Sheet metal fabrication is the process of cutting, bending, punching, and assembling flat sheets of various types of metal into desired structures or products. Sheet metal fabrication is now widely used in industries such as agricultural, aircraft, automotive, energy, robotics, and more to manufacture industrial and consumer equipment. Fabrication shops are businesses that specialize in sheet metal fabrication and employ a variety of personnel to handle the difficult process. Design, cutting, punching, bending, assembly, quality check, and packing are the main steps. The creation of a design for the final product is the first step in the sheet metal production process. CAD engineering is the starting point for the route from sheet metal to metal products. The procedure comprises specific data, including dimensions, material qualities, and tolerances that thoroughly outline how to turn a bespoke design into a tangible product. Engineers, architects, designers, and many other experts came up with concepts using schematics and blueprints before the widespread adoption of CAD models in many industries. However, all of that changed thanks to computer-aided design (CAD) models. Modern metal fabricators may use CAD software to create bespoke designs that are accurate and repeatable and can then be scaled up to mass manufacturing. If you're interested in learning about the many ways CAD aids in sheet metal fabrication, here are five of them. 1. Streamlined design process When working with CAD, a designer can take advantage of the software's ability to smooth out bumps in the sheet metal design process. CAD software aids designers in the process of synthesizing, analyzing, and documenting their designs. These factors contribute to the designer's productivity, which translates into faster design, lower design costs, and shorter project completion times. Furthermore, the amount of effort required to design the various models has been significantly reduced because the software automates the majority of the task. Designers can experiment with concepts and save draughts digitally thanks to computer software. You'll be pleased with the results of having your designers work in CAD. Furthermore, because the designer is using CAD, every step of the design process will be documented, allowing everyone to synthesize and analyze the process. 2. Better quality design CAD systems are extremely accurate, allowing error figures to drop dramatically and, as a result, improving design quality. Traditionally, if a design did not work as expected, the team would have to start over. CAD design teams, on the other hand, are better equipped to control the quality of the final engineered product. With CAD software, designers have access to a plethora of tools that aid in conducting a thorough engineering analysis of the proposed design. The low-risk virtual investigation, for example, enables organizations to improve manufacturing speeds and reduce resource waste caused by flawed designs. For starters, CAD reduces the possibility of human error significantly, allowing machinery to craft an item seamlessly while avoiding resource waste. Furthermore, the CAD design process results in fewer draught productions and wastes, resulting in a cheaper and faster production process. 3. Simplified information sharing Creating design documentation is one of the most important aspects of designing when using CAD software. In fact, CAD software aids in better design documentation. Next, all design data can be easily saved and used for future reference, reducing the need for excessive communication. These documents and files can be easily shared among partners and reviewed by teams to ensure that all details are correct. This allows for a more thorough internal understanding of the vision and the work that must be done. CAD software, especially if you're part of a large team, makes it simple to collaborate with team members. Furthermore, due to the integrity of these documents, team members on the ground can be directly allotted information about critical design features, allowing for faster development while reducing assembly errors. 4. Better visualization Visualization is an important tool in Computer-Aided Design because it allows you to effectively and efficiently design, debug, validate, market, maintain, repair, update, and recycle products. The unrivaled visualization capability of CAD software is due to higher levels of sophistication achieved with graphics and visualization techniques, which allow for the creation of images of stunning quality and realism. This is how CAD enables you to create and visualize 2D or 3D objects, as well as make as many changes as you need with less effort than drawing them on paper with a pencil. Architects, engineers, and designers can now use CAD visualizations to create 3D versions of their plans to test how well the design works before spending any money. Furthermore, a completed design will boost their confidence when selling their work to clients. 5. Speed and versatility Speed and versatility are two important aspects of CAD systems that have helped them become an important part of sheet metal fabrication and encourage us to come up with new ways to build things. Designers can use CAD software to visualize their designs and test them against real-world variables. They can easily change the same file if something needs to be changed. Before CAD, people had to do things the old-fashioned way, with paper, pencils, and rulers. They would have to redo the entire design if they wanted to change it. However, CAD eliminates the need for physical prototyping by allowing the designer to simulate all necessary testing in the program virtually. Furthermore, CAD software allows users to use various effects, typography, shapes, and backgrounds to help with artwork and creativity. Final words CAD may be the most significant innovation for metal fabrication and other industrial needs. CAD modeling enables the development of a specification for a custom metal part that is easily understood and actionable by all parties involved in the design and manufacture of the part. When you embrace the benefits of CAD, your designers, prototyping team, and project managers will all be pleased. Furthermore, increased productivity will result from improved quality and reduced waste.
