A press brake is a specialized tool used in metalworking to bend sheet metal into various shapes and angles. It's an essential piece of equipment for industries ranging from small-scale fabrication shops to large-scale manufacturing plants. The technology on which operation is based is only trivial in appearance, however it hides remarkable developments in the mechanical and technological field. Table of Contents: Press Brakes How Does a Press Brake Work? Types of Press Brakes: Mechanical Press Brakes Promecam Hydraulic Press Brakes Servo Press Brakes CNC Press Brakes Hybrid Press Brakes Benefits of Press Brakes Applications of Press Brake Limitations of Press Brakes Alternatives to Press Brakes Conclusion How Does a Press Brake Work? Press brakes operate using two essential tools: the punch and the die. The die is a stationary V-shaped tool placed beneath the workpiece, while the punch is a movable component that applies force to bend the metal. The punch's movement is driven by a ram, which can be powered by various mechanisms such as mechanical, servo motors, hydraulic, or pneumatic systems. To learn more about the different types of press brakes and how they work, check out our comprehensive guide, A Deep Dive into Press Brake Technology. Inside, you'll find detailed information on components, terminology, and tooling used in the bending process. Here are some key terms to familiarize yourself with when working with press brakes: Tonnage: The maximum bending force a press brake can exert. Bending Angle: The angle created between the two sides of the bent metal. Bending Length: The maximum length of sheet metal that can be bent with a particular press brake. When Was Press Brake Invented? Press brakes, while a relatively modern invention, have a history dating back to 1882 when the first patents were filed. Early press brakes were labor-intensive affairs, relying heavily on manual operations. To create a bend, a mold was first crafted to match the desired shape. Sheet metal was then placed on the mold and surrounded by a mixture of sand and lead shot. Workers would then use a T-stake to pound on the metal, forcing it into the mold's shape. This process, while effective, was slow and often resulted in straight, simple bends. What are the differences between old press brakes and modern press brakes? If we compare a modern press brake to one from fifty years ago, on the outside it seems that little has changed. However, the truth is that they are two completely different machines; the external elements may also have remained stationary with the typical design that we all know, but mechanics and electronics have evolved in a silent and inexorable way. Conceptually, between a bending machine from the past and a modern one, there are no changes in the process; both, in fact, share the same purpose: to bring a punch to a matrix up to a certain altitude in the most precise and repeatable way possible. Yet, the modern press brake is the result of constant evolution. Just as happened with cars, which from a simple and almost rudimentary means of transport have become truly high-tech machines, the bending machine is also now a concentration of technological and mechanical innovation. However, both in the case of the car and the press brake, the basic mechanical components have remained the same, but over time they have been improved and refined. Different types of press brakes To grasp the intricacies of sheet metal bending and discover the optimal technology that balances efficiency, effectiveness, cost-efficiency, and versatility, it's essential to delve into the rich history of press brakes. Italy, a pioneer in this field, has fostered a thriving industry in the Brianza region, where businesses have consistently elevated the standards of Italian-made bending press brakes. Renowned worldwide for their tradition and quality, Italian manufacturers, including Mariani and others, have played a pivotal role in shaping the evolution of press brake technology. Mechanical press brakes Mechanical press brakes, though still lingering in some workshops for less demanding tasks, are now largely obsolete due to safety regulations. Despite their outdated status, they were once highly regarded for their speed and pressure capability. Brands like Mariani and Omag were particularly renowned for their mechanical press brakes. These machines operate using a flywheel mechanism that drives the up-and-down movement of the punch. A clutch system controls the gear shaft, resulting in a simple and user-friendly setup. This simplicity extends to maintenance, as components are generally easy to repair or replace. Additionally, mechanical press brakes often have a higher load capacity than their rated tonnage. However, mechanical press brakes have significant drawbacks. They offer limited control over punch speed, leading to compromised bend quality and accuracy. These limitations, coupled with their safety risks, have made them obsolete in modern manufacturing environments. Promecam RG hydraulic press brakes Pioneered in France by the Italian-French inventor Roger Giordano, RG Promecam's hydraulic press brakes were known for their compact size and unique low-profile design. A key feature that set them apart from other press brakes was the movement of the workbench instead of the upper beam. While most machines lower the beam to press the sheet metal, RG Promecam machines raised the workbench using a central hydraulic system. This innovative design offered simplicity and reliability, and it played a significant role in the history of Italian press brake technology. However, these machines no longer meet modern safety standards. They lack the ability to adjust bending speed and modern safety features. Therefore, they require specific safety upgrades to remain operational. Despite their outdated safety limitations, RG Promecam press brakes were once widespread and remain in use in some workshops today. In the post-war era, they represented a groundbreaking innovation. Their low-profile design allowed for the bending of large, closed profiles as they could be embraced by the upper part of the machine Hydraulic press brakes with torsion bar These press brakes are precursors to modern synchronized press brakes, sharing a similar appearance. They function by using a beam that descends via hydraulic pistons. Typically, these machines have two or three axes: X-axis for the rear carriage Z-axis for the rear carriage height Y-axis for the beam descent A distinguishing feature of these machines is the mechanical connection between the two hydraulic cylinders via a bar. This linkage ensures synchronized movement up to the lower dead center. The position of the lower dead center is adjusted using two nuts that can be raised or lowered to modify the end-of-stroke height of the cylinders and beam. These press brakes were often controlled by a simple positioner, lacking