA Clever Crowning) Ensures excellent results and requires no in-depth technical knowledge; adjusts compensation without any need for operator intervention; guarantees a perfectly linear bend even on non-uniform materials (e.g., mixed perforated/solid material). Device for controlling structural flexions of shoulders (VICLA Flex) allows maintaining the same bending depth regardless of the sheet metal's length. The CNC receives data from the pressure sensors of the cylinders, which are then interpolated to establish the correction to be made. Limits of Robotic Bending As with any other machinery, it would be wrong to think that a robotic bending cell can do anything. These are application limits that must be known and explored before proceeding with the machinery purchase, so as not to end up dissatisfied with the investment made. Looking at the issue from another perspective, the question to ask is: what factors should be considered when choosing an automatic bending system? What kind of work do you do? The essential prerequisite is that the work is repeatable, so it cannot include prototyping. This is because it makes no sense to invest time in programming a product that will be made only once and never again. If a workshop regularly produces different parts for customers, however, the program can be easily recalled, and it might make sense to invest in a robotic bending cell. Furthermore, to get the maximum benefit from an automated system, it is crucial to ensure maximizing the variety of operations that can be performed on it. What are the best jobs for a robotic bender? Surprisingly, it covers a fairly wide range of applications: repeated high-volume jobs; low-volume jobs that are repeated; heavy jobs can all make sense. Evaluate all costs The cost of an automated system is certainly important, and it is undeniable that, for the same price, one could purchase one or more independent bending machines. However, the significant limitation of this reasoning is that, for each bending machine, an operator is needed. Are we sure the game is worth the candle? When introducing an automated bending system, it is possible to optimize human resources as well. An experienced operator can manage an independent bending machine while monitoring a robotic cell. Organize work and space In addition to choosing the right-sized tooling, a workshop must also consider how the parts will be removed from the cell. Will they be assembled into kits, placed on a conveyor belt, removed via a chute, or stacked on pallets? Decisions like these will influence the length and width requirements of the cell. Always Monitor Production It is a misconception to believe that merely programming in the technical office, hitting start, and waiting for the system to do all the work is sufficient. This oversimplification disregards the variables involved in sheet metal processing. With a traditional bending machine, the operator can manually intervene to manipulate the piece and avoid potential collisions. In the case of a robotic system, the automated bending machine will only perform what it is programmed for, so the tool configuration must be precise. A tool out of place could cause significant damage. It is crucial for the operator of the bending machine to ensure that every part is in its proper position because the robot cannot reposition the part to accommodate a misplaced tool. In conclusion, working with a robotic bending machine requires meticulous attention to detail. 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In sheet metal working, batches are increasingly small, complex and non-homogeneous. More and more efficient technologies are needed, while also trying to maintain compatibility with existing machines and services. This is why Nuova Inox decided to focus on VICLA'S ATC automatic tool changer combined with two .SUPERIOR press brakes. Nuova Inox Srl, based in Rovato (near Brescia, North Italy), is a metal carpentry company for medium-light components. Founded in 1989, the company began with the management of small metal products and immediately stood out for its excellent ability to machine stainless steel, becoming a reference point in this field in just a few years. Nuova Inox has always believed in technological innovation, investing in facilities and auto-mation, it has also implemented a next generation management system which, combined with 4.0 technologies, makes the service qualitatively better with useful information for the customer. The strengths of the Lombardy-based company, which employs around 50 people, are its speed of response to requests, efficiency in the execution of orders, and timely deliveries. The work is based on customer projects which generally require the production of sub-as-semblies of machine carpentry in their vari ous sectors, especially packaging, food and medical, given the Lombardy-based company's specialisation in stainless steel and construction steel. A comprehensive service The entire activity is based on various stag es, starting from engineering, which is the stage where the design of a manufactured article is received in preparation for its real-isation, as Fabiano Fieni, General Manager of Nuova inox, pointed out: The intervention of the engineering department serves to make any corrections to the incoming design with the intention of improving its characteristics, implementing better technical solutions to minimise the time needed for realisation. We are well organised to offer a complete service: after the technical department, there is the sheet metal and tube laser cutting department with different working ranges and thicknesses, able to meet most requirements. Then we have the bending division, in which we have recent ly concentrated our resources. More and more often we are producing small batches. these are not even prototypes for large or ders, they are really components of special machines custom-built by our customer, completely different automatic machines, true unique pieces which are very unlikely to be replicated except in very few examples Nuova Inox's services are completed by the punching, welding, assembly and finishing departments, when necessary, not forgetting deburring, which is also useful for company safety. Compatibility first and foremost The specialisation and care put into production have brought Nuova Inox great success in the market, but have also required careful optimisation of work, especially in the bending phase. The lat ter is particularly affected by both set-up times and the management of a vast number of unique codes associated with each job, including non-repeatable ones. There was a need to reduce the time as much as possible on these components of different lengths and thicknesses: the bending set becomes laborious and par ticularly difficult to manage, due to several consecutive settings and a different bending logic from the standard. With a view to reinforcing the department by purchasing more press brakes, this phase had to be made smoother: We examined the mar ket proposals. The first machines with automatic tool changers had already appeared, but we had requirements which could not be overlooked: interchangeability with our existing dies ( matrices and punches already present in the workshop), the fact of having a single magazine serving two machines and a bending CAM program which could manage the entire fleet of machines in the bending department and, finally, having machines equipped with the angle control device. At the time, our needs were met by VICLA, a company specialising in designing and building press brakes, shears and robotic cells in Italy. We therefore purchased two VICLA SUPERIOR 170 and 250 ton press brakes (3 and 4 metres respec-tively, both equipped with an automatic sheet metal loader and angle control de-vice) and a VICLA ATC tool change system to service both machines Speed and precision VICLA'S ATC automatic tool changer is designed precisely to minimise set-ups when these operations follow one after the oth-er; the system can reduce them by 4 or 5 times compared to manual operations. It also eliminates downtime between one phase and the next, allowing you to go di rectly from cutting to bending the part with out having to wait for traditional set-up times. In the new cell, office programming is now managed, a non-trivial operation in this new operational strategy, which begins with 3D 'solid mathematics and ends with bent products. The VICLA SUPERIOR hybrid press brake represents the top of the range from VICLA: brushless engines with a high energy coefficient, active crowning, flex system, angle control and double guided ram. This family of machines is available in difierent configurations (lengths, pressure forces and controls); all are characterised by an extremely solid structure made of high quality steel, capable of absorbing and eliminating mechanical stress and guaranteeing excellent bending precision. For example, the double guide preserves the stability and perpendicularity of the upper crossbar with respect to the work surface: this allows bending precision to be maintained with different tools and intermedi-ates, guaranteeing that the centring carried out at the test is maintained over time. A value not to be forgotten At Nuova inox we have seen that an operator's decades of bending experience is really an added value: we have seen, General Manager Fabiano Fieni concluded, that not infrequently these professionals are capable of inventing' a equivalent or better bending strategy than the one suggested by the soft. ware itself. But not evervone is such an ex-pert, and so cam programming combined with automation is very useful in routine op-erations, through which even beginners can become productive, indeed, they can take advantage of CAM to build on the results and therefore learn! We have put in place a system consisting of press brakes, stor age, ergonomics, set-up time reduction and safety, without neglecting the 4.0 approach and the tracking of the various steps. We are confident that this set-up in the company will allow us to consolidate our carpentry business through improvement of production capacity. As for the future, we look for ward to automation for welding and finish-ing, always ready to innovate”.
Let’s further discuss the fundamental aspects that need to be analysed before choosing a press brake. Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends... Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based. So what are the key elements to examine before signing a contract for press brake supply? #1: the Structure The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product. Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles. The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy. #2: the Double Guide The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing. This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced. #3: the Cylinders Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part. VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left. #4: the Hybrid System If in the past there were few types of bending machines, nowadays the market offers different choices: hydraulic press brakes; electrical press brakes; hybrid press brakes. These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system. Be careful, though! 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. It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines. The results in numbers of this technological innovation are significant, as seen on the graph. #5: the Clever Crowning 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-processed 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. The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length. What are the advantages of this intelligent system? Mainly three: it ensures great results even in the presence of an inexperienced operator; it uniforms the bending angle without any need for operator intervention; it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material). #6: the Flex Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet. Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon yawn and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out. #7: the Back The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities: Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance; Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence; New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength; Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference. Ultimately We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of: reducing operating costs; maximising productivity; achieving the most in terms of processing quality. By doing so, even the end client can count on a standardised and reliable supply.