The angle control is a high-tech accessory that allows the achievement of a very important consistency of the bend angle values. Over the years, manufacturers have developed many solutions to address variations in raw material properties before bending. An angle control is able to detect the deformation of the material dynamically during machining. Obviously, not all angle control systems are the same and to better understand their characteristics and peculiarities it is necessary to take an in-depth study. Below is an overview of the existing systems on the market today. O.A.C. (Optical Angle Control) optical controls Although it is part of the group of optical angle controls, IRIS plus is a solution capable of taking an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. IRIS plus does not set any space limits because it is a system housed directly inside the Lazersafe safety devices. This eliminates any interference between the workpieces and the angle control devices and achieves total versatility of use. With IRIS plus, control is perfect but non-invasive, leaving full freedom to the operator while working and always guaranteeing excellent results with all tools and materials. VICLA adopts the IRIS Plus angle control system precisely where it can guarantee the best performance: on small press brakes. The system, in fact, allows a very interesting precision and reliability if the emitter and receiver are not beyond a certain distance. In fact, when approximately 2.5 meters are exceeded, there is a natural increase in the phenomenon of refraction of light rays that reach the control system that are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not guaranteeing the same accuracy in reading the lean angles. Laser Angle Control The DATA M angle control system is one of the most effective and high-performance solutions for automatic angle measurement and control. The DATA M control is a type of laser angle control; it consists of two laser sensors mounted on linear guides that slide at the back and front of the press brake table. Compared to other types, the Data M is one of the most effective and high-performance solutions for automatic angle measurement and control: This device measures and corrects the bend angle in a few ways: • Performs a dynamic measurement while the workpiece is bent • Extrapolate the springback and calculate the correction on the numerical control • Bends based on the previously calculated correction Requirements: • Requires a minimum reading edge of 20 mm out of slot • We recommend that you use a T-matrix • It involves the installation of two linear guides on the machine bench When to buy an angle control system? Often those who have to buy a new bending machine find themselves in doubt whether to also install an angle control system. Assessing the need for angle control is a complex issue and there is no single answer for each case, because it depends a lot on the type of machining and the needs of the individual workshop. Benefits of Angle Control Systems? If you are looking for a new press brake, you must carefully evaluate all the technical aspects of the machine. Before you even choose your brand, it's important to consider what your needs are. Very often we let ourselves be enchanted by the big brand names, but there is no worse mistake than letting yourself be guided in the choice only by the notoriety of the brand or by the price; often we end up neglecting the technical aspect. It is far more important, therefore, to be clear about your company's production needs. Even when choosing whether or not to buy angle control, it's important to ask yourself at least two questions: What kind of work do you do? What is your goal? For example, if you work with small, custom batches, or you make prototypes with fine materials, or you do machining that requires extreme bending precision, you should consider equipping the bending machine with an angle control system. This device is not only an optional extra, but it is a real indispensable ally for certain processes, especially if the material is valuable and a mistake on the corner means having to throw away the piece (and your money!). Many business owners are hesitant about the idea of using angle control, for two reasons: 1. The prejudice on the initial investment, judged by many to be too high 2. The misconception that angle control slows down the work too much Are these legitimate doubts, or are they the result of errors of initial assessment? Let's try to answer them. Angle control costs too much Angle control systems are very advanced instruments, equipped with various measurement methods that facilitate the bending process. It is normal, therefore, that the initial investment reflects the complexity of the option. However, in the face of an initial investment that may seem high, the price of angle control is a completely subjective parameter and is affected by many considerations. For example, have you ever tried to quantify the cost of material thrown away due to errors and waste? You should also include the economic impact of all delivery delays and staff hours lost due to bad work in your calculation. If you haven't already, you'll be amazed to find out how a significant amount of moneyare wasted to rework due to errors, distractions, and waste! If, on the other hand, you already know the costs that are weighing on your company, you are certainly able to more correctly assess the amount of the investment of an angle control. Think about it: does the value of angle control outweigh all the money you've thrown away so far due to mistakes and material waste? Angle control slows down work Some people might wonder that angle control slows down the bending process. Of course, the measurement process takes time, which varies depending on the measurement method used and the complexity of the part to be performed. For those who do precision machining, prototyping, or using fine materials, for example, getting the part right the first time means lowering costs, increasing production quality, and reducing risk. Another important aspect to consider is that, nowadays, modern angle controls are equipped with different methods of use that allow you to choose the most suitable function depending on the type of processing. For example, if you need to make bends that have the same angle, you can set the measurement method to correct all equal angles based on the measurements made on the first bend. In the same way, if you have already derived the springback of that batch of sheets, you can use a particular function, similar to the Real Time control, but much faster. In summary, instead of thinking about how much angle control slows down your work, wouldn't it be more useful to consider how much productivity can increase?
