The importance of having the right equipment to achieve great results is often mentioned. In this case, it is not just the quality of what you have that is important, but how you use and look after it is also essential. In fact, improper use and poor maintenance are factors that will demolish even the best equipment over time. That is why, when it comes to press brake bending, you have to remember that a machine is to the operator what a winning horse is to the jockey. Looking after your press brake is a duty that, however, makes it a pleasure to work with! But what are the best practices for looking after your machine properly? 1) Know your machine technically Managing your press brake properly and taking care of it is undoubtedly the first step in making it last a long time. 2) Lubricate the machine correctly and consistently The press brake is an orchestra of moving mechanical parts conducted by electrical and electronic systems. It is extremely important to follow the manufacturer's specifications carefully regarding lubrication frequency and the location of the lubrication points. Proper lubrication also means using high-quality greases and oils, chosen exclusively on the basis of the manufacturer's specifications. The points that require lubrication include: the beam sliding points, the rear carriage and any bending supports. If there is a centralised lubrication system, check it methodically. 3) Clean the machine A clean press brake is not just beautiful to look at, but is also efficient! Usually, you can only see oil leaks if the machine is perfectly clean, even small ones such as seepage from the cylinders, or abnormal drips in the backgauge area or on the floor inside the machine. Proper cleaning means following the manufacturer’s specifications and not using aggressive detergents or other unsuitable products. In addition to this, take great care to avoid cleaning the optical scales improperly! If in doubt, contact the manufacturer. 4) Generally check correct operation and settings A press brake is composed of many moving parts, including some large ones. These large masses are actuated repeatedly for millions of cycles in a year, with extremely tight tolerances. Just think of a beam that weighs thousands of kilograms: during each cycle it is “dropped” and then braked to slow it down in just a few tenths of a millimetre. It is taken to bottom dead centre (BDC) with an accuracy in the order of hundredths of a millimetre, and is then raised for the next bend. Inertia, vibration and continuous stress can wear out some susceptible components over time. Operators who work diligently must also be diligent in relation to their machines, and immediately report any kind of anomaly, even the smallest. Only they can recognise the signs of potentially much larger problems that will harm the machine and production. For example, small gaps in the backgauge or poor positioning accuracy. Obviously, the first step is to choose a manufacturer that is able to make high-quality press brakes in order to eliminate almost all of these kinds of problem. 5) Keep the tools and bed clean Keep the mating surfaces between the dies, punches and machine clean. In fact, when bending materials such as carbon steel, or when stainless steel has small slag balls in the corners of the holes and edges caused by an imperfect laser cut, these residues often end up on the press bed. If they are not removed, they can score the supporting bases, which may compromise optimal bending over the years.
VICLA press brakes are made based on strong features: frame sturdiness, maximum efficiency, and outstanding bending accuracy. For top quality that is also expressed through the most advanced and innovative technical solutions. An example of such a solution is 3D PROV, programming software for preparing and processing 3D products that offers multiple benefits. Such as the use of automated systems that can speed up the management times of the entire process (from design to finished product), minimum downtimes thanks to the offline programming feature, fewer discarded pieces thanks to collision control during bending sequence, tool library compatibility that allows for checking the availability of the tools required for production. Some of the main features of the 3D PROV are: Direct import from SolidWorks, Solid Edge and Inventor; Import and development of 3D parts in IGES and STEP formats; Automated and manual setup based on the type of material, machine and tool properties; Automated and manual bending sequence with collision control; Automated and manual calculation of retainer position and ledge with interactive graphical control on all axes; Automated calculation of retainer retraction; 3D simulation of the bending process with collision control; Detailed report on machine setup stations, also including bending sequences, used tools, graphical information, and bending specifications. The 3D PROV programming software ensures maximum efficiency in tool selection, based on bend radius, maximum press brake force, collision control, and the availability of different tool types and splits. To make the machine even more efficient, you can have full control over the hemming process, because the software allows you to set the default tools for automatic recognition as well as the pre-bending angle (default and editable value). 3D PROV can also calculate the bending parameters automatically to avoid any collisions, taking account of the availability of tool splits, horn tools and inward back-bending. Full manual control with split of complete bends into partial bends and the option to set the pre-bending angle and interactive change of the bending sequence order. For retainer positioning, 3D PROV offers automatic and manual backgauge control options with automatic 3D simulation (retainers, tools, piece to bend, machine frame) and collision control with all parts in motion. The software also provides a full setup report, from bending sequence instructions to charts containing detailed information for each bend.