internal memory. Synchronised hydraulic press brakes Hydraulic press brakes, a significant upgrade from mechanical alternatives, utilize two oil cylinders to precisely control the punch. This hydraulic system enables superior bending capabilities and enhanced accuracy compared to mechanical press brakes. While offering these advantages, hydraulic press brakes come with increased complexity and require skilled operators. Maintenance costs can be high due to their intricate parts. Additionally, strict adherence to rated tonnage is crucial to prevent machine damage. Fluid leakage from the hydraulic cylinders remains a potential risk. CNC hydraulic press brakes have emerged as a popular choice in modern manufacturing. These machines feature automated systems that precisely control movement and timing. Synchronized hydraulic press brakes represent the state-of-the-art in press brake technology. They employ two independent hydraulic cylinders and proportional valves to regulate the upper beam's movement. This configuration offers greater versatility, allowing operators to adjust each cylinder individually to compensate for sheet irregularities. CNC control in synchronized hydraulic press brakes provides advanced capabilities compared to positioners found in torsion bar press brakes. Operators can fine-tune various parameters, including parking time, lower dead center, bending speed, and decompression. Electric press brakes or servo press brakes Electric press brakes, the latest innovation in press brake technology, remain a specialized solution for certain applications. While they offer speed, repeatability, and energy efficiency, they often lack the versatility of synchronized hydraulic press brakes, especially on large formats. Two primary methods are used to operate electric press brakes: ball screws and special belts. Servo press brakes utilize servo motors to power the punch. These motors, also known as servo-electric press brakes or electric press brakes, transfer mechanical energy to the punch via a pulley and belt system. Servo motors offer precise control over punch movement due to their numerous adjustment options. This translates to accurate bends and a quieter workplace. Eliminating hydraulic or pneumatic systems also prevents leakage issues. However, servo press brakes have a lower force capacity compared to other options. This limitation restricts their use in industries requiring higher tonnage. CNC press brakes CNC press brakes, versatile and automated machines, utilize computer numerical control (CNC) systems to deliver exceptional precision and repeatability. By incorporating CNC technology, businesses can significantly boost productivity, efficiency, and accuracy while reducing labor costs. Ideal for a diverse range of industries, including aerospace, automotive, construction, and electronics, CNC press brakes offer a powerful solution for various applications. To learn more about the specific benefits and capabilities of CNC press brakes, explore our in-depth article, CNC Press Brakes: A Comprehensive Guide Hybrid press brakes Hybrid press brakes represent the pinnacle of press brake technology, offering significant advancements over traditional synchronized hydraulic press brakes. VICLA, a pioneer in this field, specializes in hybrid technology, a solution that optimizes performance by combining the best aspects of different systems. This innovative approach delivers exceptional results in terms of precision, repeatability, energy efficiency, and cost-effectiveness. VICLA's hybrid press brakes guarantee microscopic precision in beam positioning, ensuring consistent and accurate bends. This precision is achieved through a reduction in oil usage, a hallmark of VICLA's technology. For example, a 110-ton VICLA .SUPERIOR hybrid press requires only 50 liters of oil per chamber, compared to 200 liters in traditional hydraulic press brakes. Less oil translates to fewer ducts, smaller tubing, reduced heat and expansion, and minimized clearance and wear. This efficiency is further enhanced by two powerful electric motors that operate directly on the minimal oil required. Repeatability is another key benefit of VICLA's hybrid press brakes. By minimizing oil usage, VICLA reduces the negative effects of oil heating and expansion, which can compromise precision over time. The compact oil circuit and precise construction further contribute to consistent results. Energy savings are a significant advantage of hybrid technology. Compared to traditional synchronized hydraulic press brakes, VICLA's hybrid machines can achieve up to 78% energy savings in standard conditions. This is made possible by a smart energy consumption philosophy that activates the machine's motors only when necessary. In contrast to traditional hydraulic press brakes, which keep their motors running continuously, VICLA hybrid press brakes only consume energy during the actual bending process. This reduces energy costs significantly, both in the short and long term. While hybrid technology offers a compelling cost advantage compared to electric press brakes, it also provides greater versatility. Electric press brakes, especially those using belt systems, can have limitations in bending certain shapes due to their structural design. Hybrid press brakes, on the other hand, offer the flexibility of traditional hydraulic press brakes, allowing for a wider range of applications. Benefits of Press Brakes In-house efficiency: Install a press brake on-site to streamline production and reduce costs. Unmatched safety: Modern press brakes prioritize operator safety with features like protective curtains and laser sensors. Accelerated production: CNC integration automates operations, leading to significantly faster production times. Reduced labor: Press brakes minimize the need for manual labor, especially when equipped with CNC automation. Cost optimization: Faster production and reduced labor translate to substantial cost savings. Applications of Press Brakes Machine tool components: Manufacture parts for various machine tools. Electrical components: Produce essential parts like junction boxes and enclosures. Automotive parts: Fabricate crucial components for vehicles. Construction materials: Create frames and duct parts for buildings. Limitations of Press Brakes Ram locking: Improper use or pressure can cause the ram to become locked. Limited control: Most press brakes cannot be stopped mid-cycle. Alternatives to Press Brakes Folding machines: suitable for certain applications but generally more complex and slower. Panel benders: ideal for thin metal sheets but significantly more expensive. Conclusion Press brakes are indispensable tools in any metalworking facility. VICLA offers a comprehensive range of modern electric and hydraulic press brakes designed to meet your specific needs. Contact VICLA today to find the perfect machine for your applications.