A press brake is a specialized tool used in metalworking to bend sheet metal into various shapes and angles. It's an essential piece of equipment for industries ranging from small-scale fabrication shops to large-scale manufacturing plants. The technology on which operation is based is only trivial in appearance, however it hides remarkable developments in the mechanical and technological field. Table of Contents: Press Brakes How Does a Press Brake Work? Types of Press Brakes: Mechanical Press Brakes Promecam Hydraulic Press Brakes Servo Press Brakes CNC Press Brakes Hybrid Press Brakes Benefits of Press Brakes Applications of Press Brake Limitations of Press Brakes Alternatives to Press Brakes Conclusion How Does a Press Brake Work? Press brakes operate using two essential tools: the punch and the die. The die is a stationary V-shaped tool placed beneath the workpiece, while the punch is a movable component that applies force to bend the metal. The punch's movement is driven by a ram, which can be powered by various mechanisms such as mechanical, servo motors, hydraulic, or pneumatic systems. To learn more about the different types of press brakes and how they work, check out our comprehensive guide, A Deep Dive into Press Brake Technology. Inside, you'll find detailed information on components, terminology, and tooling used in the bending process. Here are some key terms to familiarize yourself with when working with press brakes: Tonnage: The maximum bending force a press brake can exert. Bending Angle: The angle created between the two sides of the bent metal. Bending Length: The maximum length of sheet metal that can be bent with a particular press brake. When Was Press Brake Invented? Press brakes, while a relatively modern invention, have a history dating back to 1882 when the first patents were filed. Early press brakes were labor-intensive affairs, relying heavily on manual operations. To create a bend, a mold was first crafted to match the desired shape. Sheet metal was then placed on the mold and surrounded by a mixture of sand and lead shot. Workers would then use a T-stake to pound on the metal, forcing it into the mold's shape. This process, while effective, was slow and often resulted in straight, simple bends. What are the differences between old press brakes and modern press brakes? 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. Different types of press brakes To grasp the intricacies of sheet metal bending and discover the optimal technology that balances efficiency, effectiveness, cost-efficiency, and versatility, it's essential to delve into the rich history of press brakes. Italy, a pioneer in this field, has fostered a thriving industry in the Brianza region, where businesses have consistently elevated the standards of Italian-made bending press brakes. Renowned worldwide for their tradition and quality, Italian manufacturers, including Mariani and others, have played a pivotal role in shaping the evolution of press brake technology. Mechanical press brakes Mechanical press brakes, though still lingering in some workshops for less demanding tasks, are now largely obsolete due to safety regulations. Despite their outdated status, they were once highly regarded for their speed and pressure capability. Brands like Mariani and Omag were particularly renowned for their mechanical press brakes. These machines operate using a flywheel mechanism that drives the up-and-down movement of the punch. A clutch system controls the gear shaft, resulting in a simple and user-friendly setup. This simplicity extends to maintenance, as components are generally easy to repair or replace. Additionally, mechanical press brakes often have a higher load capacity than their rated tonnage. However, mechanical press brakes have significant drawbacks. They offer limited control over punch speed, leading to compromised bend quality and accuracy. These limitations, coupled with their safety risks, have made them obsolete in modern manufacturing environments. Promecam RG hydraulic press brakes Pioneered in France by the Italian-French inventor Roger Giordano, RG Promecam's hydraulic press brakes were known for their compact size and unique low-profile design. A key feature that set them apart from other press brakes was the movement of the workbench instead of the upper beam. While most machines lower the beam to press the sheet metal, RG Promecam machines raised the workbench using a central hydraulic system. This innovative design offered simplicity and reliability, and it played a significant role in the history of Italian press brake technology. However, these machines no longer meet modern safety standards. They lack the ability to adjust bending speed and modern safety features. Therefore, they require specific safety upgrades to remain operational. Despite their outdated safety limitations, RG Promecam press brakes were once widespread and remain in use in some workshops today. In the post-war era, they represented a groundbreaking innovation. Their low-profile design allowed for the bending of large, closed profiles as they could be embraced by the upper part of the machine Hydraulic press brakes with torsion bar These press brakes are precursors to modern synchronized press brakes, sharing a similar appearance. They function by using a beam that descends via hydraulic pistons. Typically, these machines have two or three axes: X-axis for the rear carriage Z-axis for the rear carriage height Y-axis for the beam descent A distinguishing feature of these machines is the mechanical connection between the two hydraulic cylinders via a bar. This linkage ensures synchronized movement up to the lower dead center. The position of the lower dead center is adjusted using two nuts that can be raised or lowered to modify the end-of-stroke height of the cylinders and beam. These press brakes were often controlled by a simple positioner, lacking internal memory. Synchronised hydraulic press brakes Hydraulic press brakes, a significant upgrade from mechanical alternatives, utilize two oil cylinders to precisely control the punch. This hydraulic system enables superior bending capabilities and enhanced accuracy compared to mechanical press brakes. While offering these advantages, hydraulic press brakes come with increased complexity and require skilled operators. Maintenance costs can be high due to their intricate parts. Additionally, strict adherence to rated tonnage is crucial to prevent machine damage. Fluid leakage from the hydraulic cylinders remains a potential risk. CNC hydraulic press brakes have emerged as a popular choice in modern manufacturing. These machines feature automated systems that precisely control movement and timing. Synchronized hydraulic press brakes represent the state-of-the-art in press brake technology. They employ two independent hydraulic cylinders and proportional valves to regulate the upper beam's movement. This configuration offers greater versatility, allowing operators to adjust each cylinder individually to compensate for sheet irregularities. CNC control in synchronized hydraulic press brakes provides advanced capabilities compared to positioners found in torsion bar press brakes. Operators can fine-tune various parameters, including parking time, lower dead center, bending speed, and decompression. Electric press brakes or servo press brakes Electric press brakes, the latest innovation in press brake technology, remain a specialized solution for certain applications. While they offer speed, repeatability, and energy efficiency, they often lack the versatility of synchronized hydraulic press brakes, especially on large formats. Two primary methods are used to operate electric press brakes: ball screws and special belts. Servo press brakes utilize servo motors to power the punch. These motors, also known as servo-electric press brakes or electric press brakes, transfer mechanical energy to the punch via a pulley and belt system. Servo motors offer precise control over punch movement due to their numerous adjustment options. This translates to accurate bends and a quieter workplace. Eliminating hydraulic or pneumatic systems also prevents leakage issues. However, servo press brakes have a lower force capacity compared to other options. This limitation restricts their use in industries requiring higher tonnage. CNC press brakes CNC press brakes, versatile and automated machines, utilize computer numerical control (CNC) systems to deliver exceptional precision and repeatability. By incorporating CNC technology, businesses can significantly boost productivity, efficiency, and accuracy while reducing labor costs. Ideal for a diverse range of industries, including aerospace, automotive, construction, and electronics, CNC press brakes offer a powerful solution for various applications. To learn more about the specific benefits and capabilities of CNC press brakes, explore our in-depth article, CNC Press Brakes: A Comprehensive Guide Hybrid press brakes Hybrid press brakes represent the pinnacle of press brake technology, offering significant advancements over traditional synchronized hydraulic press brakes. VICLA, a pioneer in this field, specializes in hybrid technology, a solution that optimizes performance by combining the best aspects of different systems. This innovative approach delivers exceptional results in terms of precision, repeatability, energy efficiency, and cost-effectiveness. VICLA's hybrid press brakes guarantee microscopic precision in beam positioning, ensuring consistent and accurate bends. This precision is achieved through a reduction in oil usage, a hallmark of VICLA's technology. For example, a 110-ton VICLA .SUPERIOR hybrid press requires only 50 liters of oil per chamber, compared to 200 liters in traditional hydraulic press brakes. Less oil translates to fewer ducts, smaller tubing, reduced heat and expansion, and minimized clearance and wear. This efficiency is further enhanced by two powerful electric motors that operate directly on the minimal oil required. Repeatability is another key benefit of VICLA's hybrid press brakes. By minimizing oil usage, VICLA reduces the negative effects of oil heating and expansion, which can compromise precision over time. The compact oil circuit and precise construction further contribute to consistent results. Energy savings are a significant advantage of hybrid technology. Compared to traditional synchronized hydraulic press brakes, VICLA's hybrid machines can achieve up to 78% energy savings in standard conditions. This is made possible by a smart energy consumption philosophy that activates the machine's motors only when necessary. In contrast to traditional hydraulic press brakes, which keep their motors running continuously, VICLA hybrid press brakes only consume energy during the actual bending process. This reduces energy costs significantly, both in the short and long term. While hybrid technology offers a compelling cost advantage compared to electric press brakes, it also provides greater versatility. Electric press brakes, especially those using belt systems, can have limitations in bending certain shapes due to their structural design. Hybrid press brakes, on the other hand, offer the flexibility of traditional hydraulic press brakes, allowing for a wider range of applications. Benefits of Press Brakes In-house efficiency: Install a press brake on-site to streamline production and reduce costs. Unmatched safety: Modern press brakes prioritize operator safety with features like protective curtains and laser sensors. Accelerated production: CNC integration automates operations, leading to significantly faster production times. Reduced labor: Press brakes minimize the need for manual labor, especially when equipped with CNC automation. Cost optimization: Faster production and reduced labor translate to substantial cost savings. Applications of Press Brakes Machine tool components: Manufacture parts for various machine tools. Electrical components: Produce essential parts like junction boxes and enclosures. Automotive parts: Fabricate crucial components for vehicles. Construction materials: Create frames and duct parts for buildings. Limitations of Press Brakes Ram locking: Improper use or pressure can cause the ram to become locked. Limited control: Most press brakes cannot be stopped mid-cycle. Alternatives to Press Brakes Folding machines: suitable for certain applications but generally more complex and slower. Panel benders: ideal for thin metal sheets but significantly more expensive. Conclusion Press brakes are indispensable tools in any metalworking facility. VICLA offers a comprehensive range of modern electric and hydraulic press brakes designed to meet your specific needs. Contact VICLA today to find the perfect machine for your applications.
A CNC press brake is a modern machine for sheet metal bending. 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. Importance of CNC Press Brakes in Manufacturing CNC press brakes are highly versatile machines capable of handling a wide range of metalworking tasks. Their programmability allows for precise control over bending operations, ensuring accurate and repeatable results. From simple bends to complex geometries, these machines can efficiently process various materials, including steel, aluminum, and stainless steel. This versatility makes CNC press brakes indispensable in industries requiring high-quality, customized metal components. Types of CNC Press Brakes Hydraulic Press Brakes Hydraulic press brakes, known for their precision and power, utilize oil cylinders to control the bending process. While offering superior performance, they can be complex to maintain and may have higher operating costs. CNC hydraulic press brakes automate many functions, improving efficiency and accuracy. Synchronized hydraulic press brakes, a more advanced version, use two independent cylinders for precise control and greater versatility. Electric Press Brakes Electric press brakes are a newer technology, offering speed, repeatability, and energy efficiency. However, they may have limitations in force capacity and versatility compared to hydraulic press brakes. Servo press brakes, a type of electric press brake, use servo motors for precise control and quieter operation. They are suitable for applications requiring high accuracy and low noise levels. Hybrid Press Brakes Hybrid press brakes combine the best aspects of hydraulic and electric press brakes, offering exceptional performance. VICLA, a leader in hybrid technology, provides machines with: Microscopic precision: Ensures consistent and accurate bends. Energy efficiency: Up to 78% energy savings compared to traditional hydraulic press brakes. Versatility: Handles a wider range of applications than electric press brakes. Key Considerations: Force capacity: Hydraulic press brakes generally offer higher force than electric or hybrid options. Versatility: Hybrid press brakes are more versatile than electric press brakes. Maintenance: Hydraulic press brakes require more maintenance due to their complex systems. Energy efficiency: Electric and hybrid press brakes are more energy-efficient than traditional hydraulic press brakes. Noise: Electric press brakes, especially servo press brakes, are generally quieter than hydraulic press brakes. CNC Press Brakes Main Components: Bed, Ram, Punch and Die, Back Gauge Frame Also called beam, which is the movable part on which the punches are installed. It runs vertically along the Y axis and is positioned by numerical control at specific positions according to the operation to be performed. There are independent Y1 and Y2 axes that regulate the possible unbalance of the machine’s main ram (in a hydraulic press these are the different strokes that the cylinders can perform). The bench or bed Is the fixed part under the beam where the dies are installed. It can contain a centering (or crowning) system to compensate for the crossbar deformation, especially in machines two meters/6’ wide and up. Such a system can be found in a variety of versions which embrace different design philosophies among manufacturers or are based on specific machine types or families. Excellent results are possible through the use of a hydraulic crowning system. In this case, a number of high pressure and low flow rate cylinders are inserted within the machine bench to compensate for the frame deformation during the pressing phase by producing a counterforce from underneath. The lateral frames Lateral frames represent the side plates or shoulders that define the width of the machine frame. These can also be different: for example, machines with synchronized hydraulics almost always have a gap, called throat, so a sheet that is wider than the distance between the shoulders or columns can be inserted into the machine frame. Rear Backgauge Tthis device ensures that the bend is positioned correctly in the part to be produced. It usually consists of a beam on which two or more finger stops (backgauges) are mounted. They are able to move sideways to find the correct position. The axes, on the other hand, are: x: Forward and backward, sets the length of the bend (flange) from the center of the die to the tip of the fingers. r: up and down, adjusts the height of the stops/fingers to allow the fingers to reach the part better and so that dies of different heights can be mounted. z: left and right, adjusts the position of the stop/s on the table, to ensure that the back fingers are in the correct support position towards the punch and die. CNC Control System: How it Works A CNC press brake's brain is its sophisticated CNC system. This system interprets instructions and controls the machine's movements for precise, automated bending. Key components include Control System, Programming and Axis Control. Control System Hardware and software that processes commands and controls machine movements. Programming Operators create programs using specialized software to define bending parameters. The CNC system then translates these instructions into machine-readable code, specific to the press brake manufacturer. Axis Control The CNC system manages the vertical movement of the ram and the horizontal positioning of the backgauge. Additionally, some press brakes feature a crowning system that adjusts the bed's curvature to ensure uniform bending. Ram: The ram applies force to the metal sheet, creating the bend. Backgauge: The backgauge positions the sheet metal accurately before bending. Crowning: This optional feature helps prevent uneven bending by adjusting the bed's shape. 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 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 sheet metal bending brakes, 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. Industry 4.0 and Smart Manufacturing CNC press brakes are increasingly integrating with Industry 4.0 technologies, transforming them into smart manufacturing assets. This involves connecting machines to networks and equipping them with sensors and data analytics capabilities. Key benefits of Industry 4.0 integration include: Predictive maintenance: Using data analytics to predict equipment failures and schedule maintenance proactively. Real-time monitoring: Tracking machine performance and identifying bottlenecks in the production process. Improved quality control: Implementing automated inspection systems to ensure consistent product quality. Enhanced connectivity: Seamless integration with other manufacturing systems for streamlined workflows. Automation and Robotics Automation and robotics are playing an increasingly important role in CNC press brake operations. Sheet metal bending automation has advanced significantly in recent years. Collaborative robots (cobots) and anthropomorphic robots have revolutionized the industry, replacing traditional Cartesian robots. These automated solutions not only speed up the bending process but also reduce human error. Benefits of automated bending cells include: Increased efficiency: Faster bending cycles and reduced downtime. Improved quality: Reduced human error and more consistent results. Ergonomics: Relieves operators from repetitive tasks. VICLA has developed advanced solutions for automated bending cells. These solutions can help you streamline your production process and improve your bottom line. To learn more about how robotic bending solutions can transform your sheet metal fabrication, read our comprehensive guide “Robotic bending: advantages and limits”. As technology continues to advance, we can expect to see even greater levels of automation and robotics in CNC press brake applications.