A modern CNC press brake can cut down on maintenance costs while improving the production performances. Over the years, manufacturers have been developing different solutions to improve the performance of their products. Through tools, functionalities and technological innovations sheet metal press brakes have evolved starting from mechanical presses to hybrid cnc press brakes. Recently we have produced two hybrid cnc press brakes to a Russian company specialized in metal and alloy processing for the design and furniture sectors. The need to reduce production costs, create many product prototypes and complete orders in a short time, were the reasons that convinced the company to buy our cnc hybrid press brakes. Scroll at the bottom to read the technical specs of these two industrial press brakes. Let's now have a closer look at the real benefits of a hybrid sheet metal press brake. Hybrid cnc press brake: less consumption and environmental impact In a traditional hydraulic press, a big pump is constantly active, whether the machine is working or not. In this way there is high and useless energy and heat dissipation. VICLA's hybrid system allows the machine to consume energy only when the pedal is activated. This means that the consumption of the press brake is minimum when tools are changed and, in general, during those steps in which the crosspiece is not involved. Low oil consumption is another key point. The quantity of oil used in our bending machines is dramatically low compared to traditional hydraulic press. Small oil tanks translate into many advantages, such as: more savings less environmental impact less maintenance costs A quicker production The brushless engines are directly connected to two small oil tanks. The advantage is that the cnc press brake is more precise and is not affected by temperature variation, as opposed to traditional machines. Moreover, such as in the case of hybrid press brakes that we have recently sent to Russia, the addition of high-tech devices to perfectly control both the bending precision and the structural flexions of frames, allow to achieve unrivaled performances. CNC press brakes: special configuration We recently produced two hybrid sheet metal press brakes for a client based in Russia and specialized in the processing of high-end furnitures. The company requirements in terms of adds-on and personalization included the choice of adding two special devices that control the bending precision and the structural flexions of the frames. See below the detailed configuration of each hybrid cnc press brake. Hybrid CNC sheet metal press brake VICLA .SUPERIOR 50/20 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Hydraulic crowning system managed by CNC Optical scales and high speed photocellls IRIS LazerSafe Tooling set for punches and dies Main power 5,5kW Oil capacity 80l Hybrid CNC sheet metal press brake VICLA .SUPERIOR 110/31 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Dynamic hydraulic crowning system managed by CNC (Clever Crowning) Management of the structural flexions of the frames (Flex System) Optical scales photocells with double optical path Lazersafe Manual quick system clamping of the punches Tooling set for punches and dies Main power: 11kW Oil capacity 50l + 50l Call us or contact us for more information Now that you now exactly how a hybrid cnc press brake can improve your production, you may want to receive a personalized quotation. Use our online configurator or contact us by filling out this form. Our international team will be more than happy to provide you with all the necessary information you need.
Superior in every aspect, even in terms of power saving, low consumption and environment protection. .SUPERIOR is a sheet metal press brake made by VICLA, able to bend and cut the costs of the entire manufacturing cycle, reducing them to a minimum, while speeding up the production times to maximum velocity. Hybrid System The standard version is equipped with an innovative hybrid system and comes at the same price as a traditional machine, ensuring exceptional power savings and a massive reduction in oil consumption thanks to the use of the double tank. The results in numbers of this technological innovation are: power savings of up to 55%, significant oil consumption reduction (e.g.: 2X40 litres – press of 110 t), output increased by 20%, 20% decrease in fast-up limit, 50% decrease in oil temperature, risk of leakages reduced by 70%, tank volume reduced by 50%, and 50% faster and easier installation. With VICLA Hybrid System, the piping system is reduced by up to 60%. Hybrid System Plus All these advantages translate into greater performance of the manufacturing system and perfect finished products. In one word: quality. Not only in terms of stability of the frame and the bending precision, but also with regard to power saving and environment protection. The Hybrid System is a standard feature included in the standard version of the .SUPERIOR press brake, but the system is however extremely versatile: optional features and accessories or custom-made solutions are also available, depending on every production requirement. Hybrid System Plus: the system that cuts down consumption to 78% compared to traditional machines and to 23% compared to the standard Hybrid System. This is VICLA’s pursuit to ensure absolute quality. Daily investments in research and development, entrusted to highly skilled engineers and staff with top qualification and skills in metal working. Ongoing efforts that show the first evidence of achievement of new and important goals. First of all, an innovative system for automated die change will be shortly completed.