A CNC press brake is a modern machine for sheet metal bending. Modern press brakes are operated and controlled by a computer that helps quickly set the specifications of a job and perform production cycles according to different needs, both short and long term. Importance of CNC Press Brakes in Manufacturing CNC press brakes are highly versatile machines capable of handling a wide range of metalworking tasks. Their programmability allows for precise control over bending operations, ensuring accurate and repeatable results. From simple bends to complex geometries, these machines can efficiently process various materials, including steel, aluminum, and stainless steel. This versatility makes CNC press brakes indispensable in industries requiring high-quality, customized metal components. Types of CNC Press Brakes Hydraulic Press Brakes Hydraulic press brakes, known for their precision and power, utilize oil cylinders to control the bending process. While offering superior performance, they can be complex to maintain and may have higher operating costs. CNC hydraulic press brakes automate many functions, improving efficiency and accuracy. Synchronized hydraulic press brakes, a more advanced version, use two independent cylinders for precise control and greater versatility. Electric Press Brakes Electric press brakes are a newer technology, offering speed, repeatability, and energy efficiency. However, they may have limitations in force capacity and versatility compared to hydraulic press brakes. Servo press brakes, a type of electric press brake, use servo motors for precise control and quieter operation. They are suitable for applications requiring high accuracy and low noise levels. Hybrid Press Brakes Hybrid press brakes combine the best aspects of hydraulic and electric press brakes, offering exceptional performance. VICLA, a leader in hybrid technology, provides machines with: Microscopic precision: Ensures consistent and accurate bends. Energy efficiency: Up to 78% energy savings compared to traditional hydraulic press brakes. Versatility: Handles a wider range of applications than electric press brakes. Key Considerations: Force capacity: Hydraulic press brakes generally offer higher force than electric or hybrid options. Versatility: Hybrid press brakes are more versatile than electric press brakes. Maintenance: Hydraulic press brakes require more maintenance due to their complex systems. Energy efficiency: Electric and hybrid press brakes are more energy-efficient than traditional hydraulic press brakes. Noise: Electric press brakes, especially servo press brakes, are generally quieter than hydraulic press brakes. CNC Press Brakes Main Components: Bed, Ram, Punch and Die, Back Gauge Frame Also called beam, which is the movable part on which the punches are installed. It runs vertically along the Y axis and is positioned by numerical control at specific positions according to the operation to be performed. There are independent Y1 and Y2 axes that regulate the possible unbalance of the machine’s main ram (in a hydraulic press these are the different strokes that the cylinders can perform). The bench or bed Is the fixed part under the beam where the dies are installed. It can contain a centering (or crowning) system to compensate for the crossbar deformation, especially in machines two meters/6’ wide and up. Such a system can be found in a variety of versions which embrace different design philosophies among manufacturers or are based on specific machine types or families. Excellent results are possible through the use of a hydraulic crowning system. In this case, a number of high pressure and low flow rate cylinders are inserted within the machine bench to compensate for the frame deformation during the pressing phase by producing a counterforce from underneath. The lateral frames Lateral frames represent the side plates or shoulders that define the width of the machine frame. These can also be different: for example, machines with synchronized hydraulics almost always have a gap, called throat, so a sheet that is wider than the distance between the shoulders or columns can be inserted into the machine frame. Rear Backgauge Tthis device ensures that the bend is positioned correctly in the part to be produced. It usually consists of a beam on which two or more finger stops (backgauges) are mounted. They are able to move sideways to find the correct position. The axes, on the other hand, are: x: Forward and backward, sets the length of the bend (flange) from the center of the die to the tip of the fingers. r: up and down, adjusts the height of the stops/fingers to allow the fingers to reach the part better and so that dies of different heights can be mounted. z: left and right, adjusts the position of the stop/s on the table, to ensure that the back fingers are in the correct support position towards the punch and die. CNC Control System: How it Works A CNC press brake's brain is its sophisticated CNC system. This system interprets instructions and controls the machine's movements for precise, automated bending. Key components include Control System, Programming and Axis Control. Control System Hardware and software that processes commands and controls machine movements. Programming Operators create programs using specialized software to define bending parameters. The CNC system then translates these instructions into machine-readable code, specific to the press brake manufacturer. Axis Control The CNC system manages the vertical movement of the ram and the horizontal positioning of the backgauge. Additionally, some press brakes feature a crowning system that adjusts the bed's curvature to ensure uniform bending. Ram: The ram applies force to the metal sheet, creating the bend. Backgauge: The backgauge positions the sheet metal accurately before bending. Crowning: This optional feature helps prevent uneven bending by adjusting the bed's shape. All mechanical components of the press brakes are integrated with numerical control, which is responsible for setting the bending parameters. The most important parameters in the bending process are: thickness of the sheet; dimensions of the sheet; bending angle; One of the many advantages of numerical control lies in the possibility of implementing bend simulations, during which the machine verifies if there are any collisions or overloads. What are the benefits of using a press brake with numerical control? There are many benefits obtained from numerical control programming on CNC press brakes: Speed Precision Repeatability Adaptation Flexibility Agility The main technologies of ESA numerical control ESA 650 and 660 numerical control This version, with colour graphics and multilingual function, allows the automatic calculation of the PMI according to the type of tool and the required angle, and the automatic calculation of the bending force. Optimisation options include optimal bending sequence, and display of any collisions in the sequence proposed by the operator, also carrying out anti-collision checks between the axes and the matrix in the automatic phase. ESA 675 numerical control It is equipped with an ultra-large 21” LCD HD Multi-touch colour screen and integrated Windows PC, which allows drawings to be opened in PDF format or in another format directly on the machine. Furthermore, it allows optimal management of all Cad-Cam 3D. It is equipped with RAM 8 Gb, 4 USB ports 2.0 + 4 USB ports 3.0. Delem numerical control It is a simple and intuitive Numerical Touch Screen control, with a high level of functionality and a user-friendly and modern graphic environment. It is available with screens of different sizes and features customised to your needs. Press brake programming: management of 3D projects Modern press brakes can be equipped with programming software for the preparation and processing of 3D projects that guarantees multiple advantages. The programming software available on VICLA sheet metal bending brakes, for example, guarantee maximum efficiency in tool selection, based on bend radius, maximum force of the press brake, collision control, and the availability of different types of tools and splits. It is also able to recognise and automatically manage the flattened bend thanks to definition of the angles of the pre-bend and the inner counter-bends, calculating the best bending sequence, avoiding collisions and taking into account the availability of splits and skids. Although automatic management almost always finds a solution, the operator also has the possibility to intervene manually and change the data set by the software. For positioning of the stops, the software available on VICLA press brakes provides automatic and manual control options for the back gauge, thanks to the 3D simulation that allows you to view all the moving elements, including the tools, the part to bend and the machine structure. Finally, the software provides the complete tooling report, from the 3D bending sequence, including detailed information bend by bend. The report can be printed or displayed directly on the numerical control. Industry 4.0 and Smart Manufacturing CNC press brakes are increasingly integrating with Industry 4.0 technologies, transforming them into smart manufacturing assets. This involves connecting machines to networks and equipping them with sensors and data analytics capabilities. Key benefits of Industry 4.0 integration include: Predictive maintenance: Using data analytics to predict equipment failures and schedule maintenance proactively. Real-time monitoring: Tracking machine performance and identifying bottlenecks in the production process. Improved quality control: Implementing automated inspection systems to ensure consistent product quality. Enhanced connectivity: Seamless integration with other manufacturing systems for streamlined workflows. Automation and Robotics Automation and robotics are playing an increasingly important role in CNC press brake operations. Sheet metal bending automation has advanced significantly in recent years. Collaborative robots (cobots) and anthropomorphic robots have revolutionized the industry, replacing traditional Cartesian robots. These automated solutions not only speed up the bending process but also reduce human error. Benefits of automated bending cells include: Increased efficiency: Faster bending cycles and reduced downtime. Improved quality: Reduced human error and more consistent results. Ergonomics: Relieves operators from repetitive tasks. VICLA has developed advanced solutions for automated bending cells. These solutions can help you streamline your production process and improve your bottom line. To learn more about how robotic bending solutions can transform your sheet metal fabrication, read our comprehensive guide “Robotic bending: advantages and limits”. As technology continues to advance, we can expect to see even greater levels of automation and robotics in CNC press brake applications.