Purchasing a press brake can be a daunting task, given the wide range of options available. This comprehensive guide will provide you with essential information on how to choose the right press brake, including selecting press brake punch and dies. We'll delve into key factors to consider, potential pitfalls to avoid, and valuable tips for getting the most out of your investment. By the end of this guide, you'll have a clear understanding of how to choose the right press brake for your specific needs. Primary Factors to Consider When Buying a Press Brake There are various factors at play when buying a press brake. Bending 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. How Do I Calculate Press Brake Tonnage? Our online press brake tonnage calculator is your ideal tool for accurately determining bend parameters for your sheet metal. In just a few simple steps, you'll get detailed information on: Tonnage: The force required to perform the bend. Inside radius: The inner curvature of the bend. Minimum flange length: The shortest possible length of the flange to prevent breakage. You should always oversize the press brake capacity by around 20 – 30% with respect to your data in order to allow for the variability in the characteristics of the metal and so that you are not in danger of working to the limits of the machine’s 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 Length 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. Material Thickness Different metals have varying properties and behave differently when subjected to bending. For instance, aluminum is generally more malleable than stainless steel. Understanding the characteristics of the specific material you’re working with is essential in determining the appropriate press brake and bending parameters. Our Ultimate Guide to Sheet Metal Materials provides expert insights and practical advice. Explore now to choose the perfect material for your project. Operator Skill Level Complex press brakes offer advanced features and automation, but they often require skilled operators. If your team lacks the necessary expertise, consider the time and resources needed for training. Weigh the benefits of increased capabilities against the potential challenges of operator training and maintenance. Types of bending brakes There are many different types of press brake machines. Each of these comes with its own set of advantages and limitations. You can choose the right press brake based on your use case. These different types of press brakes are: Mechanical Press Brakes: simpler and more affordable, but with lower precision and speed. Hydraulic Press Brakes: offer better precision and control but require more maintenance. Pneumatic Press Brakes: fast and easy to operate but have lower force capacity than hydraulic presses. Servo Press Brakes: highly precise and efficient. CNC Press Brakes: fully automated for maximum productivity and accuracy. Hybrid Press Brakes: combine the best features of hydraulic and electric press brakes for optimal performance. Tandem press brake: particular configuration that involves the connection of two machines into one, but there are also solutions that combine three bending machines (tridem) or 4 bending machines (quadrem). Read our guide on What to know before choosing a tandem press brake. Secondary Factors to Consider For the Right Press Brake 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 clumping 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 VICLA's 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 often underestimated. Companies, sometimes unconsciously, prioritize other areas of their production chain. For example, they may invest in state-of-the-art technical offices while using outdated press brakes. Sheet metal is a challenging material to bend, and underestimating its complexities can lead to costly mistakes. Fortunately, technological advancements have enabled manufacturers to develop efficient press brake equipment. While press brakes have matured in terms of operation and structure, the equipment used to enhance and increase their performance has also evolved. Essential Equipment for Press Brakes: Hybrid systems: modern hybrid systems offer exceptional energy savings and precise beam positioning (accurate to thousandths of a millimeter). VICLA, for example, has created the .Superior press brake, which allows to save up to 78% of energy consumption compared to hydraulic press brakes. Active crowning: Automatic systems with sensors ensure consistent bending angles throughout the workpiece. Multi-axis backgauges: Quick and accurate positioning of backgauges is crucial for complex shapes and small batches. Off-line programming (CAM): Standardize processes and transfer expertise to new operators. User-friendly numerical control: Intuitive interfaces facilitate easy operation for both experienced and inexperienced operators. Press brakes with hybrid technology 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. Real time 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 for press brakes 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. Metal bending 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. CNC press brakes have 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.
Industry 4.0, the fourth industrial revolution. You hear about it often, but what does it actually mean? It is a change to the production parameters used up until now or, better still, an inevitable and necessary evolution in the way we manufacture in order to improve quality and working conditions. The fourth major change in the industrial age – known as “revolution” for good reason – is taking place through computerisation and system digitisation. In fact, Industry 4.0 refers to a new way of conceiving today's industrial systems, a transformation that affects the structure of the industry as a whole. To be 4.0 involves not only individual machines, but the entire factory system. Innovation, integration, efficiency Transforming a company into 4.0 involves first of all an in-depth analysis of all aspects of its structures, and of its own needs and goals. Every business is first and foremost called upon to understand where actions are needed and feasible and, most importantly, how to structure the change towards the digital world internally. There are three elements in this new way of viewing industry: technological innovation, based in particular on a drive towards computerisation that allows close collaboration between all the elements involved in the production process; integration between systems, between different parts of the company and between the various components of the entire supply chain; efficient energy use, in which consumption reduction is a major consideration. The data above all But where to start? Based on the digitisation process, Industry 4.0 requires knowledge and systematic collection of the data produced; all of the data! This means not just the data from the actual production process, but also data, for example, from handling incoming and outgoing goods, or even from management of resources and relationships throughout the supply chain. In essence, any aspect of company life. When properly managed and shared, this massive amount of information – the so-called Big Data – can be used to optimise resources and reduce waste. All of this results in a decrease in material and time losses for the company. It streamlines processes and work flows, making the business more efficient, with cost savings and therefore a financial benefit. The evolution toward Industry 4.0 also brings new job opportunities. From a professional perspective, over the coming years digitising industries will require specialist professionals with digital skills, figures that did not exist until recently, and greater attention to continual personnel training.
Press brakes are essential tools in metal fabrication, but neglecting their maintenance can have serious consequences. Just like any other machine, press brakes are susceptible to wear and tear that can lead to breakdowns, reduced efficiency, and even safety hazards. Press brakes overview Press brakes are essential machines in metal fabrication, designed to bend sheet and plate metal into various shapes. There are many different options for generating force and moving the ram. This results in many different types of press brake, such as hydraulic press brakes, cnc press brake, electric press brakes and hybrid press brakes. This guide will show you the daily, weekly and monthly procedures we recommend. In addition, there is a list of procedures to be carried out at least once a year in order to keep your press brake in perfect working condition at all times. Always bear in mind that these are routine procedures; for more serious problems, always rely on our VICLA qualified technicians. The Cost of Downtime Imagine the impact of a press brake malfunction in the middle of a critical production run. Downtime translates to lost revenue, delayed deliveries, and frustrated customers. Studies show that metalworking companies experience hundreds of hours of downtime per year due to equipment failure. Beyond Downtime: The Hidden Costs of Neglect The financial impact goes beyond immediate downtime. Unmaintained press brakes are more likely to experience: Reduced Accuracy and Quality: worn components can cause inconsistencies in bends, leading to scrap metal and rework. Increased Energy Consumption: inefficient machines require more power to operate, driving up energy costs. Safety Risks: malfunctioning brakes pose a threat to operators and can lead to costly accidents. Higher Repair Costs: early detection and prevention through maintenance is significantly cheaper than major repairs after breakdowns. Building a Cost-Effective Maintenance Strategy There's no single silver bullet approach to press brake maintenance. The optimal strategy depends on factors like your usage patterns, the age of your machine, and your budget. However, a proactive approach offers the best return on investment. Consider implementing a combination of practices: Preventive Maintenance Is done before a failure occurs and consists of maintenance types like: Time-Based Maintenance, Failure Finding Maintenance, Risk-Based Maintenance, Condition Based, Maintenance and Predictive Maintenance. Corrective Maintenance Is done after a failure has occurred either as Deferred Corrective Maintenance or as Emergency Maintenance. By investing in a comprehensive press brake maintenance plan, you can improve your machine's efficiency, longevity, and safety. This ultimately translates to a more robust manufacturing operation, increased profitability, and a competitive edge in your industry. Remember, preventive maintenance is an investment, not an expense. Planned Preventive Maintenance Planned Preventive Maintenance includes inspections, checks, and interventions to maintain the condition of wear parts and machine lubrication, preventing failures and malfunctions. While these operations are relatively simple, they must be performed by qualified staff. Press Brake Care: Key Areas of Focus Always clean your bending brake Regular cleaning is essential for maintaining a press brake's optimal performance. Dirt and debris can accumulate, increasing friction and leading to component wear, potential breakdowns, and reduced accuracy. A clean work environment also helps minimize the frequency of machine cleaning. Lubrication: A Critical Component of Press Brake Maintenance Proper lubrication is essential for ensuring smooth operation, reducing wear and tear, and extending the lifespan of your press brake. Lubricants help minimize friction between moving parts, preventing excessive heat buildup and potential damage. Lubrication Points and Frequency Press brakes have various lubrication points, each with specific requirements. Some parts may need weekly lubrication, while others might require less frequent attention. The exact lubrication schedule depends on the press brake's design and operating conditions. Lubricant Types Common lubricants for press brakes include: Lithium grease: A versatile lubricant suitable for many applications. Silicone grease: Offers good resistance to high temperatures and chemicals. Synthetic non-petroleum lube: Provides excellent performance in extreme conditions. Dry film graphite lubrication: Ideal for applications requiring minimal lubrication. Avoiding Over-Lubrication Excessive lubrication can lead to the accumulation of dirt and debris, which can counteract the benefits of lubrication. Follow the manufacturer's recommendations for lubrication intervals and quantities. Regular lubrication, combined with proper cleaning and inspection, is a key component of effective press brake maintenance. By adhering to lubrication guidelines, you can significantly improve your machine's performance and longevity. Inspection Regular inspections help identify potential problems before they escalate, saving time and money. Conduct visual inspections at regular intervals, both when the machine is stationary and in operation. This allows you to identify any signs of wear, damage, or misalignment. Test all components, including safety devices, controls, and moving parts, to verify their proper operation. Create a comprehensive checklist to guide your inspections. This ensures thorough coverage of all critical areas and helps you track maintenance history. Note any areas of concern or potential issues in your inspection checklist for further investigation or corrective action. Calibration Ensuring accurate calibration of components like the back gauge is essential for maintaining precision in bending operations. Electrical and Hydraulic Maintenance These systems require specific attention to prevent malfunctions and safety hazards. Press brake maintenance: preparing the press brake Before cleaning, you must prepare the machine to ensure your safety and that of your colleagues. We recommend the following procedure: At the start of the work shift, inspect the machine and check that the table and die area are free of residues from the previous shift. Delimit the area with barriers and signs. Lower the mobile beam until the tip of the top tool touches the bottom tool. Keep the tools closed until all maintenance work is complete. Switch off the power supply and padlock the main disconnector switch on the electrical cabinet door. Turn the mains switch to the 0 position. The five precautions to take during press brake maintenance When combined with correct press brake use, scheduled maintenance makes a significant difference to its performance and efficiency. When carrying out maintenance or repair work, always follow the instructions in your press brake maintenance manual carefully. Here is a generic list of precautions you should observe: Do not use solvents and flammable materials Take care not to disperse cooling lubricants in the environment Use suitable equipment to access the highest parts of the machine Do not climb on parts of the machine as they have not been designed to support people When the work is complete, reinstate and secure all safety devices and guards removed, opened or disabled previously Scheduling press brake maintenance Daily maintenance Carry out the following checks at the end of the shift or working day: Check that the safety devices are working. For example, our VICLA press brakes are equipped with Lazersafe devices. They are optical safety devices fitted with lenses that focus laser beams to monitor the danger zone under the beam. The front lenses of the transmitter and receiver must be cleaned whenever you notice any traces of dust, grease, fingerprints, oil, stains or dirt. Remember to check that the three-position down pedal is working. Use a dry cloth to remove all processing residues. NEVER use compressed air and always protect your hands with neoprene or PVC gloves. Clean the tools, bed, supports and backgauge carefully. Do not forget to check any accessories installed on the machine. Weekly maintenance Make sure that the emergency stop button is working correctly. Check that the rear guard is working. Check the side guards. Check the filter clogging indicator. Replace the filter element if the vacuum switch pointer is on yellow. Monthly maintenance Clean the hydraulic pipes and components. Clean the outside of the hydraulic system (manifolds, valves, motor/pump unit, pipes, etc.) at least once a month. This cleaning serves to identify possible leakage areas and reduce the risk of contaminants entering the system when replacing components. It also prevents a reduction in heat exchange between the system and environment. Visually inspect the fittings to ensure that they are sealed, and tighten them if necessary. Remember to check that the hydraulic circuit connections are tight after the first 160 hours of press brake operation. Monthly maintenance of the rigid pipes, especially near fittings, pump and cylinders is important to identify leaks. Consider also the hoses connecting the pump to the system; replace them if there are any bulges. Oil level: remember to check this after any maintenance work on the hydraulic system. Clean the air filter on the compressed air tank. Annual maintenance Clean and lubricate the guides of the mobile beam with a clean cloth every year. Air filter unit with condensate separators. Replace the oil separator micro-filter once a year or when the pressure drop reaches 1 bar. Change the oil in the hydraulic circuit. Clean the tank and replace the filter element in the oil filter. Conclusion In this guide we have seen how to keep your press brake in good working condition. In fact, a clean machine is also a monitored machine, because damage or small oil leaks can appear at any point. Now that you know what to do every day, every week and every year, you can create a complete maintenance schedule for your press brake.