Nowadays it’s possible to have both speed and accuracy when bending sheet metal, you just have to know how to choose: in fact, to create this apparently impossible marriage, you need a press brake that provides real added value to the production chain. Today we will find out what are the most important – and often overlooked – things to consider to finally have speed and accuracy in your company at the same time. Sheet meal bending brings with it physiological issues, first of all from a number of environmental and material variability factors. The production line of a sheet metal workpiece is similar to a chain, which begins with an idea developed in a technical office, which is subsequently roughed during the cutting phase, to then be “brought to life” and given form by the press brake. If every link in the chain is not high quality and well lubricated, your company's movement risks jamming or working badly, resulting in unacceptable speed and efficiency losses. That is why it’s counter-productive to invest inconsistently in the technologies you need. For example: it’s unreasonable to think of reducing waste sufficiently by purchasing a laser cutting machine of the latest generation, a champion of speed, if you then accompany it with an obsolete or low-cost press brake. So here are some tips to avoid having to choose between speed and accuracy. 1) Choose a robust, well-built machine Being able to count on machines designed specifically and manufactured with care and quality is a key factor in ensuring speed and accuracy at the same time. In this sense, made in Italy is in itself a great business card, especially considering experience, professionalism, capability and general quality. Contrary to any false stereotypes, Italy is one of the top five countries in machine tool production, and it’s no coincidence that the sector worldwide has always recognized Italian manufacturing as offering great added value. 2) Choose a manufacturer that listens to you This is a much undervalued issue, but several sources confirm that choosing a good machine without having the same good support can turn out to be completely counter-productive. For example, relying on a manufacturer that is smaller in size but large in service gives a huge competitive advantage that is hard to quantify. What you need is a partner that is willing to let you visit its site, talk to its owners and employees and, of course, directly to its service department for any need. Because speed and accuracy must also go together in support. 3) Choose a manufacturer that focuses on your needs If you need a particular component or accessory in order to work with speed and accuracy, it's good if the manufacturer has it in its catalogue and, above all, that it can advise which one is best for you with transparency and expertise. Sheet metal bending supports, hybrid technology, multi-axis backguages, quick tool connections, etc. All devices that should never be considered a running cost, but a real investment to improve process quality and effectiveness. Therefore, bending speed and accuracy can only coexist if you have a high-quality machine made by a professional manufacturer that is willing to listen to your needs. These have become essential conditions in order to ensure that your work provides added value. None of your customers will ever be willing to pay a premium for waste because your machine is slow and inaccurate, especially in an extremely competitive market like ours.