Purchasing a press brake can be a daunting task, given the wide range of options available. This comprehensive guide will provide you with essential information on how to choose the right press brake, including selecting press brake punch and dies. We'll delve into key factors to consider, potential pitfalls to avoid, and valuable tips for getting the most out of your investment. By the end of this guide, you'll have a clear understanding of how to choose the right press brake for your specific needs. Primary Factors to Consider When Buying a Press Brake There are various factors at play when buying a press brake. Bending length The length of the press brake depends on the maximum length of the part to work. Furthermore, if bent per stations, it is useful to consider the purchase of a longer press brake, which allows multiple stations to be implemented. For example, for a sheet measuring 1100 x 700 mm, you are advised to choose a press brake measuring 2000 mm long. Tonnage It is intended as the bending force of the machine. In other words, it refers to the capacity to bend of the press brake. Tonnage depends on various factors, first of all the material: a ductile part requires less bending force; on the contrary, a more resistant material such as stainless steel or high strength steel requires greater force. How Do I Calculate Press Brake Tonnage? Our online press brake tonnage calculator is your ideal tool for accurately determining bend parameters for your sheet metal. In just a few simple steps, you'll get detailed information on: Tonnage: The force required to perform the bend. Inside radius: The inner curvature of the bend. Minimum flange length: The shortest possible length of the flange to prevent breakage. You should always oversize the press brake capacity by around 20 – 30% with respect to your data in order to allow for the variability in the characteristics of the metal and so that you are not in danger of working to the limits of the machine’s capacity. One of the most common misjudgements is to confuse the total force needed to bend a given sheet metal part with the tons per metre for the specific thickness, material and die. Find out more in this guide. Clearance and Stroke Length Clearance is simply the front opening of the press brake. A press brake with a larger stroke is a machine equipped with greater intermediates that allow easier extraction of the bent parts. Material Thickness Different metals have varying properties and behave differently when subjected to bending. For instance, aluminum is generally more malleable than stainless steel. Understanding the characteristics of the specific material you’re working with is essential in determining the appropriate press brake and bending parameters. Our Ultimate Guide to Sheet Metal Materials provides expert insights and practical advice. Explore now to choose the perfect material for your project. Operator Skill Level Complex press brakes offer advanced features and automation, but they often require skilled operators. If your team lacks the necessary expertise, consider the time and resources needed for training. Weigh the benefits of increased capabilities against the potential challenges of operator training and maintenance. Types of bending brakes There are many different types of press brake machines. Each of these comes with its own set of advantages and limitations. You can choose the right press brake based on your use case. These different types of press brakes are: Mechanical Press Brakes: simpler and more affordable, but with lower precision and speed. Hydraulic Press Brakes: offer better precision and control but require more maintenance. Pneumatic Press Brakes: fast and easy to operate but have lower force capacity than hydraulic presses. Servo Press Brakes: highly precise and efficient. CNC Press Brakes: fully automated for maximum productivity and accuracy. Hybrid Press Brakes: combine the best features of hydraulic and electric press brakes for optimal performance. Tandem press brake: particular configuration that involves the connection of two machines into one, but there are also solutions that combine three bending machines (tridem) or 4 bending machines (quadrem). Read our guide on What to know before choosing a tandem press brake. Secondary Factors to Consider For the Right Press Brake Locks and intermediates Intermediates are adaptors to insert between the beam and the punches and are very useful because they allow deep box structures to be easily made. The tool clumping systems are sub-divided into: manual locks; semi-automatic locks: pneumatic blocks; hydraulic locks; The choice of correct locking is fundamental to reduce the work times and correctly manage the work zone. Semi-automatic locks It is a manual semi-automatic lock with rapid front locking-unlocking system of the punch. Operation is very simple and, compared to the traditional manual solution, allows faster and easier re-equipment of the machine. In fact, by moving the locking lever, the punch is released to remove it from the front; while, on closure, the punch is automatically brought to stop and perfectly aligned. Automatic locks The automatic tool locking systems allow equipping of the press brake in complete safety. The tools are automatically aligned, positioned and fastened. This solution drastically reduces the equipping time and considerably increases production. Automatic tool change for press brakes Today, a modern and innovative solution exist that allows automated change of the punches and matrixes. For example, VICLA hybrid press brakes can be connected to an automatic tools warehouse that allows equipping, even on multiple stations, of higher and lower tools. This system is customisable and designed to measure according to client requirements; it reduces setup by 4 or 5 times compared to manual tasks and automatically performs even the most complex equipping, managing 70 mm wide V matrices, rod holding tools and allowing the tool to rotate 180°. Automation covers everything, including upstream operations. One of the more interesting aspects is programming by the technical office: the CAD/CAM system processes the three-dimensional file, creates the best bending cycle and sends the program to the machine that is automatically equipped, referencing the bending sequence directly on the numerical control. All tooling and machining data are automatically saved at the end of the work and exported to management for a 4.0 key data analysis. Back gauge The rear gauge is a motorised structure on which the references are set and can be moved and positioned to allow a variety of complex bends. Movement of the back gauge along the depth of the machine is called axis X. Vertical lifting is called axis R. References It consists of very important and useful tools to support thin sheets. They are equipped with pneumatic operation and a Teflon coating that prevents marks on the material. They can also be activated by numerical control. There are 2 references and they are usually manual, but they can be automated and controlled directly by the CNC; the positioning of the stops is along the Z