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 Materiale: Acciaio Alluminio Ottone Spessore T [mm]: Raggio interno R [mm]: Lunghezza piatta L [mm]: Lato A [mm]: Lato B [mm]: Mostra calcoli: Fattore K: Bend Allowance: Calcola 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.
The word “efficiency” is mostly associated to “saving”. Even if the link between the two is real, because a saving - be it a material, energy, time or fatigue saving – is very often the result of being efficient, they are two very distinct factors. Making a system, a production line, a process or just a single machine efficient means being able to make the most of what is available, its features and resources, elements that must work together to give the best possible result on the basis of the goals to be achieved. All this, paying attention to reduce waste. The heart of machine: the work area The possibility to customize a machine based on the specific operative needs of the company that will use it becomes an important thing to improve its production efficiency and, thus, it's competitive ability. Talking specifically of metal sheet working machines, such as industrial presses, the work area is an important element. From this station, machine operations are managed and production flow is set: for this, it is essential trying to ensure the best man-machine interaction, from which a relevant part of the final quality of what is produced depends. Comfort during the working stages and ergonomics of the station are the first two elements one thinks to: they are surely important, but not the only ones to be considered; the following factors are determinant as well: the adaptability of the work area, that allows to safely manage all the processing stages and to smartly pass to different tasks, ensuring in this way the production of different lots - also small ones - minimizing times; the custom setting of the station for an ideal access to tools; machine layout, so as to adapt it to the space in which it will be placed; safety, strictly respecting the relative current legislation. The cornerstones of efficiency In general, in the search for efficiency both generic elements, that is common measures that can be applied to any working condition, and specific factors based on the specificity of any single production or production exigency intervene; so they can differ depending on the situation, even when they interests the same type of machine. In this way, the search for efficiency becomes a real company strategic process that pivots on some fundamental factors (besides what has just been considered): collaboration supplier-user. Being able to understand and interpret a company necessity becomes the pass for new market shares. Starting from the design stage - just think of what has been already said about work area - the comparison with the customer allows to realize custom solutions, able to make a unique product from a standard one and to indulge the user company needs. the ability to look at the market, to understand its trends and, if possible, to anticipate them paying attention to innovation. Projecting solutions that can ensure high performances, energy and resources saving and a reduced environmental impact is part of this ability. relying on expert and certified suppliers. Choosing the right partner determines the final quality of the machine, in terms of material quality, speed in the answer and respect of delivery times, that need to be quicker and quicker. providing structured pre and after-sales able to respond to its customer needs, possibly by offering custom solutions. From planning consultancy to supply of spare parts, from assistance to maintenance, the service offered - on the ground or remote - needs to be professional, precise and prompt. investing in a continuous R&D (Research and Development) that focuses on the most innovative materials, components and technologies. Facts show that this approach is a valid one: the company that could develop flexibility in the management and realization of their machines have been able not only to keep, but also to increase their market shares, even during the long years of economical crisis. Basically, becoming efficient to ensure in turn solutions that make efficient the production process of customer companies.
When we talk about problems in engineering production and, more specifically, of a press brake, we are tackling an issue that represents a huge source of waste. In fact, a given problem can affect several parts of a machine tool and generate others within the entire production flow. In the field of press brakes, we can make two major distinctions, between: problems when purchasing problems arising over time The former are mainly linked to a lack of attention when it comes to its design and construction. In particular, the aspects that inevitably turn into problems are: Lack of structural precision There is no denying that machines offered at cheap prices and which come from countries where quantity is preferred over production quality, cannot boast an acceptable constructive attention. So, among the issues we can immediately encounter on a press brake, there are the poor alignment of the beam and the bed, and the perfect parallelism between the frames. But there’s more: also the perpendicularity of the assembled elements and their respect for dimensional tolerances. All this translates into lack of bending precision. Quality of the moving parts and their management We refer to cylinders and optical lines, but also and above all about the backgauge. In particular, in the latter element you can immediately see the construction quality of the press brake, the speed of the movements, their precision and the speed with which the matching parts are positioned, as well as how they stop. Robustness. It might seem self-evident, but it’s not. Always be wary of press brakes with structures that are too thin. Regardless of whether our core business is focused on making thin gauge parts, it is not acceptable for a single different process to irreparably damage our press brake. Deflections must be compensated for by special systems, such as camber, but they must not be excessive due to an undersized structure. The distortions of the machine, in fact, do not affect only the beam, but also the frames with the opening, the so-called “yawn. Instead, the problems encountered over time are often linked to poor build quality, which comes in the form of: Irreversible distortion of the machine or components It is not acceptable that the structure of a bending press undergoes irreversible distortions, nor that fundamental accessories such as, for example, intermediaries undergo it. When the structures are thin sheets or of unsuitable material, they can yield under not too excessive tensions. Overall unreliability A press brake is only apparently a simple machine. In reality it is an orchestra of components that must be chosen and manufactured to perfection, and which must also last over time. Cylinders, fittings, recirculating ball rails, motors, bearings, encoders: every single part, even the smallest, if it stops working creates a much bigger problem. Scarce availability of spare parts subject to wear or failures The reliability of the components, as well as the availability of spare parts are closely linked to the price of the press brake. What is the point of spending a low sum if the press brake not only breaks down continuously, but is also difficult to repair? The problems of a press brake, even if we refer strictly to the machine and not the supplier or after-sales service, turn out to be the biggest causes of all the waste of money that a company is forced to face. A press brake that does not function correctly could still manufacture parts, but the time spent in constant adjustments and fine-tuning is a bleed of money that no business can afford. Choose your next press carefully: find out what you need to know in the bending manual, which you can find for free below.
The ease of use of the Vicla CNC also for inserting a matrix in the library. The efficiency and reliability of a press brake is also measured by the machine's ability to allow simple and accurate programming of each type of processing. Vicla® presses are designed to offer the best in terms of operator control. This video tutorial shows metalworking enthusiasts how to quickly and easily insert a matrix into the library through programming on the Vicla CNC. First of all, you must select the icon of the matrix list and choose between new designated or default matrix. Let’s say we want to insert a matrix through the second option. Now all we have to do is set the following data: the height, the angle of the slot, the measure of the V, the distance between the center of the V and the side of the matrix, the height of the base, the radius that is detected from the data of the matrix, and finally the load. Now all you have to do is save the entered data and name our matrix. Once back in the library, it will be possible at any time to recall the saved matrix with all its stored data.
SET UP A WORK STATION FOR IMMEDIATE CALCULATION OF Z AND BENDS. A few simple steps to create a CNC workstation on a VICLA® press brake. In this short video tutorial we’ll show you how the operator can quickly and easily create one or more workstations by programming on the CNC. First, access the Tools menu and enter the tool name and the tooling values of the punch and die (initial quantity and length). The position of the tools on the press brake is now established and work station n°1 is created. To set station n°2 just repeat the steps. At this point you can calculate the Z value and set, for example, bend n°1 on station n°1 and bend n°2 on station n°2. In this way you obtain 2 different values of Z.
From VICLA’s CNC it is possible to insert the punch in the list through a few simple and quick steps. Programming on VICLA CNC is simple and intuitive. It is in fact designed to optimize processing times, minimize machine downtime, and increase press brake productivity. In this video tutorial we’ll show you how easy it is to insert a punch in the tools library. First you need to access the punches menu and choose the type of punch you want to insert in the library. From the standard and gooseneck punch, to the acute punch up to the reverse clamp one. For example, if you wish to create a new classic punch, all you have to do is just enter all the punch data, available from the catalogs of the manufacturers, such as height, bend angle and all parameters. Then simply save the recorded data with a name, to add the punch in the library list.
CNC graphics program: VICLA PRESSES ARE EQUIPPED WITH TECHNOLOGIES ABLE TO PROVIDE QUICK AND PRECISE SOLUTIONS.
The scenario is typical of today's market: huge workload, unmatched pieces, very high level of quality required and strict deadlines Everything seems to be going smoothly. The machine bought at a terrific price is turning out to be a real bargain: it folds everything and seems to be having no issues. The operator has finally adapted to the new press brake and his hands run as fast as the wind on the buttons of the CNC. Suddenly the unexpected happens: the operator presses the pedal, the press emits an unusual sound, as if it were unable to stand the pressure. The beam lowers, first aligned, then it goes down on one side. At the same time, a yellowish trickle pours down from the crankcase of one of the two cylinders. The situation is clear: the press brake is broken. The moment in which the damage occurs, you start counting your losses, an activity that bears the name of calculation of lost earnings from lost profit. It is difficult to quantify the waste of money, only after careful analysis is it possible to have a plausible estimate of its extent. It must be said that, unfortunately, collecting data costs time and effort. However, if we do not rely on precise and reliable numbers, we will not have an indication of which ones are the really convenient choices for our company. This is why it is very important to catalog the costs of a machine downtime. Some are intangible and difficult to estimate, but most are absolutely recognisable in a short time, by answering a few simple questions: 1) How much does your press brake operator cost? A bender is usually a skilled worker, so he is not the one with the lowest salary as he creates some type of added value. From the moment this element goes missing, the cost for the company immediately begins to have a certain weight. He could, perhaps, devote himself temporarily to other tasks, but the bending department will certainly travel at reduced speed due to machine downtime. 2) How much does the assistance cost? It depends on whether an agreement has been made with the manufacturer. Often, if the machine is not new, you can turn to the parent company service or to freelance technicians. In any case, there is an hourly cost to be incurred, which obviously increases in relation to the duration of the repair. 3) How much do the spare parts of our press brake cost? And let's add, how easy is it to find them? Their cost is what we immediately see, but the difficulty in finding them immediately extends the downtime, increasing the cost of the first point, and all the others that we will see later. Among the costs that cannot be quantified quickly, but that can have heavy implications, there are what we could define as risks, including: Stress of the adjacent units In other words, it means that the work that the faulty press brake does not do must be disposed of by the other machine(s) present in the company. Often this leads to an acceleration of processes which can increase the chance of error. Or, the need to increase the hours of employees, or add a shift for the entire downtime. All this has an obvious impact on the total cost of the breakdown. Manufacturing outsourcing. Contacting a workshop that carries out our same business could be a solution to temporarily solve the problem of halted deliveries. Obviously the cost of labor will be different, and is added to all other costs determined by the machine downtime. Delivery delays. This is the worst risk that a subcontractor can face, together with the non-conformity of the processed parts. Unfortunately, the consequences of this disservice can be different and depend on the type of relationship with your customers. With some, a late delivery can result in a penalty, which partially or totally affects your earnings. With others it can lead to the end of the business relationship, especially when it has just begun. So, you should always ask yourself how much does a downtime cost? whenever you’re choosing the supplier and the press to buy. It is necessary to look beyond appearances to see beyond the price! Choosing your next press is therefore a crucial choice that will determine your production. Choose the one that suits you best: trust the experts!