The art of press brake bending is often underestimated. Companies, sometimes unconsciously, prioritize other areas of their production chain. For example, they may invest in state-of-the-art technical offices while using outdated press brakes. Sheet metal is a challenging material to bend, and underestimating its complexities can lead to costly mistakes. Fortunately, technological advancements have enabled manufacturers to develop efficient press brake equipment. While press brakes have matured in terms of operation and structure, the equipment used to enhance and increase their performance has also evolved. Essential Equipment for Press Brakes: Hybrid systems: modern hybrid systems offer exceptional energy savings and precise beam positioning (accurate to thousandths of a millimeter). VICLA, for example, has created the .Superior press brake, which allows to save up to 78% of energy consumption compared to hydraulic press brakes. Active crowning: Automatic systems with sensors ensure consistent bending angles throughout the workpiece. Multi-axis backgauges: Quick and accurate positioning of backgauges is crucial for complex shapes and small batches. Off-line programming (CAM): Standardize processes and transfer expertise to new operators. User-friendly numerical control: Intuitive interfaces facilitate easy operation for both experienced and inexperienced operators. Press brakes with hybrid technology For most processing, a hybrid system of the latest generation guarantees an indisputable energy saving and can position the top beam with an accuracy in the order of thousandths of a millimetre. These are all benefits that bring great economic savings for the company. Real time crowning As is known, press brakes are subject to natural structural deformation during processing. Bending of the top beam is the most obvious. An automatic system with special sensors located in strategic areas of the press to ensure that the punches and dies are the right distance apart along the whole length of the working area is undoubtedly an invaluable benefit. This ensures that a bent workpiece will have the same desired angle in the middle as at the ends. A multi-axis backgauge for press brakes Having backgauges that can be positioned quickly and accurately almost anywhere has become a must. In fact, the market increasingly demands production of high-quality complex workpieces in small batches: tapered bends, edges that are not parallel to the deformation line, processing stations and so on. With multi-axis backgauges, these and many other complex processes can be carried out more easily. Metal bending off-line programming On other words: standardisation. Being strictly linked to the human factor, bending efficiency depends on the skill and experience of the operator, as well as the quality of the machine used. Where the company has a high personnel turn-over or a growth in volumes that must also be supported by an increase in personnel, the use of CAM can be extremely useful in bending. In fact, in this case the know-how and experience of an expert can be “spread” over the new recruits in a short time, bringing great benefits to production. CNC press brakes have user-friendly numerical control In any case, even if there is no off-line programming, numerical control is the main tool that allows even unskilled press brake operators to interface effectively with their machines in a short time through a clear, simple and complete interface. When the start-up time of a new machine is longer than expected, the problem is often due to difficulty in understanding and controlling an unclear system, which can create problems for operators, regardless of whether they are expert or inexperienced.
A press built to the highest standards, with numerous process parameter checks and alarms to warn when any of them drifts is able to maintain a consistent level of bend quality, but there is much more to be considered. The spring back variable Let’s look at sheet metal bending: it’s a material with many variables: bending response to laser cutting, plasma cutting, size tolerances and so on. Whenever you have to tackle a different workpiece, you also have to think about aesthetics if you are dealing with materials such as pre-painted sheets and steel. For those working with the press brake, everything has to do with the ever-present forming variable: spring back. This is a variable that occurs when the material attempts to return angularly to its original shape after being bent. Tensile strength, material thickness, tool and press brake type naturally all affect spring back. It is essential to predict and evaluate spring back effectively, especially when working with tight bends, as well as with thick, high-strength materials. Laying out workpieces for bending The material normally deforms during bending. The length of the workpiece to be bent is naturally not the same as that of the axis of the bent workpiece. The axis that retains its original line (known as the neutral axis) shifts towards the inside of the bend, and its position depends on various factors such as the sheet metal thickness, bend radius and material quality. These are the factors that can be used to establish the layout of the workpiece to be bent. The tools Many types of press brake tools are available, such as radial, gooseneck and bending/flattening tools, for which the load limit becomes a decisive factor. There are two limits to consider: the limit that the tool itself can withstand, and the load limit at the centre line of the press brake. When it comes to tools, take great care to choose the correct tool and consider the load that the tool can withstand. Work is often carried out at the tool load limit, which risks damaging the punch and die. To avoid damaging tools or even worse the press brake, always observe the load limits. Cleaning Dirt particles can enter the hydraulic circuit if it's not sealed properly, so make sure that the tank cover and breather seals are in good condition. The breathers are fitted on the tank cover, and allow air to flow into the tank to avoid creating a vacuum inside when oil is pumped into the cylinders. Dirt in the oil can result in malfunctions and faults in the pump and valves. Most hydraulic circuit problems are related to contaminated oil, which can cause the valves to stick in the “on or off” position. This means that tool cleaning is very important: dust, oil, debris, chips and other material that builds up over time can scratch the workpiece surfaces.
