PRESS BRAKE MAINTENANCE: THE COMPLETE GUIDE

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:

1. Do not use solvents and flammable materials
2. Take care not to disperse cooling lubricants in the environment
3. Use suitable equipment to access the highest parts of the machine
4. Do not climb on parts of the machine as they have not been designed to support people
5. 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.