THE INNOVATION THAT CUTS DOWN COSTS, CONSUMPTION AND POLLUTION. Superior in every way, also in terms of energy saving, consumption reduction, and respect for the environment. .SUPERIOR is the press brake designed by VICLA, able to bend and cut the costs of the entire manufacturing cycle and to speed up production times. It is equipped with a standard innovative hybrid system, with no price difference compared to a traditional machine, guaranteeing exceptional energy savings and a significant reduction in oil consumption thanks to the use of the double tank. The results in numbers of this technological innovation are: energy saving of up to 78%, a significant oil consumption reduction (eg: 2X40 liters - press 110 t), an increase in productivity by 20%, decrease in fast-up limit by 20%, 50% decrease in oil temperature, 70% less risk of leakage, 50% reduction in tank volume, and 50% faster and easier installation process. With VICLA Hybrid System there is also a 60% reduction in the piping system. All these advantages translate into a greater manufacturing system efficiency and perfect finished products. In one word: quality. Not only in terms of frame stability and bending precision, but also energy saving and minimisation of pollutants. The Hybrid System is a standard feature present in the standard version of the .SUPERIOR sheet metal press brake which, depending on production needs, offers extreme flexibility even in terms of optional features and customised solutions. Such as the Hybrid System Plus: the system that cuts down consumption to 78% compared to traditional machines and to 23% more compared to the standard Hybrid System. Hence VICLA's commitment to endure absolute quality continues. Through daily investments in research and development activities entrusted to highly specialized staff and engineers, with top qualification and skills in metal working. Ongoing efforts that already demonstrate the achievement of new and important goals. First of all, the development of an innovative system for automated die change will be completed shortly. Now that you know about Hybrid System, find out what you need to know about your new press brake: Download the free press brake manual now.
The Hybrid Press Brake is the latest evolution of bending in the current market. Over the years, manufacturers have been looking for solutions to reduce the difficulties of standardization and manufacturing sheet metal parts but bending has many variables related to the material and the environment. Through tools, functionalities and technological innovations bending has evolved starting from mechanical presses, similar in terms of operation to eccentric presses for stamping. They are now completely unusable because they do not comply with current safety regulations and cannot be adapted. Promecam RG, French machines are no longer on the market, with a single central thrust point which raises the bench instead of lowering the crossbar. Hydraulic torsion bar presses, they are apparently similar to today's ones structurally but actually have the big limitation of not having independent cylinders. Synchronized hydraulic presses, evolution of the torsion bar machines, make bending easier and more effective, thanks to superior versatility and precision. Electric presses, in reality not widely used. Hybrid presses, represent the latest evolution of bending on the market. The latter contains the best of hydraulic technology combined with an excellent electronic management system. Hybrid bending machines This system upsets many of the set rules that the operators have firmly rooted in their experience. For example, a bad bending is almost always attributable to a piece of sheet metal with a thickness that is inconsistent and poor quality. But when you finally can rely on millesimal positioning of the crossbar, all the defects of the old technologies used up to that moment come up. The hybrid system allows three advantages that no company that wants quality and competitiveness can give up: Greater precision That translates into not only greater reliability on the single piece, but also into great repeatability. The punch always reaches the same low dead point (LDP) to the thousandth of a millimeter each time with consistency. This is also because the oil handled is much less than in traditional synchronized hydraulic presses. This means that the thermal range during operation does not affect the movement of the crossbar at all. Higher speed The hybrid system allows fast and precise crossbar movements. Even if the speed of execution is not only this, it is above all having to make fewer checks and adjustments on the parts produced in order to streamline the process infinitely, increasing productivity exponentially. Reduced consumption It is also under this aspect that the hybrid system gives the best of itself. When you turn on a traditional press you can easily understand that the energy absorption is huge and constant, because of the hydraulic pump that remains always running. All for an operation that takes place in only few seconds. The actual bending of a piece takes very little time compared to the set-up, handling and control phases. The hybrid system only absorbs the energy it needs when the operator activates the bending press. Although it may be an invisible cost, because it is not seen as a living cost, energy saving is absolutely important. So it is worth buying a bending press with a hybrid system, even if it means spending more than traditional systems. Why? Just read the three previous points and the conclusion is drawn! Find out everything you need to know about press bending. Download the free manual that will guide you on what to look for on your new bending press now.
VICLA announces the upgrade of the 3D PROV with two new, exciting features. The new 3D PROV Software Data Rec and Track Prod for an improvement in business performance. Since its launch in the world of metal working, VICLA has been operating with a future-oriented mindset. Bypassing the production of traditional machines and focusing on creating hybrid products. A choice that, together with the high-quality of the materials and components, has allowed the brand to establish itself as an ambassador of the Made in Italy style. This is just an example that proves VICLA's full adherence to every innovation capable of leading the company to ever higher levels of competitiveness. And to a growing processes automation. Through the implementation of interfaces and languages that promote interaction between operator and machine. Creating value with the use of data that enhance the computing ability of the machines. And again with the use of tools interconnected with physical and digital systems and real time adaptations (3D printing, robots, interaction between machines). All features that are at the basis of the definition of Industry 4.0 within which VICLA fully recognizes itself. In this regard, we are pleased to announce that we have taken a further step in this direction. With the upgrade of VICLA’s 3D PROV, designed for the preparation and processing of 3D products. This regards the ability to install two new features. Software that allow the machines, and the companies that use them for their productions, to operate according to Industry 4.0 standards. The first of the two new features is the Data Rec Software. A tool capable of acquiring machine data and inserting it into an sql or access database. It provides detailed information for job scheduling such as the production times of parts, processing in manual, semi-automatic or automatic mode. Basically, it allows access to the data relating to the programming, tooling, test execution on the first part, and running parts times. The second feature is the Software Track Prod. It offers the ability to monitor, view and track data on the company management program with a valorisation of the entire manufacturing cycle. In fact, it provides information, analysis and reports in order to guarantee optimal use of the machine and a remote control Alarm History. A very useful service for identifying critical issues by simply viewing the history of messages sent by the machine. The new functions of the Data Rec and Track Prod Software therefore offer the possibility of identifying any problem. In order to optimize and minimize them. With beneficial effects on business performance and the processe examination. And all while encouraging the development of approaches based on data analysis between operators and the company organization. A significant number of advantages that represent a revolution in the manufacturing systems of companies that choose VICLA brand for their production. Discover how to choose your next press brake: download the free press brake manual now.
The highly competitive market of our days brings companies to travel the road of increasing efficiency and reducing wastes simultaneously. It is really possible to get the two things? Without any doubt, if the card of technological innovation is played. Today, in press brake sector an extremely interesting system to produce more pieces, more quickly and with a special care to environment exists: it's hybrid system by Vicla. It represents the vanguard and the natural evolution of synchronized hydraulic press brakes that, thanks to hybrid technology, reach performances that were unimaginable until some time ago. It is useful to explain why we talk about hybrid technology: first of all because it puts together the best of hydraulic and electrotechnics, managed by exceptional electronics. Let's see its advantages. Producing more pieces Thanks to the presence of two powerful brushless engines, the movement of the cross piece is fluid and extremely precise. The upper tools distort the pieces with extreme precision and repeatability, and the movements reach incredible precision for a completely new bending experience. How many times, if the bending is not precise, the pin is on materials? Well, with hybrid system by Vicla all the limits of the machines we have always used emerge. Having available such a precise lower dead end makes everything simpler: in this way productivity increases. A quicker production Brushless engines, that are quick and precise, are directly connected to two small oil tanks. This means that the machine with the new hybrid system by Vicla has a simpler but more efficient hydraulics. The oil used to activate the crosspiece is much less than that used in traditional hydraulic press brakes. The result is more precision, since hybrid system by Vicla is not affected by temperature variation, as opposed to traditional machines. In this field, a precise machine is without any doubt the best way to increase the speed of pieces execution. 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. Thanks to hybrid system by Vicla, the consumption is linked to the effective use of the machine (which consumes only when it is active). Brushless electrical engines move the crosspiece (consuming energy) only when the pedal is activated, otherwise they are off. 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. Another aspect that makes hybrid system by Vicla really green is the low quantity of oil used compared to traditional hydraulic press. Replacement and disposal costs are drastically cut: in other words, more saving and less environmental impact. In the competition dictated by the market, innovating is not an option anymore, but an obligation. And Vicla proposed to innovate thanks to its hybrid system, by offering performances never seen before, new levels of productivity, precision and saving.
Everybody looks for speed at work, which translates into process efficiency. But what does speed mean? A quick press brake is not that which axels Y, X, R and possibly Z are quicker than the others. The speed of a press brake is compared only to the quality it offers to the whole production process. For this, it is important to know the evolution of technology and the limits that have been gradually overcome: this is useful to choose the quickest machine according to what we produce and what is offered by the market. Speed is, therefore, a partial component that can be reached only along with an evolved press brakes' builder and can be overcome thanks to most suitable suggestions for your needs. But first of all, it is necessary to know more about the obsolete technologies that in the past contributed to reach the current standards. If the three-points bending (see bending manual) is about a relatively simple notion, during the years many technologies have tried to get the same effect, that is the controlled approach of a stamp to a mold in the most precise and quick way. Mechanical press brakes It was the first bending press, now it is obsolete. Connected to a flywheel and with a movement similar to the one given by molding eccentric presses, they gave a focused and apparently rapid push. Indeed, with no precision nor adjustable gauges, the speed of axel Y is not enough to really improve the process. Moreover, they were really dangerous. RG Promecam One of the most historical machines, produced by the French company Promecam that doesn't exist anymore. Unconventionally, it worked the other way around (it went upside to fix stampings, rather that downside). Torsion Bar Hydraulic Press Brakes Apparently identical to synchronized hydraulic press brake still used today, they represent their forerunner. The descent of the two cylinders was synchronized by a system of levers connected to a torsion bar. The limits, instead, were often made by two pieces moved by universal joints that shifted the cylinders setbacks. Synchronized hydraulic press brakes They represent the majority of the machine used today. The two cylinders are independent and moved by the action of dedicated valves. They are a great compromise to reach the speed needed. Also, the technology used is established and reliable: since various tools can be added (multi-axels back gauges, graphic numerical controls and many more), it may represent the most suitable technology for you. Hybrid hydraulic press brakes Sometimes called electrical press brakes, they are the natural evolution of synchronized hydraulic machines. In this case there is a very high speed, thanks to the match between a great precision and the technologies just described. The secret is the presence of two brushless engines that directly move two separate small oil tanks. It follows that speed and precision go hand in hand with reduced consumptions. Electrical press brakes They represent a niche because they are suitable only for specific works. They can be moved by belts or by recirculation screws in traction or in pressure. Another aspect, that may not seem to be connected with speed, is its dimension: this is especially important if thinking in terms of workflow speed and not relying on a single machine. This could be the case of who produces the 80% of pieces or more which bending is under 1500-2000 mm. A valid alternative can be relying on a builder that has on the catalogue a very small and speed machine that does most of the work in terms of variety and tools.