Industry 4.0, the fourth industrial revolution. You hear about it often, but what does it actually mean? It is a change to the production parameters used up until now or, better still, an inevitable and necessary evolution in the way we manufacture in order to improve quality and working conditions. The fourth major change in the industrial age – known as “revolution” for good reason – is taking place through computerisation and system digitisation. In fact, Industry 4.0 refers to a new way of conceiving today's industrial systems, a transformation that affects the structure of the industry as a whole. To be 4.0 involves not only individual machines, but the entire factory system. Innovation, integration, efficiency Transforming a company into 4.0 involves first of all an in-depth analysis of all aspects of its structures, and of its own needs and goals. Every business is first and foremost called upon to understand where actions are needed and feasible and, most importantly, how to structure the change towards the digital world internally. There are three elements in this new way of viewing industry: technological innovation, based in particular on a drive towards computerisation that allows close collaboration between all the elements involved in the production process; integration between systems, between different parts of the company and between the various components of the entire supply chain; efficient energy use, in which consumption reduction is a major consideration. The data above all But where to start? Based on the digitisation process, Industry 4.0 requires knowledge and systematic collection of the data produced; all of the data! This means not just the data from the actual production process, but also data, for example, from handling incoming and outgoing goods, or even from management of resources and relationships throughout the supply chain. In essence, any aspect of company life. When properly managed and shared, this massive amount of information – the so-called Big Data – can be used to optimise resources and reduce waste. All of this results in a decrease in material and time losses for the company. It streamlines processes and work flows, making the business more efficient, with cost savings and therefore a financial benefit. The evolution toward Industry 4.0 also brings new job opportunities. From a professional perspective, over the coming years digitising industries will require specialist professionals with digital skills, figures that did not exist until recently, and greater attention to continual personnel training.
Press brakes are essential tools in metal fabrication, but neglecting their maintenance can have serious consequences. Just like any other machine, press brakes are susceptible to wear and tear that can lead to breakdowns, reduced efficiency, and even safety hazards. Press brakes overview Press brakes are essential machines in metal fabrication, designed to bend sheet and plate metal into various shapes. There are many different options for generating force and moving the ram. This results in many different types of press brake, such as hydraulic press brakes, cnc press brake, electric press brakes and hybrid press brakes. This guide will show you the daily, weekly and monthly procedures we recommend. In addition, there is a list of procedures to be carried out at least once a year in order to keep your press brake in perfect working condition at all times. Always bear in mind that these are routine procedures; for more serious problems, always rely on our VICLA qualified technicians. The Cost of Downtime Imagine the impact of a press brake malfunction in the middle of a critical production run. Downtime translates to lost revenue, delayed deliveries, and frustrated customers. Studies show that metalworking companies experience hundreds of hours of downtime per year due to equipment failure. Beyond Downtime: The Hidden Costs of Neglect The financial impact goes beyond immediate downtime. Unmaintained press brakes are more likely to experience: Reduced Accuracy and Quality: worn components can cause inconsistencies in bends, leading to scrap metal and rework. Increased Energy Consumption: inefficient machines require more power to operate, driving up energy costs. Safety Risks: malfunctioning brakes pose a threat to operators and can lead to costly accidents. Higher Repair Costs: early detection and prevention through maintenance is significantly cheaper than major repairs after breakdowns. Building a Cost-Effective Maintenance Strategy There's no single silver bullet approach to press brake maintenance. The optimal strategy depends on factors like your usage patterns, the age of your machine, and your budget. However, a proactive approach offers the best return on investment. Consider implementing a combination of practices: Preventive Maintenance Is done before a failure occurs and consists of maintenance types like: Time-Based Maintenance, Failure Finding Maintenance, Risk-Based Maintenance, Condition Based, Maintenance and Predictive Maintenance. Corrective Maintenance Is done after a failure has occurred either as Deferred Corrective Maintenance or as Emergency Maintenance. By investing in a comprehensive press brake maintenance plan, you can improve your machine's efficiency, longevity, and