axis. Independent tower gauge All towers are equipped on VICLA press brakes with a visual LED stop. Switch on of the LED ensures contact of the sheet with the reference. In more accessorised versions, the towers are: Motorised (axes z1- z2) Independent (axes x2 - x3) Anthropomorphic (axes r1 - r2) Bending compensation The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well worked part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. Thanks to special sensors in the beams, crowning enables measurement and compensates deformations in real time. There is no need to set any data; the system actively reacts to changes in characteristics. Each press brake, despite its robustness, is subject to structural bending, during the bending phase, and obviously the deformations are much bigger the greater the effort the machine has to make. The main deformation is crowning, which corresponds to bending of the beam which is pushed into position by the side cylinders; the other (and for many reasons semi-unknown), is called in jargon “yawn” and is the tendency of the frames to open in the throat zone. Thanks to the Flex system the sheet metal press brake dynamically compensates any deformations based on the effort required: the CNC receives the data from the pressure sensors of the cylinders, which are interpolated in real time to establish the correction to implement. Energy saving systems It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. The results in numbers of this technological innovation are significant, as seen on the graph. Angle control systems VICLA's angle control consists of two laser sensors mounted on linear guides that slide to the rear and front of the press brake bench taking the measurement in one or three points depending on the length of the piece. Located on the sides of the matrixes, they have the purpose of reading, through a system of lasers and cameras, the inclination of the edges of the bends during deformation. It is the most complete and performing solution for automatic angle measurement and control. Angle reading takes place in 3 phases: A laser beam is projected on the sheet metal surface The camera detects the elastic recovery of the material The CNC automatically sets the correction suitable to obtain the system desired angle that we use on our VICLA press brakes and is the best you can find on the market. The guaranteed precision is very high and in the order of fractions of a degree. The system is also able to historicize the elastic recovery of the sheets, ensuring a constant and specific self-learning of the press based on the real situation of the company. Obviously the angle control system guarantees the best performance if it is supported by solid and precise mechanics and perfect integration with numerical control. With the latter, there is a continuous data exchange dialogue that allows perfect application with each item being processed. If, for example, for volume issues, a specific bend cannot be measured by the angle control system, it can be linked to the previous reading made on another flap of the same piece. Vicla optical angle control is a safe investment and surprisingly quick return as it makes continuous measurement operations by the operator completely unnecessary with an exponential increase in productivity and quality. Probe angle control There are essentially three types: inserts in the punch, hosted in the matrixes or applied to parallel sliding trolleys the exact same as those of the optical systems and placed on the sides of the bench. On first examination, it could appear a definitive solution, however these are also not without limitations which, in practice, only appear during their real use. The first is without doubt the installation difficulty. This is the typical limit of the controls inserted in the tools that include use of special punches and matrixes equipped with sophisticated, sensor-based strips. Such angle control systems have very poor versatility when you consider they are not usable by changing tool set-ups. Another limitation is their characteristic fragility. Being small and very sophisticated mechanical elements, they are easily subject to failure caused by accidental impacts or malfunctions due to the accumulation of dust and dirt. O.A.C. (Optical Angle Control) Optical control is directly assembled on photocells to capture images of the profile detecting, calculating and correcting the bending angle. One of the most sophisticated optical controls is the IRIS PLUS system. Although it is part of the optical angle control unit, IRIS plus is an alternative solution because it can perform an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. This eliminates any interference between the parts and the angle control devices and achieves totally versatile use. The system, in fact, allows very interesting accuracy and reliability if the emitter and the receiver are not beyond a certain distance. After approximately 2.5 metres, in fact, there is a natural increase in the phenomenon of refraction of light rays that reach the control system which are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not ensuring the same accuracy in the reading of the bend. Optionals and accessories on the press brakes Bending flattening table The bottom bed has a bending/flattening table in order to perform flat hem bends without the need for a dedicated die. Its versatility makes it the ideal solution for companies that carry out many flat hem bends. The option is built directly into the die holder, and therefore can be used in conjunction with any other die that has a standard connection without the need to disassemble the table. Front sheet metal supports These front supports have a linear guide that extends beyond the bottom beam. Their height can be adjusted and they also slide sideways and rotate. A practical clamp-release system makes them very easy to mount and remove quickly. Metal sheet bending followers They can lift weights up to 380kg. Use of the metal sheet bending followers offers an important advantage to reduce risks for the operator and increase the quality of the bent parts: it was designed to avoid counter-bend effects and reduce the need for other operators. It can also be easily removed from the front and placed on another bending machine. Side parking An extension of the linear guides, extending beyond the bench. This solution is used to park the sheet metal supports when not in use. Wireless 2-pedal foot switch It is powered by an integrated solar panel that allows you to get up to 20% more autonomy from battery life; it does not require connection, nor cable laying. The ultrasonic sensors are located on either side of the lower bench to transmit and receive data wirelessly. Tool locator The system indicates via the incorporated LED the right locking position of the equipment during tool configuration and indicates the position of the active tool in production mode. It is a real and proper visual aid immediately available to the operator who, by doing so, does not waste time measuring and understanding where to position the tool and can dedicate his time to other operations.