The motor pool updating has become a real necessity for all those entrepreneurs who want to keep up with the market. When choosing the press brake, there are many features to consider since the machinery must be compliant with the company necessities and several requirements in terms of efficiency and performance. Press brakes by Vicla have cutting-edge features that, along with an open and settable software, ensure the possibility to answer all the company needs. .SUPERIOR PRESS BRAKE .Superior is Vicla high-end press brake. The study on the structure flexion allowed to design a press brake that properly responds to mechanical stress. One of the advantages of .Superior is the possibility to upgrade it and to add extras also at a later stage. Thanks to the Hybrid System included in the high-end .Superior press brake, the producer allows to use the hybrid system at the same price of the standard one: this translates into many advantages, especially the energy saving (up to 55% more than standard machines) and oil reduction, also thanks to its dual tanks. The parallel shoulders are a feature of this machine that ensure the precision and speed of back gauges. IRIS AND IRIS PLUS Iris and Iris Plus are two upgrades for .Superior press brake that ensure quicker work cycles thanks to the fact that its gear is at zero millimeters from the sheet and the speed is adjusted according to the pieces in working. Iris Plus ensures precision and speed thanks to this feature and the check of the angle ensures optimal results from the first bending. BEING .FIRST Besides the high working speed that ensures the maximum productivity, other remarkable features are the very quick axles movement, its ergonomic design that - along with its reduced dimensions - allows a perfect management of the machine, a led lighting of the work area, it's quietness, the possibility to customize the tool holders according to the customer's needs and many other features that make it safe and very precise. BE .SMART The little .Smart has been designed for a versatile, functional and flexible production. It has a non-active hydraulic convexity and 4 axels (that can be updated until a maximum of 6) and a 250 mm stroke. .Smart is a traditional machine with the technology of .Superior, completely assembled in Italy by using Italian and European components. An interesting feature is that it reduces flexions to the minimum thanks to the dimension of the blade holder. .Smart cylinders are made from high-resistance shaped bars lapped on the sliding part. VICLA SAFETY WORK Vicla is one of the youngest companies in press brake sector and in only ten years has become an important reference point for national and international markets, reaching Europe and Northern America, thanks to Research & Development and Safety investments, also redefining safety as safety work. Its press brake respects the strictest regulations in force, so as to respect all the standards, including legal ones.
There are several laws and safety certificates to be considered both in Europe and outside, because press brakes are a type of machine that involve many laws according to the safety disposal used on the machine itself. Let’s try to understand the importance and the application fields of such laws, but also legislative decrees of who is subjected to suc obligations and how this can help to choose the best in the field of press brakes. The importance of certifications Products manufacturer are the first to be involved in the field of laws and certifications: once identified the press brake, it is important trying to understand if it respects the standards required by rules or laws. In this regard, we consulted the Inail manual (ex Ispesl) for the safe use of press brakes (Caratteristiche di funzionalità e sicurezza dei dispositivi a protezione del fronte lavorativo delle presse piegatrici idrauliche, Features of functionality and safety of devices to protect the working front of hydraulic press brakes). Legislation is made of already operating State laws (in this case we refer to Presidential Decree of April 27th 1955 n. 547 Norme per la prevenzione degli infortuni sul lavoro, Rules for the prevention of accidents at work), as well as European directives that became laws and apply to machines where there is a significant number of cold working of metals machines. Regulations, laws and decrees in Italy The contents of the said Decree are applied to residential Decree 547/55 to press brakes, more in general to Title IV Norme particolari di protezione per determinate macchine (Special protection rules for specific machines) in chapter VI Presse e Cesoie (Presses and shears): 115 says that presses, shears and similar machines must be equipped with shelters or disposals in order to avoid that hands or other parts of the body are hurt by the stamp or by other mobile working organs; according to 117 a slow movement or other similar disposals or expedients to avoid possible dangers must exist; 78 involves the presence of a foot control; 77 involves set in motion controls; according to 76 every machine must have easy-to-recognize and clearly to access start and stop controls. Safety requirements Therefore, the manufacturer must produce machines that respond to essential safety requirements, but we highlight that the document of a technical rule is mandatory only if it is required by a law, otherwise the manufacturer can insert such rule only on a voluntary basis. Later we will see what are the systems and technologies for which Italy and the European Union get busy. Systems: pros and cons Different systems, different pros and cons. What we have just said about rules and decrees actually reverses on technology: as regards the photo-electric barrier, the limitations of use are those of pieces and boxed of small dimensions, the reflection possibility of infrared rays while using mirroring metal sheets or the danger for the operator if s/he fails to set the muting point; while the pros are the high performances, the possibility to operate with barrier both vertically and horizontally and with every type of tool. The advantage of laser systems that moves with the crossbeam is the possibility to work with little pieces and boxed, and the limitation of use regards a higher muting point and the respect of the safety distance only in particular working condition; the danger is in case of stamp replacement. Old inadequate technologies For the monitoring systems fixed to the press brake board there is laser monitoring that, like inconsistent light monitoring (we will see it later), is no longer representative of the state-of-the-art of these machines. The first one doesn’t ensure a complete protection of the dangerous area, it is obliged to frequent adjustments of the laser beam and, in case of uneven metal sheets, the adjustment is difficult to achieve. Instead, the infrared ray of the inconsistent light monitoring can be reflected by the metal sheet in progress and the ray divergence doesn’t ensure the proper Tx-Rx operation. Now we will try to understand the different features it must have to be considered safe by law. The importance of the various stages “During the design stage, the press brake already has to take into account the security integration principle that concerns not only the use of the press on duty, but also the regulation, maintenance, assembly and dismantling stages” the Inail Security Manual on press brakes quotes. So, the best moment to achieve the goals and secure press brakes is – as can be deduced – during the design stage, because during the metal sheet pressing nothing can be left to chance and to reach such goals we start from the premise that the mchine we want to buy and use must be safer than a spaceship. Factors to be considered Let’s start from this: muting and blanking. Muting is about the fact that press brakes are usually designed so that for a stretch of race, the stamp has a certain speed (e.g. 100 mm/s). Later, at a point called “muting” programmed when the CNC is on board, the stamp continues its race at low speed until it performs the fold (≤10 mm/s). This is possible only if the machine has a hold-to-run device and a system with a photocell system device. Blanking, instead, is a feature available for optical barriers: in some parts of the sensitive field they can be disabled. This means that one or more areas of the detection area of the optical barrier are made inactive to allow a part of the performing piece to enter a detection area without activating the protective device. Suppression can be incorporated into the optoelectronic protective device only as long as the safety distance is such as to guarantee that reaching the dangerous area is impossible. Other security points We know that a single post can’t explain all the topic, so here it is an hypothetical list to consider when buying a good press brake: for example, we need to consider the setting of the physical barriers (guards that can be of two types: fixed, at total segregation, that avoid the access to the dangerous area on all sides, solidly fixed to the machine, to another rigid structure or to the ground; and the one called “interlocked guard” associated to a micro-switch made for avoiding the access to the dangerous area during any dangerous movement, if used along with fixed guards) and intangible barriers (that is, safety photocells made of electro-sensitive protection devices that use opto-electronic protection devices active where the operator safety is given by the detection of that part of the human body that enters the dangerous zone and provokes the stop of dangerous movements). And then, in vertical or horizontal position, laser scanner systems, two-hand control, with other body areas to be protected, such as the front, side and back areas of who works with a press brake are just some of the factors to consider when talking about safety of machinery. Designers, manufacturers and safety Designers have to take all the practical measures to ensure that the devices inserted into the designing machines don’t become a danger for whoever assemble, install, keep or make fixings, while the designers, manufacturers and suppliers of press brakes and individual protection devices have legal duties that must satisfy also all the international laws. Indeed, the different control system such as the two-hand one and the three-position pedal and, more in general, all the press brake control systems and the associated safety components (laser, scanner, and so on) have a primary relevance for press brakes. Considering all the features just listed, a greater security will be achieved, even when buying a used product: wide and well stocked and, as we noticed, that every manufacturer has in the company.
Various factors influence fast and precise part manufacturing. With the possibility of remote programming and use of innovative systems for thickness detection, active crowning and angle control. VICLA has qualified, young engineers and technicians working for it. With an open mentality capable of designing fast and flexible solutions, designed for optimal operation of the entire bending presses machining process: from profile to manufacturing of the part. What you expect from an artisan is part precision, fast execution and the ability to group multiple processes in a single machine. VICLA bending presses, from the .SUPERIOR for large-sized bends to the .FIRST, a compact bending press for small and medium-sized formats, are equipped with systems for programming on the machine and from remote. Programming is guaranteed by the numerical control systems on board enabling enhanced quality of the parts, while at the same time reducing production costs and times. Programming from the office also enables the possibility of reducing operator intervention to a minimum, also in relation to difficulties of finding specialist staff. The first step to achieve part production involves drafting a 2D drawing (dxf or dwg) or 3D drawing (iges or Step). The cad/cam system on VICLA bending presses can host 2D and 3D files through a USB interface or a network card and recognises the bending lines and tools to use. This is how the software automatically calculates the profile, thickness and type of material, the development of the sheet metal as well as the bending sequence, force, positioning of the axes and crowning. Perfection of the part and rapid and error-free realisation also depends on other factors, such as detection systems for thickness, active crowning and angle control. Technical prerogatives finding ample use in VICLA bending presses.
Here is a quick tour of the dates and stop-offs in the world of trade shows. Where to find the best in sheet metal processing. In addition of course to the prerogatives of efficiency, stability and precision, in a rapidly growing, competitive market, as is the sector we work in, the quality of a sheet metal working machine is measured above all through the technological innovations with which it is equipped. Innovations which can gain maximum visibility at all the international fairs: excellent showcases and privileged meeting points for those who work in the world of sheet metal, and the industry's decision makers who are looking to discover the latest technological innovations to improve production efficiency. From those related to finished or semi-finished products to moulds, from CAD/CAM/CIM systems to the latest strategies in research and development. For these reasons, the success which comes from participating in a trade show for a brand such as VICLA® is a sign that the company is taking steps in the right direction, giving credence to their day-to-day efforts as they journey towards seamless perfection. Evidence of this can be seen from their last participation in the 2016 Euroblech trade show in Hannover, and that of Lamiera 2017 in Milan, important events that have enabled the VICLA® brand to become known and appreciated by a large number of interested and competent operators. With the view to providing a useful service to all those with a passion for the world of sheet metal processing, here below you will find information on the key stop-off points of the international trade show network. Starting with the most recent event, which took place just a short time ago in Poland from 6 to 9 June: the Mach-Tool Poznan annual trade show, which is one of the largest trade shows in Europe featuring the latest technologies in a wide variety of industrial sectors. Such as metallurgy, casting and welding, painting, hydraulics and pneumatics. The next upcoming European event in chronological order is in the Czech Republic with MSV, the 59th edition of the International Engineering Trade Fair, to be held in Brno from 9 to 13 October 2017. This is the most important event in the sector in Central and Eastern Europe which sees all the major sectors from the mechanical industry taking part and which traditionally enjoys the presence of a significant number of Italian companies from the sector. Event numbers are impressive: 1.500 exhibitors, and 75.000 visitors from 59 different countries. Once again in Europe, from 7 to 10 November 2017, operators in the sector will shift their attention to Stuttgart in Germany for the 13th Blechexpo, the international trade fair for sheet metal working: the only event in the world that deals with the complementary technologies of sheet metal processing and joining technology, an extensive trade fair with a focus on mechanical and thermal joining and connecting procedures, and thermal welding processes. Moving overseas to the USA, from 6 to 9 November 2017, the Fabtech Chicago trade show will be held, America's biggest metal forming, fabricating, tube & pipe and welding trade show, An event that can host over 35.000 visitors from all over the world with over 1.100 exhibitors. Meanwhile, on the other side of the world, in Shanghai in China, from 7 to 11 November 2017 the MWCS will take place, the major Asian trade show in the sheet metal processing industry, with a particular focus on intelligent production systems, digitalised technologies, and flexible, integrated systems. An event that has drawn audiences of over 120.000 trade visitors from all over Asia. We then head back to Europe, once again in Germany, from 23 to 26 October 2018 for the Euroblech Hannover: the World's no.1 for innovation in sheet metal working event, an eagerly awaited date for industry professionals, with a large trade show area devoted to the latest in technology and innovation. The last edition, held in October 2016, proudly saw our brand's participation with the launch of our SUPERIOR press brake, the flagship of VICLA products, on an international stage. It was an amazing success in terms of sales and marketing.
