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.