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!