The VICLA is not just synonymous with efficiency and accuracy in the sheet metal processing world. Another real strength is our ability to design ergonomic machines with a simple, user-friendly interface. We have studied these features to make them easier to use. Discover our video tutorial to learn how to power a VICLA machine up and
VICLA has been working on systems to help fabricators reduce setup time and minimize production time through stage bending. VICLA Automatic Tool Changer provides the ability to produce multiple bending stations that require various tooling types with only one setup. The demand for smaller, more complex and heterogeneous batches requires finding solutions to shorten production times and lower costs. The smaller the batch, the more the setup times impact on the productivity of the machine and on the production cost. VICLA ATC system - Single or Twin – is designed to automate and speed-up the setups for efficiently producing small batch sizes. The system combines one or two hybrid press brakes with an automatic tool changer, allowing for multiple tooling setups, reducing setup times by 4 or 5 times compared to the ordinary manual operation. The main element of the system is a compact shuttle that serves as robotic tool changer that places the tool sets, up to 1-3/4” V opening, in the clamping systems of the upper and lower beams. This shuttle retrieves and replaces tools in the tool magazine, which can store up to 197 ft. of dies and punches. The tooling can be used in manual or robotic setups. The upper tools can also be rotated 180 degrees. A modular and custom-made solution One of the many other advantages of the VICLA automatic tool changer is the offline programming capability. The CAD / CAM system processes the three-dimensional file, creates the best bending sequence and sends the program to the machine, which is automatically equipped, and calls-up the bending sequence directly on the numerical control screen. All tooling and processing data are automatically saved at the end of the job and exported to the management system for data analysis. About VICLA Sheet Metal Machineries VICLA is an Italian manufacturer specialized in the design and engineering of high performance and customizable bending press brakes, shears and robotic cells. Each machine is tailored to the needs of the individual customer and designed based on its specific production needs. As a result, there is no VICLA machine equal to the other and each of its products excel in terms of production performance and productivity. Thanks to detailed attention, continuous research of high quality, and cutting edge technologies, VICLA has what it takes to provide its customers with the most innovative, robust and reliable technology on the market. This is the company mission since 2008 which has brought VICLA to steadily grow as a machine manufacturer and increase its market shares in Italy, Europe and North America. VICLA official USA Dealer: Comeq Inc., +1 410-933-8500, vicla.eu VICLA Headquarters (Italy): +39 031-622-065, vicla.eu
Sheet metal fabrication is the process of cutting, bending, punching, and assembling flat sheets of various types of metal into desired structures or products. Sheet metal fabrication is now widely used in industries such as agricultural, aircraft, automotive, energy, robotics, and more to manufacture industrial and consumer equipment. Fabrication shops are businesses that specialize in sheet metal fabrication and employ a variety of personnel to handle the difficult process. Design, cutting, punching, bending, assembly, quality check, and packing are the main steps. The creation of a design for the final product is the first step in the sheet metal production process. CAD engineering is the starting point for the route from sheet metal to metal products. The procedure comprises specific data, including dimensions, material qualities, and tolerances that thoroughly outline how to turn a bespoke design into a tangible product. Engineers, architects, designers, and many other experts came up with concepts using schematics and blueprints before the widespread adoption of CAD models in many industries. However, all of that changed thanks to computer-aided design (CAD) models. Modern metal fabricators may use CAD software to create bespoke designs that are accurate and repeatable and can then be scaled up to mass manufacturing. If you're interested in learning about the many ways CAD aids in sheet metal fabrication, here are five of them. 1. Streamlined design process When working with CAD, a designer can take advantage of the software's ability to smooth out bumps in the sheet metal design process. CAD software aids designers in the process of synthesizing, analyzing, and documenting their designs. These factors contribute to the designer's productivity, which translates into faster design, lower design costs, and shorter project completion times. Furthermore, the amount of effort required to design the various models has been significantly reduced because the software automates the majority of the task. Designers can experiment with concepts and save draughts digitally thanks to computer software. You'll be pleased with the results of having your designers work in CAD. Furthermore, because the designer is using CAD, every step of the design process will be documented, allowing everyone to synthesize and analyze the process. 2. Better quality design CAD systems are extremely accurate, allowing error figures to drop dramatically and, as a result, improving design quality. Traditionally, if a design did not work as expected, the team would have to start over. CAD design teams, on the other hand, are better equipped to control the quality of the final engineered product. With CAD software, designers have access to a plethora of tools that aid in conducting a thorough engineering analysis of the proposed design. The low-risk virtual investigation, for example, enables organizations to improve manufacturing speeds and reduce resource waste caused by flawed designs. For starters, CAD reduces the possibility of human error significantly, allowing machinery to craft an item seamlessly while avoiding resource waste. Furthermore, the CAD design process results in fewer draught productions and wastes, resulting in a cheaper and faster production process. 3. Simplified information sharing Creating design documentation is one of the most important aspects of designing when using CAD software. In fact, CAD software aids in better design documentation. Next, all design data can be easily saved and used for future reference, reducing the need for excessive communication. These documents and files can be easily shared among partners and reviewed by teams to ensure that all details are correct. This allows for a more thorough internal understanding of the vision and the work that must be done. CAD software, especially if you're part of a large team, makes it simple to collaborate with team members. Furthermore, due to the integrity of these documents, team members on the ground can be directly allotted information about critical design features, allowing for faster development while reducing assembly errors. 4. Better visualization Visualization is an important tool in Computer-Aided Design because it allows you to effectively and efficiently design, debug, validate, market, maintain, repair, update, and recycle products. The unrivaled visualization capability of CAD software is due to higher levels of sophistication achieved with graphics and visualization techniques, which allow for the creation of images of stunning quality and realism. This is how CAD enables you to create and visualize 2D or 3D objects, as well as make as many changes as you need with less effort than drawing them on paper with a pencil. Architects, engineers, and designers can now use CAD visualizations to create 3D versions of their plans to test how well the design works before spending any money. Furthermore, a completed design will boost their confidence when selling their work to clients. 5. Speed and versatility Speed and versatility are two important aspects of CAD systems that have helped them become an important part of sheet metal fabrication and encourage us to come up with new ways to build things. Designers can use CAD software to visualize their designs and test them against real-world variables. They can easily change the same file if something needs to be changed. Before CAD, people had to do things the old-fashioned way, with paper, pencils, and rulers. They would have to redo the entire design if they wanted to change it. However, CAD eliminates the need for physical prototyping by allowing the designer to simulate all necessary testing in the program virtually. Furthermore, CAD software allows users to use various effects, typography, shapes, and backgrounds to help with artwork and creativity. Final words CAD may be the most significant innovation for metal fabrication and other industrial needs. CAD modeling enables the development of a specification for a custom metal part that is easily understood and actionable by all parties involved in the design and manufacture of the part. When you embrace the benefits of CAD, your designers, prototyping team, and project managers will all be pleased. Furthermore, increased productivity will result from improved quality and reduced waste.
