Press brake tutorial: how to create a workstation
SET UP A WORK STATION FOR IMMEDIATE CALCULATION OF Z AND BENDS.
A few simple steps to...
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
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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.
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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.
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Hydraulic fluid: this fluid acts as the machine's lifeblood, transmitting pressure from the cylinders to the bending ram.
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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:
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Microscopic precision: ensures consistent and accurate bends.
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Energy efficiency: up to 78% energy savings compared to traditional hydraulic press brakes.
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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
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Body panels: hydraulic press brakes form the intricate curves of car and truck bodies.
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Chassis components: frames, brackets, and other structural elements are shaped using these machines.
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Internal structures: dashboards, consoles, and other interior components are also formed with hydraulic press brakes.
The Aerospace Industry
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Aircraft parts: wings, fuselages, and landing gear are shaped with precision using hydraulic press brakes.
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Structural components: internal frames and supports are fabricated to exacting standards.
The Construction Industry
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Structural elements: beams, columns, and other components for buildings and bridges are formed using hydraulic press brakes.
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Metal roofing and wall panels: these machines create the intricate shapes needed for modern construction.
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HVAC components: ducts, vents, and other parts are fabricated using hydraulic press brakes.
The Shipbuilding Industry
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Hull formation: large sheets of metal are bent and shaped to create the hull of ships.
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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.