The word “efficiency” is mostly associated to “saving”. Even if the link between the two is real, because a saving - be it a material, energy, time or fatigue saving – is very often the result of being efficient, they are two very distinct factors. Making a system, a production line, a process or just a single machine efficient means being able to make the most of what is available, its features and resources, elements that must work together to give the best possible result on the basis of the goals to be achieved. All this, paying attention to reduce waste. The heart of machine: the work area The possibility to customize a machine based on the specific operative needs of the company that will use it becomes an important thing to improve its production efficiency and, thus, it's competitive ability. Talking specifically of metal sheet working machines, such as industrial presses, the work area is an important element. From this station, machine operations are managed and production flow is set: for this, it is essential trying to ensure the best man-machine interaction, from which a relevant part of the final quality of what is produced depends. Comfort during the working stages and ergonomics of the station are the first two elements one thinks to: they are surely important, but not the only ones to be considered; the following factors are determinant as well: the adaptability of the work area, that allows to safely manage all the processing stages and to smartly pass to different tasks, ensuring in this way the production of different lots - also small ones - minimizing times; the custom setting of the station for an ideal access to tools; machine layout, so as to adapt it to the space in which it will be placed; safety, strictly respecting the relative current legislation. The cornerstones of efficiency In general, in the search for efficiency both generic elements, that is common measures that can be applied to any working condition, and specific factors based on the specificity of any single production or production exigency intervene; so they can differ depending on the situation, even when they interests the same type of machine. In this way, the search for efficiency becomes a real company strategic process that pivots on some fundamental factors (besides what has just been considered): collaboration supplier-user. Being able to understand and interpret a company necessity becomes the pass for new market shares. Starting from the design stage - just think of what has been already said about work area - the comparison with the customer allows to realize custom solutions, able to make a unique product from a standard one and to indulge the user company needs. the ability to look at the market, to understand its trends and, if possible, to anticipate them paying attention to innovation. Projecting solutions that can ensure high performances, energy and resources saving and a reduced environmental impact is part of this ability. relying on expert and certified suppliers. Choosing the right partner determines the final quality of the machine, in terms of material quality, speed in the answer and respect of delivery times, that need to be quicker and quicker. providing structured pre and after-sales able to respond to its customer needs, possibly by offering custom solutions. From planning consultancy to supply of spare parts, from assistance to maintenance, the service offered - on the ground or remote - needs to be professional, precise and prompt. investing in a continuous R&D (Research and Development) that focuses on the most innovative materials, components and technologies. Facts show that this approach is a valid one: the company that could develop flexibility in the management and realization of their machines have been able not only to keep, but also to increase their market shares, even during the long years of economical crisis. Basically, becoming efficient to ensure in turn solutions that make efficient the production process of customer companies.