The angle control is a high-tech accessory that allows the achievement of a very important consistency of the bend angle values. Over the years, manufacturers have developed many solutions to address variations in raw material properties before bending. An angle control is able to detect the deformation of the material dynamically during machining. Obviously, not all angle control systems are the same and to better understand their characteristics and peculiarities it is necessary to take an in-depth study. Below is an overview of the existing systems on the market today. O.A.C. (Optical Angle Control) optical controls Although it is part of the group of optical angle controls, IRIS plus is a solution capable of taking an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. IRIS plus does not set any space limits because it is a system housed directly inside the Lazersafe safety devices. This eliminates any interference between the workpieces and the angle control devices and achieves total versatility of use. With IRIS plus, control is perfect but non-invasive, leaving full freedom to the operator while working and always guaranteeing excellent results with all tools and materials. VICLA adopts the IRIS Plus angle control system precisely where it can guarantee the best performance: on small press brakes. The system, in fact, allows a very interesting precision and reliability if the emitter and receiver are not beyond a certain distance. In fact, when approximately 2.5 meters are exceeded, there is a natural increase in the phenomenon of refraction of light rays that reach the control system that are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not guaranteeing the same accuracy in reading the lean angles. Laser Angle Control The DATA M angle control system is one of the most effective and high-performance solutions for automatic angle measurement and control. The DATA M control is a type of laser angle control; it consists of two laser sensors mounted on linear guides that slide at the back and front of the press brake table. Compared to other types, the Data M is one of the most effective and high-performance solutions for automatic angle measurement and control: This device measures and corrects the bend angle in a few ways: • Performs a dynamic measurement while the workpiece is bent • Extrapolate the springback and calculate the correction on the numerical control • Bends based on the previously calculated correction Requirements: • Requires a minimum reading edge of 20 mm out of slot • We recommend that you use a T-matrix • It involves the installation of two linear guides on the machine bench When to buy an angle control system? Often those who have to buy a new bending machine find themselves in doubt whether to also install an angle control system. Assessing the need for angle control is a complex issue and there is no single answer for each case, because it depends a lot on the type of machining and the needs of the individual workshop. Benefits of Angle Control Systems? If you are looking for a new press brake, you must carefully evaluate all the technical aspects of the machine. Before you even choose your brand, it's important to consider what your needs are. Very often we let ourselves be enchanted by the big brand names, but there is no worse mistake than letting yourself be guided in the choice only by the notoriety of the brand or by the price; often we end up neglecting the technical aspect. It is far more important, therefore, to be clear about your company's production needs. Even when choosing whether or not to buy angle control, it's important to ask yourself at least two questions: What kind of work do you do? What is your goal? For example, if you work with small, custom batches, or you make prototypes with fine materials, or you do machining that requires extreme bending precision, you should consider equipping the bending machine with an angle control system. This device is not only an optional extra, but it is a real indispensable ally for certain processes, especially if the material is valuable and a mistake on the corner means having to throw away the piece (and your money!). Many business owners are hesitant about the idea of using angle control, for two reasons: 1. The prejudice on the initial investment, judged by many to be too high 2. The misconception that angle control slows down the work too much Are these legitimate doubts, or are they the result of errors of initial assessment? Let's try to answer them. Angle control costs too much Angle control systems are very advanced instruments, equipped with various measurement methods that facilitate the bending process. It is normal, therefore, that the initial investment reflects the complexity of the option. However, in the face of an initial investment that may seem high, the price of angle control is a completely subjective parameter and is affected by many considerations. For example, have you ever tried to quantify the cost of material thrown away due to errors and waste? You should also include the economic impact of all delivery delays and staff hours lost due to bad work in your calculation. If you haven't already, you'll be amazed to find out how a significant amount of moneyare wasted to rework due to errors, distractions, and waste! If, on the other hand, you already know the costs that are weighing on your company, you are certainly able to more correctly assess the amount of the investment of an angle control. Think about it: does the value of angle control outweigh all the money you've thrown away so far due to mistakes and material waste? Angle control slows down work Some people might wonder that angle control slows down the bending process. Of course, the measurement process takes time, which varies depending on the measurement method used and the complexity of the part to be performed. For those who do precision machining, prototyping, or using fine materials, for example, getting the part right the first time means lowering costs, increasing production quality, and reducing risk. Another important aspect to consider is that, nowadays, modern angle controls are equipped with different methods of use that allow you to choose the most suitable function depending on the type of processing. For example, if you need to make bends that have the same angle, you can set the measurement method to correct all equal angles based on the measurements made on the first bend. In the same way, if you have already derived the springback of that batch of sheets, you can use a particular function, similar to the Real Time control, but much faster. In summary, instead of thinking about how much angle control slows down your work, wouldn't it be more useful to consider how much productivity can increase?
Nowadays it’s possible to have both speed and accuracy when bending sheet metal, you just have to know how to choose: in fact, to create this apparently impossible marriage, you need a press brake that provides real added value to the production chain. Today we will find out what are the most important – and often overlooked – things to consider to finally have speed and accuracy in your company at the same time. Sheet meal bending brings with it physiological issues, first of all from a number of environmental and material variability factors. The production line of a sheet metal workpiece is similar to a chain, which begins with an idea developed in a technical office, which is subsequently roughed during the cutting phase, to then be “brought to life” and given form by the press brake. If every link in the chain is not high quality and well lubricated, your company's movement risks jamming or working badly, resulting in unacceptable speed and efficiency losses. That is why it’s counter-productive to invest inconsistently in the technologies you need. For example: it’s unreasonable to think of reducing waste sufficiently by purchasing a laser cutting machine of the latest generation, a champion of speed, if you then accompany it with an obsolete or low-cost press brake. So here are some tips to avoid having to choose between speed and accuracy. 1) Choose a robust, well-built machine Being able to count on machines designed specifically and manufactured with care and quality is a key factor in ensuring speed and accuracy at the same time. In this sense, made in Italy is in itself a great business card, especially considering experience, professionalism, capability and general quality. Contrary to any false stereotypes, Italy is one of the top five countries in machine tool production, and it’s no coincidence that the sector worldwide has always recognized Italian manufacturing as offering great added value. 2) Choose a manufacturer that listens to you This is a much undervalued issue, but several sources confirm that choosing a good machine without having the same good support can turn out to be completely counter-productive. For example, relying on a manufacturer that is smaller in size but large in service gives a huge competitive advantage that is hard to quantify. What you need is a partner that is willing to let you visit its site, talk to its owners and employees and, of course, directly to its service department for any need. Because speed and accuracy must also go together in support. 3) Choose a manufacturer that focuses on your needs If you need a particular component or accessory in order to work with speed and accuracy, it's good if the manufacturer has it in its catalogue and, above all, that it can advise which one is best for you with transparency and expertise. Sheet metal bending supports, hybrid technology, multi-axis backguages, quick tool connections, etc. All devices that should never be considered a running cost, but a real investment to improve process quality and effectiveness. Therefore, bending speed and accuracy can only coexist if you have a high-quality machine made by a professional manufacturer that is willing to listen to your needs. These have become essential conditions in order to ensure that your work provides added value. None of your customers will ever be willing to pay a premium for waste because your machine is slow and inaccurate, especially in an extremely competitive market like ours.