safety. This ultimately translates to a more robust manufacturing operation, increased profitability, and a competitive edge in your industry. Remember, preventive maintenance is an investment, not an expense. Planned Preventive Maintenance Planned Preventive Maintenance includes inspections, checks, and interventions to maintain the condition of wear parts and machine lubrication, preventing failures and malfunctions. While these operations are relatively simple, they must be performed by qualified staff. Press Brake Care: Key Areas of Focus Always clean your bending brake Regular cleaning is essential for maintaining a press brake's optimal performance. Dirt and debris can accumulate, increasing friction and leading to component wear, potential breakdowns, and reduced accuracy. A clean work environment also helps minimize the frequency of machine cleaning. Lubrication: A Critical Component of Press Brake Maintenance Proper lubrication is essential for ensuring smooth operation, reducing wear and tear, and extending the lifespan of your press brake. Lubricants help minimize friction between moving parts, preventing excessive heat buildup and potential damage. Lubrication Points and Frequency Press brakes have various lubrication points, each with specific requirements. Some parts may need weekly lubrication, while others might require less frequent attention. The exact lubrication schedule depends on the press brake's design and operating conditions. Lubricant Types Common lubricants for press brakes include: Lithium grease: A versatile lubricant suitable for many applications. Silicone grease: Offers good resistance to high temperatures and chemicals. Synthetic non-petroleum lube: Provides excellent performance in extreme conditions. Dry film graphite lubrication: Ideal for applications requiring minimal lubrication. Avoiding Over-Lubrication Excessive lubrication can lead to the accumulation of dirt and debris, which can counteract the benefits of lubrication. Follow the manufacturer's recommendations for lubrication intervals and quantities. Regular lubrication, combined with proper cleaning and inspection, is a key component of effective press brake maintenance. By adhering to lubrication guidelines, you can significantly improve your machine's performance and longevity. Inspection Regular inspections help identify potential problems before they escalate, saving time and money. Conduct visual inspections at regular intervals, both when the machine is stationary and in operation. This allows you to identify any signs of wear, damage, or misalignment. Test all components, including safety devices, controls, and moving parts, to verify their proper operation. Create a comprehensive checklist to guide your inspections. This ensures thorough coverage of all critical areas and helps you track maintenance history. Note any areas of concern or potential issues in your inspection checklist for further investigation or corrective action. Calibration Ensuring accurate calibration of components like the back gauge is essential for maintaining precision in bending operations. Electrical and Hydraulic Maintenance These systems require specific attention to prevent malfunctions and safety hazards. Press brake maintenance: preparing the press brake Before cleaning, you must prepare the machine to ensure your safety and that of your colleagues. We recommend the following procedure: At the start of the work shift, inspect the machine and check that the table and die area are free of residues from the previous shift. Delimit the area with barriers and signs. Lower the mobile beam until the tip of the top tool touches the bottom tool. Keep the tools closed until all maintenance work is complete. Switch off the power supply and padlock the main disconnector switch on the electrical cabinet door. Turn the mains switch to the 0 position. The five precautions to take during press brake maintenance When combined with correct press brake use, scheduled maintenance makes a significant difference to its performance and efficiency. When carrying out maintenance or repair work, always follow the instructions in your press brake maintenance manual carefully. Here is a generic list of precautions you should observe: Do not use solvents and flammable materials Take care not to disperse cooling lubricants in the environment Use suitable equipment to access the highest parts of the machine Do not climb on parts of the machine as they have not been designed to support people When the work is complete, reinstate and secure all safety devices and guards removed, opened or disabled previously Scheduling press brake maintenance Daily maintenance Carry out the following checks at the end of the shift or working day: Check that the safety devices are working. For example, our VICLA press brakes are equipped with Lazersafe devices. They are optical safety devices fitted with lenses that focus laser beams to monitor the danger zone under the beam. The front lenses of the transmitter and receiver must be cleaned whenever you notice any traces of dust, grease, fingerprints, oil, stains or dirt. Remember to check that the three-position down pedal is working. Use a dry cloth to remove all processing residues. NEVER use compressed air and always protect your hands with