Equip the .SUPERIOR press brake with CNC controlled bending supports to optimise bending of large sheets such as panels or doors. This system increases productivity, halving operator’s intervention. Moreover, since the bending supports hold the sheet properly during processing, the deformation risks are zero. WATCH THE VIDEO
These are input we look for continue whit determination on the progressive innovation way. Today we ask an opinion about brand VICLA to Mr Danilo La Croce from company LMC, Pinerolo (TO), which produce on drawing for third parties, specialized in cutting and bending, going from thin sheet metal to the thicker one. “I found Vicla through the web site” he says, “and I bought a press brake .SUPERIOR 3 m 170 t, equipped whit clever crowning and with the possibility of frontal punch release. It’s a machine really fast. It allows me to go from a configuration to another one in rapid times. We learned to use the machine quite quickly.: a half-day briefing with Vicla technician was enough and then I didn’t have much difficulty. I have read the cnc manual and I learned all during a week, even if some details we will learn with time.” Mr Danilo Lacroce shows enthusiasm also about VICLA services: “it’s a machine built on my specific needs. During the pre-sales moment VICLA gave me all information I needed and I received the machine in the established times. Post-sales service and assistance is professional and complete too.” Thank to Mr Danilo Lacroce for the time you’ve been devoted to us: the opinion who, uses our machine all days is very precious for us.
The best business card for all potential customers of a company is the express satisfaction from who has already used its products or services. About this today we have asked an opinion to Mr Giordano Riva, the boss of CTL – CENTRO TAGLIO LAMIERE s.r.l., company at Stezzano (Bergamo), which is involved in the production of metallic materials for carpentry, plant, petrolchemical and whatever else field related to iron transformation through flat cutting or folding. “I met VICLA through Mr Vittorio Bestetti, great expert about press brake, and in 2016 I decided to buy a .SUPERIOR 4 m 320 t for my company: a versatile machine equipped with innovative technologies.” Says the boss of this north Italy company, who about this add some details: “…we uses this machine from a short time and it’s the first within the company. So to be honest, I haven’t all instrument to make accurate comparisons. I say just that on bases of my past experiences, when I was technical director of other companies, I can assert with certainty that press brake .SUPERIOR is up to a center of services like ours, where versatility and efficiency are indispensable prerogatives.” The businessman has got clear ideas also about technologies: “We chose a machine with base equipment and then we have strenghtened it according to our needs. We are very pleased with Clever Crowning or Hybrid System. We are able to bend all the thicknesses, even from 20 mm, getting the desired results each times.” “Excellent” CTL’s boss continues “is the turning off the engines during the moment of inactivity: this is an important feature because it allows us to obtain great saving energy”. Mr Giordano Riva also expresses his satisfaction about pre-post sales services offered by VICLA: “during the pre-sales period we have received complete and professional information, and then, the full machine knowledge will come with the use. I believe in the innovation and so we have been entrusted with versatility of a young company like VICLA, which is able to innovate.” About post-sales services, he says: “The machine has been delivered to us according to the scheduled time and installed in a couple of days. Some constructive anomalies have been overcome quickly and today the machine is doing its job well. And every time we need it, we can rely on VICLA technicians: rapid answers which allow us not to stop the working.” The use of the machine is easy and intuitive, says the businessman, with whom young, trained and dotated with great will to learn people work, also with the help of CNC ESA of machine, precise and interactive, which allows a good easy to use. Cited merits and benefits. But the superior also has some defect? “The machine is well done. Obviously something you could improve: some building solutions could be optimized in order to improve the exchange tools timing and production.” Thanks to Mr Giordano Riva, the boss of CTL – CENTRO TAGLIO LAMIERE, for the time devoted to us and for his cordiality. In order to know more details about this company which chose VICLA, you can go on the website ctltagliolamiere.it
VICLA offers effective and efficient solutions for press brakes automation thanks to new technologies and last innovation. There are many features of Industria 4.0 used in VICLA machines. And these elements guarantee: great fexibility and rapidity of production short set-up time reducing machine stops and errors in order to obtain productivity high quality. This solution increases the competitiveness of the created products. Other important features are the ability to personalize the warehouse capacity, only use Promecam Style upper and lower tools and the rotation for the inserting of the inverted tool. The Matrix Code also recognizes the features and size of the tool during loading in the warehouse. TOP SHIFT is also equipped by a software realized to manage the communications with different CNC about 4 axes, about warehouse stock, about the information of tools. The software manages the charger set up with total autonomy, charge and edit the programs. The APR robot, for complete automation of bending process through hydraulic press, is another innovation by VICLA, with instrument for pieces with a weight until 250 kg and with the possibility of a manual use. The APR robot follows the press brake linear structure thank to its 5 axes, of which 3 linear and 2 polar, which allow to do easily perform bending operations, overturning and tilting of the piece. The programming of the APR robot is more easy thank to the application on the transducer press directly connected to the robot. This characteristic allows to the operator not to perform any adjustments and to monitor in every moment the bending process through the warning of possible anomalies and preventing the production of faulty parts. There are two monitors for the operator to manage the Antil robot: the touch screen one and the joystick for movements. The software allows to do all picking operations of sheet in a comfort and easy way, with also the possibility to divide the area into little zone of work. VICLA offers Matrix bending cells for completely automatic procedures of picking operations: machines able to work on pieces until 400 kg thanks to laser cut. Among the main characteristics there are reliability of electronics, gear couplings with game recovery which allows the repeatability of placement, a controlled force of the thrust against back gauges, to the advantage of greater lifetime of the machine. The software out of line BendWizard is the brain that manage through a user-friendly, easy and intuitive interface, to certificate an important decrease of stops. The software allows the planning until 4 different cells with bending robot. To complete the range of VICLA’s product, Flexbender and Robot Studio with Virtual controller are the standard and flexible solution realized for press brakes. The Virtual Controller is the platform that shows the same control system used by robot and that allows to simulate robot’s behavior for its movement, working area accessibility, collision and stats.
A perfect sheet metal processing causes the systematic operation of several elements, all necessary to achieve whises performance. In addition to the options provided by the machine, the experience of operator is always important in order to coordinate the workings, but the progress achieved so far by VICLA brand machines enables more rapid and intuitive management. The technologies are really important in order to achieve high level of performance. About this, our main reference is press brake VICLA .SUPERIOR, a jewel of innovation which encloses all secrets to achieving performance at the highest levels of the market. Today we want to name some of the most important. Beginning with all those elements that are fundamental to produce extremely precise bending. At first, we would like to name the Flex System, the innovative system for the management of structural flexions, that ensures the same bending lenght of the sheet. This is a system of which are equipped only SUPERIOR machines: a revolution which underline the excellent relationship between quality/price of press brake .SUPERIOR, as well as a growning commercial success in the national and foreign markets. An other innovation that brings at VICLA’s brand is the availability to apply in upgrade the Clever Crowning Kit: the optional which offer the insurance to a perfect bend also in non uniform material (for example perforated/slotted mixed with full material) and to improve working in workshop. The Clever Crowning kit works in real time in order to avoid manual intervention. Finally for completing VICLA’s bending effectiveness, there’s the piping system reduction: a solution which brings a higher performance and high precision level. The sum of this prerogatives take our machines to a true reference model in the sheet metal working machine sector. The commercial numbers show the truth of this view.
Along with the continuous increase in power and length, the rear mechanisms must keep up the pace. In this case, the .SUPERIOR 6 m 250 ton comes with a Back5 back gauge characterised by a new larger and thicker rugged crossbeam that still preserves its high positioning speed. Rack and pinion system with linear guides mounted directly on the frame of the press, a feature common to all .SUPERIOR presses VICLA's strength points: rear retractable supports mounted to the sides of the back gauges that guide and support the sheet metal until it reaches the contact point, avoiding any positioning errors and eliminating downtimes thanks to their automatic CNC-controlled movement. They also feature a Teflon coating that facilitates material handling leaving no marks on the pieces. WATCH THE VIDEO
The attendance of Vicla at Lamiera 2017 successfully closed in an happyness, coordination and accomodation atmosphere. (that was held at the Fiera Milano Rho from 17 to 20 may). “When i founded this firm I didn’t expect to get here so early”. This is Marcello Ballacchino’s view about VICLA attendance at Fiera Lamiera. He also thinks that Fiera Lamiera was “One of the best professional experience tested till now”. It had been a success based since the early start on a futuristic view: building hybrid machines able to achieve an high energy saving. These machines are really well manufactured as well as they are easy using for the final user. “A bending press”, follows Ballachino, “should fully satisfy the needings of an artificier. This one is not a technician or an engineer but it’s a person which looks for easy and fast solutions for the most common troubles. For achieving the perfection we are hardly working and we’ll continue in this way”. The brand commitment in this direction reached lots of awards, first of all the access at full title in Industria 4.0, insurance of a continuous success market growth and a brand approach on the sheet metal world. VICLA stand space tripled compared to previous editions of Lamiera, signed lots of visits during the whole 4 days. In this show, it reached lots of contacts and requests coming 80 percent from Italy – in particular Lombardia, Veneto, Piemonte, Liguria and Emilia Romagna but also Sicilia, Puglia and Campania – and 20 percent from Foreign Market. VICLA Stand guest star was the best of Albavilla trademark: .SUPERIOR 3 meters / 170 Ton with a wide set of Technology add on – lots of this internally developed – and the littler one .FIRST 1,25 meters / 40 Ton really good for little and medium bendings. “At Fiera Lamiera we showed the best available technology in sheet metal working world”, word of CoFounder Corrado Nucci, “…one of the biggest attractive of the .SUPERIOR, for example, was the ’Hybrid System Plus: an hydraulic system which helps to achieve an energy saving up to 80% compared to traditional system. The .SUPERIOR allows to avoid lots of proportional valves and use few oil, only 9 litres per cilinder. The Machine equips also the angle control, clever crowning, Shoulder control with Flex system: these topics are more and more requested nowadays from the market and should give at our machines high fastness and precision”. The Same success was reached from the compact .FIRST, shown for the first time in an event like this: a really solid machine, compact, fast and accurate that allows to manage little pieces and be placed side by side with a traditional 3 or 4 meters bending press. Visits are also highly appreciated by tests carried out by VICLA technicians at the stand. Practical demostrations have allowed to touch with hand the precision and the efficiency of press brakes Vicla, from easier processing to the more complex ones. To conclude the great teamwork done for the praparation to this important event was the commitment in terms of investments and creativity for studying efficient marketing and communication strategies, “really important instruments for brand affirmation and, in our case, have contributed considerably to increasing a great perception of the brand from visitors” stresses Mr Corrado Nucci. This questioni s a must: What are VICLA’s projects for the next future? “doubling the company shed and so the production resulting with qualified staff recruitment” says enthusuastically Mr Marcello Ballacchino. He adds: “my dream is to guarantee the order evasion to 90 days”. Judging by the speed with which the VICLA brand is affirming in national and international markets, it is easy to keep and hold on to this promise.