When we talk about problems in engineering production and, more specifically, of a press brake, we are tackling an issue that represents a huge source of waste. In fact, a given problem can affect several parts of a machine tool and generate others within the entire production flow. In the field of press brakes, we can make two major distinctions, between: problems when purchasing problems arising over time The former are mainly linked to a lack of attention when it comes to its design and construction. In particular, the aspects that inevitably turn into problems are: Lack of structural precision There is no denying that machines offered at cheap prices and which come from countries where quantity is preferred over production quality, cannot boast an acceptable constructive attention. So, among the issues we can immediately encounter on a press brake, there are the poor alignment of the beam and the bed, and the perfect parallelism between the frames. But there’s more: also the perpendicularity of the assembled elements and their respect for dimensional tolerances. All this translates into lack of bending precision. Quality of the moving parts and their management We refer to cylinders and optical lines, but also and above all about the backgauge. In particular, in the latter element you can immediately see the construction quality of the press brake, the speed of the movements, their precision and the speed with which the matching parts are positioned, as well as how they stop. Robustness. It might seem self-evident, but it’s not. Always be wary of press brakes with structures that are too thin. Regardless of whether our core business is focused on making thin gauge parts, it is not acceptable for a single different process to irreparably damage our press brake. Deflections must be compensated for by special systems, such as camber, but they must not be excessive due to an undersized structure. The distortions of the machine, in fact, do not affect only the beam, but also the frames with the opening, the so-called “yawn. Instead, the problems encountered over time are often linked to poor build quality, which comes in the form of: Irreversible distortion of the machine or components It is not acceptable that the structure of a bending press undergoes irreversible distortions, nor that fundamental accessories such as, for example, intermediaries undergo it. When the structures are thin sheets or of unsuitable material, they can yield under not too excessive tensions. Overall unreliability A press brake is only apparently a simple machine. In reality it is an orchestra of components that must be chosen and manufactured to perfection, and which must also last over time. Cylinders, fittings, recirculating ball rails, motors, bearings, encoders: every single part, even the smallest, if it stops working creates a much bigger problem. Scarce availability of spare parts subject to wear or failures The reliability of the components, as well as the availability of spare parts are closely linked to the price of the press brake. What is the point of spending a low sum if the press brake not only breaks down continuously, but is also difficult to repair? The problems of a press brake, even if we refer strictly to the machine and not the supplier or after-sales service, turn out to be the biggest causes of all the waste of money that a company is forced to face. A press brake that does not function correctly could still manufacture parts, but the time spent in constant adjustments and fine-tuning is a bleed of money that no business can afford. Choose your next press carefully: find out what you need to know in the bending manual, which you can find for free below.
The ease of use of the Vicla CNC also for inserting a matrix in the library. The efficiency and reliability of a press brake is also measured by the machine's ability to allow simple and accurate programming of each type of processing. Vicla® presses are designed to offer the best in terms of operator control. This video tutorial shows metalworking enthusiasts how to quickly and easily insert a matrix into the library through programming on the Vicla CNC. First of all, you must select the icon of the matrix list and choose between new designated or default matrix. Let’s say we want to insert a matrix through the second option. Now all we have to do is set the following data: the height, the angle of the slot, the measure of the V, the distance between the center of the V and the side of the matrix, the height of the base, the radius that is detected from the data of the matrix, and finally the load. Now all you have to do is save the entered data and name our matrix. Once back in the library, it will be possible at any time to recall the saved matrix with all its stored data.
SET UP A WORK STATION FOR IMMEDIATE CALCULATION OF Z AND BENDS. A few simple steps to create a CNC workstation on a VICLA® press brake. In this short video tutorial we’ll show you how the operator can quickly and easily create one or more workstations by programming on the CNC. First, access the Tools menu and enter the tool name and the tooling values of the punch and die (initial quantity and length). The position of the tools on the press brake is now established and work station n°1 is created. To set station n°2 just repeat the steps. At this point you can calculate the Z value and set, for example, bend n°1 on station n°1 and bend n°2 on station n°2. In this way you obtain 2 different values of Z.
From VICLA’s CNC it is possible to insert the punch in the list through a few simple and quick steps. Programming on VICLA CNC is simple and intuitive. It is in fact designed to optimize processing times, minimize machine downtime, and increase press brake productivity. In this video tutorial we’ll show you how easy it is to insert a punch in the tools library. First you need to access the punches menu and choose the type of punch you want to insert in the library. From the standard and gooseneck punch, to the acute punch up to the reverse clamp one. For example, if you wish to create a new classic punch, all you have to do is just enter all the punch data, available from the catalogs of the manufacturers, such as height, bend angle and all parameters. Then simply save the recorded data with a name, to add the punch in the library list.
CNC graphics program: VICLA PRESSES ARE EQUIPPED WITH TECHNOLOGIES ABLE TO PROVIDE QUICK AND PRECISE SOLUTIONS.