neoprene or PVC gloves. Clean the tools, bed, supports and backgauge carefully. Do not forget to check any accessories installed on the machine. Weekly maintenance Make sure that the emergency stop button is working correctly. Check that the rear guard is working. Check the side guards. Check the filter clogging indicator. Replace the filter element if the vacuum switch pointer is on yellow. Monthly maintenance Clean the hydraulic pipes and components. Clean the outside of the hydraulic system (manifolds, valves, motor/pump unit, pipes, etc.) at least once a month. This cleaning serves to identify possible leakage areas and reduce the risk of contaminants entering the system when replacing components. It also prevents a reduction in heat exchange between the system and environment. Visually inspect the fittings to ensure that they are sealed, and tighten them if necessary. Remember to check that the hydraulic circuit connections are tight after the first 160 hours of press brake operation. Monthly maintenance of the rigid pipes, especially near fittings, pump and cylinders is important to identify leaks. Consider also the hoses connecting the pump to the system; replace them if there are any bulges. Oil level: remember to check this after any maintenance work on the hydraulic system. Clean the air filter on the compressed air tank. Annual maintenance Clean and lubricate the guides of the mobile beam with a clean cloth every year. Air filter unit with condensate separators. Replace the oil separator micro-filter once a year or when the pressure drop reaches 1 bar. Change the oil in the hydraulic circuit. Clean the tank and replace the filter element in the oil filter. Conclusion In this guide we have seen how to keep your press brake in good working condition. In fact, a clean machine is also a monitored machine, because damage or small oil leaks can appear at any point. Now that you know what to do every day, every week and every year, you can create a complete maintenance schedule for your press brake.
The importance of knowing how to assess your perfect press supplier. In an extremely competitive sector such as that of sheet metal machines, it's very easy to come across false legends, old beliefs and complete speculation. It is said that: “all that glisters is not gold”, and nothing is more true. Very often, the market is influenced by misleading news and messages that can lead potential buyers to make sub-optimal or even bad choices. Large renowned brands or those that have simply been on the market for a long time are often chosen “blindly” for the aura of “sacredness” surrounding them. But can we be sure that a significant investment, such as that of a press brake, a long-lasting and demanding asset, does not deserve a more in-depth analysis? The characteristics of the perfect manufacturer A manufacturer that can fully meet the needs of a modern company facing today’s stormy market head-on must be: technological. It must be able to manage, and therefore offer, the best applied technology currently available on the market. Simple and user-friendly numerical controls that allow total, interactive machine management, fast, accurate and green motion systems, as well as state-of-the-art safety systems. It is better to be wary of suppliers who only offer obsolete systems in their catalogues. reliable. Your perfect press supplier does not leave the customer alone under any circumstances. The perfect supplier provides support to clarify all the customer's doubts: support that is ready, available and provided by extremely competent personnel is among the most important ingredients to prevent unnecessary and harmful downtime. This is because even the best machine in the world can have problems, and they are not necessarily related to its quality. Sometimes external factors can also affect press brake operation. available. A manufacturer offering standard machines or machines with few customisation options are rarely able to meet customer needs: even more so in a context like today, in which almost all orders are for special parts, in small batches, of high-quality and with a quick turnaround. It is not acceptable to spend large sums on a standard machine and then realise that it's unable to perform many jobs. You need versatility and flexibility when choosing, designing, and then using. near. Or better: “close”. We do not mean physically close: the closeness of a supplier is measured in its willingness to open its doors and listen to potential customers, and to accompany them through all the stages of making the correct choice. Understanding customers’ core business together, knowing how to explain the solutions that are right for them and how they work: this is closeness, because the perfect supplier cannot take anything for granted. Potential customers, even the most expert, are not press brake manufactures, so they may not be aware of all the aspects to be assessed at the configuration stage. That is why the perfect supplier, besides being able to offer the most suitable technological machine, must also educate customers about it. In short, buying a seemingly banal machine like a press brake is not at all easy. The perfect supplier is one that lets customers make the right choice and offers the best solutions… and know how to explain them!