The art of press brake bending is often underestimated. Companies, sometimes unconsciously, prioritize other areas of their production chain. For example, they may invest in state-of-the-art technical offices while using outdated press brakes. Sheet metal is a challenging material to bend, and underestimating its complexities can lead to costly mistakes. Fortunately, technological advancements have enabled manufacturers to develop efficient press brake equipment. While press brakes have matured in terms of operation and structure, the equipment used to enhance and increase their performance has also evolved. Essential Equipment for Press Brakes: Hybrid systems: modern hybrid systems offer exceptional energy savings and precise beam positioning (accurate to thousandths of a millimeter). VICLA, for example, has created the .Superior press brake, which allows to save up to 78% of energy consumption compared to hydraulic press brakes. Active crowning: Automatic systems with sensors ensure consistent bending angles throughout the workpiece. Multi-axis backgauges: Quick and accurate positioning of backgauges is crucial for complex shapes and small batches. Off-line programming (CAM): Standardize processes and transfer expertise to new operators. User-friendly numerical control: Intuitive interfaces facilitate easy operation for both experienced and inexperienced operators. Press brakes with hybrid technology For most processing, a hybrid system of the latest generation guarantees an indisputable energy saving and can position the top beam with an accuracy in the order of thousandths of a millimetre. These are all benefits that bring great economic savings for the company. Real time crowning As is known, press brakes are subject to natural structural deformation during processing. Bending of the top beam is the most obvious. An automatic system with special sensors located in strategic areas of the press to ensure that the punches and dies are the right distance apart along the whole length of the working area is undoubtedly an invaluable benefit. This ensures that a bent workpiece will have the same desired angle in the middle as at the ends. A multi-axis backgauge for press brakes Having backgauges that can be positioned quickly and accurately almost anywhere has become a must. In fact, the market increasingly demands production of high-quality complex workpieces in small batches: tapered bends, edges that are not parallel to the deformation line, processing stations and so on. With multi-axis backgauges, these and many other complex processes can be carried out more easily. Metal bending off-line programming On other words: standardisation. Being strictly linked to the human factor, bending efficiency depends on the skill and experience of the operator, as well as the quality of the machine used. Where the company has a high personnel turn-over or a growth in volumes that must also be supported by an increase in personnel, the use of CAM can be extremely useful in bending. In fact, in this case the know-how and experience of an expert can be “spread” over the new recruits in a short time, bringing great benefits to production. CNC press brakes have user-friendly numerical control In any case, even if there is no off-line programming, numerical control is the main tool that allows even unskilled press brake operators to interface effectively with their machines in a short time through a clear, simple and complete interface. When the start-up time of a new machine is longer than expected, the problem is often due to difficulty in understanding and controlling an unclear system, which can create problems for operators, regardless of whether they are expert or inexperienced.
A press built to the highest standards, with numerous process parameter checks and alarms to warn when any of them drifts is able to maintain a consistent level of bend quality, but there is much more to be considered. The spring back variable Let’s look at sheet metal bending: it’s a material with many variables: bending response to laser cutting, plasma cutting, size tolerances and so on. Whenever you have to tackle a different workpiece, you also have to think about aesthetics if you are dealing with materials such as pre-painted sheets and steel. For those working with the press brake, everything has to do with the ever-present forming variable: spring back. This is a variable that occurs when the material attempts to return angularly to its original shape after being bent. Tensile strength, material thickness, tool and press brake type naturally all affect spring back. It is essential to predict and evaluate spring back effectively, especially when working with tight bends, as well as with thick, high-strength materials. Laying out workpieces for bending The material normally deforms during bending. The length of the workpiece to be bent is naturally not the same as that of the axis of the bent workpiece. The axis that retains its original line (known as the neutral axis) shifts towards the inside of the bend, and its position depends on various factors such as the sheet metal thickness, bend radius and material quality. These are the factors that can be used to establish the layout of the workpiece to be bent. The tools Many types of press brake tools are available, such as radial, gooseneck and bending/flattening tools, for which the load limit becomes a decisive factor. There are two limits to consider: the limit that the tool itself can withstand, and the load limit at the centre line of the press brake. When it comes to tools, take great care to choose the correct tool and consider the load that the tool can withstand. Work is often carried out at the tool load limit, which risks damaging the punch and die. To avoid damaging tools or even worse the press brake, always observe the load limits. Cleaning Dirt particles can enter the hydraulic circuit if it's not sealed properly, so make sure that the tank cover and breather seals are in good condition. The breathers are fitted on the tank cover, and allow air to flow into the tank to avoid creating a vacuum inside when oil is pumped into the cylinders. Dirt in the oil can result in malfunctions and faults in the pump and valves. Most hydraulic circuit problems are related to contaminated oil, which can cause the valves to stick in the “on or off” position. This means that tool cleaning is very important: dust, oil, debris, chips and other material that builds up over time can scratch the workpiece surfaces.