The attendance of VICLA at Hanover exhibition in Germany from 25th to 29th October 2016 has had amazing feedback, both in term of sales and marketing both affluence. Euroblech 2016 has rapresented the ideal stage to lay the groundwork to internalization of brand from Albavilla, near Como, to achieve new customers and create relationship with important working people. 1.550 exhibitors from 40 States, 90.000 m2 of exhibition space and 60.000 visitors from all over the world. With these numbers Euroblech has demonstrated once again to represent in a excellent way the best showcase for experts of this sector who want exhibit their innovations about sheet metal working. So German, Indian, Argentine, Swedish, Finnish, Spanish, Russian people have had the opportunity to appreciate the quality and efficiency of machineries branded VICLA®at event number 1 for innovation in sheet metal working in the world. The absolute protagonist of our success has been the leading edge of VICLA: press brake .SUPERIOR. Guests of our stand could touch its quality of precision, solidity and reliability with demonstrative video and bending tests: test to check the perfection of our machinery, result of depth engineering studies which have allowed to ensure a great stability and a extreme precision of bend. In addition to solidity and to efficiency of .SUPERIOR, visitors have particularly appreciated the innovation of hydraulic crowning system – warranty of an excellent structural stability - the great variety of standard components of press brake and its versatility upgrading according to specific customer needs. The choose of an effective communication strategy has been a straordinary contribute for the success of this event. For a so prestigious occasion, it’s important make a good impression. This is the reason why the brand presentation, with demonstrative video and communication equipment for strong impact, has been studied taking care of every single detail. A strategy designed to leave a indelible mark on the memory of who for the first time came into contact with the brand VICLA. And after the success of this special international kermesse of sheet metal working, the VICLA’s thought already go with pride to the next event which will be at Hanover 2018: an event not to be missed to consolidate the brand’s presence and to show the exclusive potentiality of innovation in Europe and in the world. We would like to thank all the people who have helped in the preparation of this event or who, more simply, have showed interest for our products. Have you participated? Send us your comments! For this event we would like you send us a feedback with the aim to express your impressions about your visit: fill the form with your opinion, it will be a special suggestion in order to continue to improve the efficiency and the quality of our products.
25th - 29th October 2016 HANOVER PAV 11 – STAND A166 When there is something new in VICLA our first thought is to tell those, like you, who are passionate about real, state-of-the-art technology. Today, we are delighted to inform you that we will be among the 1,550 exhibitors from 40 countries participating in the International Sheet Metal Working Technology Exhibition which will take place in Hanover in Germany. We will be at the Euroblech Exhibition from the 25th to 29th October 2016 Pavilion 11, Stand A166 Euroblech, Euroblech, International Sheet Metal Working Technology Exhibition, is a leading international event in terms of innovative equipment and services. For the occasion, we are proud to present our .SUPERIOR press brake, the flagship of VICLA® products, a machine capable of guaranteeing extreme bending precision thanks to use of the CLEVER CROWNING hydraulic system, the FLEX device and the considerable stability of the structure; it also comes with the innovative hybrid system as standard. During the prestigious event, visitors will have the opportunity to know in advance the details of the latest VICLA® technology, such as the .DIAMOND shears, the perfect synthesis of creativity, design and innovation, all Made in Italy together with the compact VICLA .FIRST press brake, ideal for bending small and medium sized pieces. VICLA will attend the International Trade Fair for Sheet Metal Working Technology, Hannover!
When dealing with quality and excellence in VICLA we are extremely strict. This is why our management recently choose to sign an agreement in close collaboration with the company that is now the leader in the production of machinery parts for sheet metal machining: the German HOERBIGER Group, a world leader in the sectors of compression and drive technologies, production of hydraulic systems and numerous mechanical engineering applications. A company that has been in business since 1895, currently with 6,858 staff and turnover of 1.115 billion euro. A giant that is synonymous with continuous innovation and high performance parts. This partnership is wholly satisfying and sets the foundation for the production of sheet metal working machines manufactured by VICLA to ever-increasing perfection. Our clients are fully guaranteed maximum levels of quality and efficiency. VICLA and HOERBIGER, together guaranteeing innovation and quality Atelier means a laboratory, where a photographer, designer or artist in general works. In VICLA we offer our services in sheet metal, like a tailor in the fashion industry. Our flexibility enables us to create customised machines made to client specifications. Being more than just a company, VICLA® was set up and structured as an artisan's laboratory, a real and proper, all-Italian atelier for sheet metal machinery. In fact, every single project was developed through a continuous process of listening to our clients' needs, each different from the other. We are not just sheet metal machinery suppliers, but true partners capable of manufacturing products made to measure. With utmost attention to continuous research, quality and the most innovative technologies, in VICLA we have the resources to provide our clients which the most innovative, solid and reliable machinery the market has to offer. The crowning jewel in VICLA lies in its Research & Development department, a highly important strength to innovate and perfect our machinery and find state-of-the-art solutions in terms of the highest quality materials and parts. Our business is this, and much more. In fact, the difference in our sector lies in better structuring of the machinery, with masterful, meticulous and functional assembly of every single part. Today, more than ever, we are also committed to designing high performance products with huge energy savings while reducing waste and pollution. This takes place by reducing the quantity of hydraulic oil and maintenance intervention. Speed and precision are fundamental characteristics of machinery for sheet metal machining: obtain the best in the least time possible, group multiple machining processes on a single machine. In VICLA we work to optimise the entire production system. This is the philosophy which, from 2008 to present day, has led us to acquire a considerable share of the market. In Italy, Europe and North America. Requests are always different. Clients are increasingly asking for machinery to work small, long or complex parts. Following the insertion of two devices, CLEVER CROWNING and FLEX, machining at any level of difficulty is limitless with .SUPERIOR. Our machines are hybrids to better respond to market needs. In fact, we offer the innovative hybrid system at the same price as the traditional system, meaning multiple advantages. First of all, considerable energy savings (55% compared to a traditional machine) and a considerable reduction in oil, also thanks to the double tank.The research and development department designed the innovative HYBRID system, now standard on all .SUPERIOR machinery. Another intuition, the Flex, is an innovative control device for structural flection of frames to maintain the same bending depth independent of the length of the metal sheet. Such innovations have allowed us to offer our services on new markets which are increasingly attentive to consumption, speed and production cycles.The leading models are those in the .SUPERIOR range, starting with the 1250 mm 30 t, the fastest machine, followed by other models, which you can find in the catalogue. Our production is not 100% made-to-measure, since our standard models meet most of our clients' needs. For example, the openings and strokes on the standard models are bigger than those of competitors. Having designed and manufactured high quality machinery, all the machined parts are centesimal and built in a solid structure to guarantee excellent repetition over time and high precision of axis positioning. In VICLA we clearly known that selling a machine is not a conclusive act, but rather the start of a relationship based on loyalty. We want our machinery to always guarantee maximum performance and efficiency and, at the same time, minimise costs. This is why we design special, made-to-measure support packages capable of preventing faults or malfunctions and include a scheduled maintenance plan over time. VICLA is developing new machinery as we speak. We can announce in advance the release of our .SMART range to complete our press brakes and our latest shears called .DIAMOND, however you will have to wait a little longer for its release to appreciate its manufacturing and technical qualities. We promise you won't be disappointed. The most important invention is definitely the FLEX system. Marketing and communication activities aimed at positioning the leading market brand are fundamental elements to value products. We do it all the time, through institutional communications, aimed at B2B through various media: websites, technical catalogues, sector exhibitions, magazines and also through our ever-present sales network available to our clients. For over 2 years, VICLA market shares have been continuously expanding. In fact, we have clients in new markets such as Poland, Spain, Germany and France.Selection of the best suppliers in the sector is one of the main strategic factors to success. This is why, in VICLA, we only collaborate with certified companies, capable of guaranteeing the working times, quality materials and parts at the best market prices. Flexibility and reduced re-supply times are other decisive characteristics when choosing a partner. In VICLA the engine powering everything is passion. The same passion expressed each day and in every phase of every single project, while paying utmost attention to details and the clients' requests. In other words: aiming towards excellence. The framework of our system of values is completed by our attitude of continuous comparison through our work team, both internally and with clients and suppliers. This quality instils a relationship based on mutual satisfaction intended to last over time. We saw Hoerbiger as an ideal partner with whom we could share our vision. Our collaboration began in 2008, the year VICLA was established.We are convinced there is always room for improvement. In a continuously evolving market, the secret to expansion is anticipating where the innovation wind blows. In VICLA we are always open to change. This is what we expect from our partners. One should never stop being curious. Curiosity produces creativity. Creativity is the ability to generate new and useful ideas, solutions to everyday problems. In VICLA we support creativity by attending workshops, themed discussions and brainstorming on a weekly basis. In VICLA we plan our production to optimise work flow. Chez VICLA nous planifions la production afin d'optimiser le flux de travail. Marcello Ballacchino President and Co-Founder of VICLA Corrado Nucci Executive Director and Co-Founder of VICLA Highly trained and motivated staff, an important element for a successful company.
11-14 of May 2016 BOLOGNA PAD 30 - STAND A14 Even this year, VICLA - Sheet metal machinery will attend to “Lamiera”, the most important national exhibition in the field of equipment for processing of sheet metal, which it will be from 11 to 14 May in Bologna. For years it is landmark in this field, more than 18.000 visitors and 350 exhibiting companies in the last edition. Regular visitors are highly qualified and get directly involved in purchase decisions, in the fields mostly involved: steel structures, sheet metal working, automotive, subcontract working, food and packaging, stainless steel processing, aerospace.VICLA staff will be available to increase strengths about the last technologies implemented on the most important press brakes .SUPERIOR Press brakes Superior will be set up with new systems aimed to a market more and more demanding. Eco-saved hydraulic system, the latest generation angle control, Clever crowning and Flex System are some of the innovations which will be possible view at the fair. Stay connected on our social networks.
The innovative Flex system is a dynamic control device to management the structural flexions during the bending and it allows to keep the same depth of fold whatever the length of the sheet metal. The operation is based on the interpolation of data received from two pressure transducers places on cylinders and the deformation read by optical lines. During the testing phase it produces a table where pressure and deformation data are revealed. In this way, without operator support, the CNC receives the data from cylinders pressure sensors, which are interpolated to define the correction to be made in order to ensuring so the same result both bending a long sheet and a short one, speeding up greatly the production cycle.
22 - 24 of March 2016 Stand n° 1121 Toronto Congress Centre Goes on the VICLA Sheet metal machinery exhibition time table, after the great success obtained the last November at Fabtech in Chicago, Vicla will be at north American Trade Show in Toronto with the most important VICLA® press brakes: .SUPERIOR. It will be again the protagonist of the event where experts of this field could increase their knowledge about the machinery obtained by the research, specific attention on details and on the international market. In VICLA® passion moves everything, so Fabtech is the ideal place in order to have a productive comparison with new proposals from all over the world. At VICLA’s stand it will be possible to view Superior Press brakes 170/31 with CNC ESA S660, quick pneumatic clamps system for the punches, Lazersafe Iris system, two retractile arms and tool kit.
9 - 12 November 2015 Hall North – Stand 4150 Chicago McCormick Place 2301 S. Martin Luther King Dr Vicla is going to present the new press brake .SUPERIOR at FABTECH 2015 in Chicago, the space dedicated to sheet metal sector with its 40.000 visitors and 1.500 exhibitors from all over the world. The ideal place to meet importers and exporters, to send products or buy instruments in order to improve the productivity. The North American Trade Show is characterized by the variety of solutions, innovative and with an high technological content, offers by exhibitors. During the four days of fair in McCormick Place, an area of over 51.000 m2, it will be possible appreciate not only the present but also the future of this sector. There are over 100 appointments on the calendar including training sessions, workshop, conferences and special events where important experts will show market trends of the sheet. These appointments are also good networking opportunities both online and off line.
3 - 6 November 2015 Hall 3 - Stand 3103 Stoccarda New Stuttgart Trade Fair Centre Landesmesse Stuttgart GmbH Messepiazza 1 70629 - StuttgartWith pride we are pleased to communicate VICLA is going to be at 12th edition of Blechexpo/ Schweisstec: the international fair dedicated to sheet metal working and to joining technologies, to the thermal and mechanical connection and to thermal welding processes. Here we’re going to present the flagship of press brakes by VICLA: .SUPERIOR. This year the primary German fair will make record numbers. Exhibitors, spread on an area of 90.000 m2, will be 1.200 from 36 countries ( +14% than the last edition) and they will present high-tech services and products also in world preview. More than 40.000 visitors will come from over 96 countries in the world. It isn’t a coincidence if BLECHEXPO is the leader European fair and second in the world among those in the sheet metal sector.