When designing sheet metal components, it is crucial to consider various factors that influence the quality and functionality of the final product. For example, k-factor, bending tolerances, material selection and press brake configuration can have a significant impact. If you want to delve deeper into this last aspect, find out more about the different types of bending machines that exist on the market. Today we will talk about the K factor, because it is a fundamental element in bending and is closely linked to springback, a concept that you can learn more about in this article. What is the k-factor? The K factor represents the ratio of the neutral axis location to the material thickness during bending. It indicates how a material will behave under tension and compression forces during the bending process. The neutral axis is the imaginary line within the material that experiences neither tension nor compression. Accurately determining the neutral axis is essential for calculating the bend allowance, which is the additional length required to form a bend. What is the neutral axis? The neutral axis 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. Simplified Explanation of k-factor Think of the K factor as a fraction: the distance from the inside of the bend to the neutral axis divided by the material thickness. For most materials, the K factor is approximately 0.33, meaning the neutral axis is located about one-third of the material thickness from the inside of the bend. However, factors like material type, bend radius, and bending process can influence the actual K factor. Factors Affecting the K Factor Several factors influence the K factor, including: Material: Different materials have varying K factors due to their unique mechanical properties. Bend radius: A smaller bend radius generally results in a higher K factor. Bending process: Air bending, bottom bending, and coining produce different bend results and thus affect the K factor. Calculating the K Factor 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 K Factor Calculation Simplified: VICLA's Online Calculator. Streamline your bending operations with our free K factor calculator. Input material properties and bend geometry to obtain accurate results: vicla.eu/en/calculators/calculate-k-factor Reverse Engineering The K-factor Calculating the k-factor for your sheet metal bending operations can seem daunting at first. Essentially, it's a way to account for the material's behavior during bending, ensuring your CAD models accurately predict the final dimensions of your parts. Here's a practical method to determine the k-factor: Prepare a Test Strip: Start by cutting a strip of the material you'll be working with. Measure its length and thickness precisely. The width isn't critical, but a standard width like 100mm (4 inches) usually suffices. Perform a Test Bend: Bend the strip at a 90-degree angle. Carefully measure the lengths of the two sides of the bend (let's call them Length X and Length Y). Calculate the K-Factor: While the exact bend radius can be tricky to measure, it's not as critical as you might think. The k-factor you calculate will inherently account for minor discrepancies in the actual bend radius. The key is to find a k-factor that, when used in your CAD software with your typical bend radius, accurately predicts the real-world bend dimensions you just measured. This means that even if your real-world tooling radius differs slightly from the radius you input into your CAD software, the calculated k-factor will compensate for this difference. The formula for calculating the k-factor is: K-Factor = (-BendRadius + (BendAllowance / (π * BendAngle / 180))) / thickness where: BendAllowance = (2 * OutSideSetBback) – BendDeduction OutSideSetBback = (Tan(BendAngle / 2)) * (thickness + BendRadius) BendDeduction = Length X + Length Y - Total Flat Length Validate and Adjust If your calculated k-factor falls outside the acceptable range for your CAD software (usually between 0 and 1), double-check your measurements and calculations. This method provides the most accurate k-factor for your specific material and bending setup. Developing a Sheet Metal Blank: The Role of the K Factor There are several methods used in sheet metal fabrication workshops to determine the correct blank size for a bent part. While modern software tools have become increasingly popular, many shops still rely on empirical methods and experience. Traditional Methods: Empirical Tables: These tables are created by conducting physical tests to determine the necessary compensation values for different materials and bend radii. Compensation values are added to the inside bend dimensions to account for material stretching during the bending process. DIN Tables: Similar to empirical tables, DIN tables provide values that are subtracted from the outside dimensions of the bent part. Geometric Calculations: Using the calculated K factor and the bend radius, engineers can determine the bend allowance through geometric formulas. Advanced Methods: Software-Based Calculations: Modern CAD software can automatically calculate bend allowances based on the material properties, bend radius, and K factor. Designers can adjust the K factor to fine-tune the results. Percentage Method: A widely used method where the inside bend radius is simplified based on the die and material, and then the appropriate K factor from a table is applied. Applications of the K Factor in Sheet Metal Fabrication The K factor is a critical parameter in various aspects of sheet metal fabrication, including: CAD Design: CAD software uses the K factor to generate accurate flat patterns for bent parts. Part Production: The K factor ensures that fabricated parts fit together correctly without requiring post-production modifications. Prototyping: The K factor helps to verify the feasibility and accuracy of bends during the prototyping phase. Understanding the K Factor By grasping the concept of the K factor and its calculation, you can accurately determine the required blank size for your sheet metal bending operations. This ensures precise part production and reduces the need for costly rework.
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!