The Ultimate Guide to Choosing hydraulic aluminum sheet press brake manufacturer

Press brakes are one of the most essential metal forming machine tools in the shop, offering manufacturers the capability to do the simplest and most precise metal bends. The most advanced models can perform precise bends on a variety of materials in a wide range of sizes. Basic models execute easier bends on thinner materials, efficiently completing projects on budget. 

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Today's press brakes also come equipped with features that improve productivity and allow these workhorses to make the most precise bends. It can be difficult to sort through the models and features; this buying guide explores the types of press brakes, things to know before buying, key advances in press brake bending, factors to consider during the purchase, and features to consider so you can get the best press brake for your projects and budget.

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Types of Press Brakes

There are several types of press brakes, each designed for specific applications and manufacturing needs. Here are some common types of press brakes:

• Mechanical Press Brake. Mechanical press brakes use a mechanical flywheel to generate force for bending metal. They are known for their reliability and durability but may have limitations in terms of speed and flexibility.
• Hydraulic Press Brake. Hydraulic press brakes use hydraulic cylinders to apply force for bending. They offer precise control over bending operations and can handle a wide range of materials and thicknesses. Hydraulic press brakes are often used for high-precision and high-volume applications.
• Servo-Electric Press Brake. Servo-electric press brakes use electric motors and ball screws to control the bending process. They are known for their accuracy, speed, and energy efficiency. These machines are suitable for applications that require high precision and fast setup times.
• CNC Press Brake. CNC (Computer Numerical Control) press brakes are equipped with computerized controls that allow for precise programming and automation of bending sequences. They are highly versatile and can handle complex bending tasks with ease. CNC press brakes are commonly used in modern sheet metal fabrication shops.
• Synchro Press Brake. Synchro press brakes have multiple hydraulic cylinders that work together to maintain parallelism and synchronization during the bending process. This ensures uniform bending across the entire length of the workpiece.
• Pneumatic Press Brake. Pneumatic press brakes use compressed air to apply force for bending. They are often used for lighter sheet metal bending applications but may lack the precision and power of hydraulic or servo-electric press brakes.

Press brakes can also be configured for max productivity, such in bending cells or in tandem. Tandem press brakes are multiple press brake located together to bend longer and heavier sheets or plates. They are typically used when the length of the workpiece exceeds the capacity of a single press brake.

What to Know Before Buying

There are several factors that influence the price of a press brake and add to the price (i.e. longer bed length, higher tonnage, etc.) Therefore, if you want to purchase the right machine (without overspending for features you won't use), you should compile the following information:

• Type of metal being formed. The type (or types) of metal (i.e. steel, aluminum, etc.) you bend is a significant factor in a press brake purchase. You may need a machine with more ram stroke or a higher tonnage if you are bending certain materials because of their tensile strength.
• Max metal thickness. If you are bending a thicker metal, you are going to require a press brake with a higher tonnage. Remember, it is best to overestimate the amount of tonnage required; underestimation can lead to machine damage and significantly increase the risk of costly workplace injuries.
• Size of metal sheets. The width of the metal sheets is an important factor when choosing the right bed length. The correlation is simple: bigger sheets need to be bent on machines with a longer bed length. Additionally, for bigger or heavier sheets, you should consider purchasing a machine with front support arms or sheet lifters that can assist with the bend. These features can boost productivity because less operators are required for sheet handling. Sheet lifters can also reduce the risk of workplace accidents. (Support arms and sheet lifters can also be purchased separately and added to the press brake.) Multiple press brakes can also be configured into a tandem set-up to bend larger sheets.  

Ideally, it would be best to have specs for parts you plan to bend on the press brake before you purchase a machine. If that is not an option, you can contact your sales team with a few general specs and ask them connect you with the right press brake.

Press Brake Technology

The first press brakes were invented in the s, though today's machines are capable of much more than their predecessors. As technology advances, press brake bending has evolved to become more efficient and precise. Here are some advanced techniques and tools that have revolutionized the industry:

CNC Control. Computer Numerical Control (CNC) systems have automated and streamlined the bending process. CNC press brakes allow computers to control the processes of the brake, offering precise control over parameters, and reducing errors and setup time.

4-Point Bending. This technique utilizes a special tool setup to achieve complex bends with minimal deformation, making it ideal for parts with stringent geometric requirements.

Offline Programming. Software solutions allow operators to program bending sequences offline (often while the machine is running). The result is optimized production efficiency and a minimized risk of trial-and-error during setup.

Material Handling Systems. Automated material loading and unloading systems increase throughput and reduce manual labor, improving overall productivity. The most advanced systems include a combination of robotics and material handling systems for a completely automated metal forming process.

Factors to Consider When Buying a Press Brake

There are a number of factors to consider when buying a press brake, so you don't 'overbuy' and purchase capabilities and features you don't need. In the same way, you don't want to 'underbuy' and purchase a press brake that can't meet all your needs. 

Once you have the specs for future projects, as well as an idea of the scope of the press brake technology needed (i.e. automation, offline programming, etc.), it's time to consider the following factors.  

• Tonnage. Basically, tonnage is the force needed to bend material. Materials require more or less force because of their different tensile strengths. Therefore, it is important to have an idea of the types of materials you are bending on the press brake; a material like stainless steel typically requires a press brake with more tonnage than mild steel or aluminum. (Get more information about calculating press brake tonnage in this article from The Fabricator.)
• Ram Stroke. Put simply, the larger the ram stroke, the deeper the bend. The ram stroke is the amount of space the ram has to bend. This is the area below the punch and above the die. In terms of price, a press brake with a larger ram stroke cost more.
• Features. Typically, if you need more precise bends, you need a press brake with more features. This leads to the next question, 'what features do you need?' This is an answer that depends on the complexity of the project. Some press brakes come with features that ensure precise bending by accounting for the spring back of the material. While many of these features are optional, the features that shouldn't be optional are the safety features that prevent costly workplace accidents. 
• Control System. The right control system can impact your operations significantly, by allowing you to utilize offline programming and/or to reduce set-up errors. 
• Accessories and Automation. Support arms and sheet lifters can boost productivity, minimize workplace injuries, and even decrease the amount of labor needed for material handling. Some press brakes come with these accessories included, while others require an additional purchase. In the same way, material automation can boost productivity and improve efficiency. 

When it comes to purchasing the right press brake, it's important to make a careful and informed decision. The right press brake can significantly impact production efficiency, accuracy, and overall cost-effectiveness. Several factors must be considered to make the best selection. 

Firstly, understanding the specific needs of your operation is crucial. This involves evaluating the range of materials, thicknesses, and bending angles you'll be working with. Additionally, the required tonnage capacity and bending length must be determined to ensure the press brake can handle your projects effectively. Next, considering the control system and automation features is vital, as modern technology can greatly enhance precision and productivity. Furthermore, assessing the reputation and support offered by the manufacturer is essential to ensure reliable performance and responsive service. In summary, purchasing the right press brake is a strategic investment that demands thorough research and thoughtful consideration of your operational requirements and long-term objectives. Fortunately, it's not a process you need to navigate through alone. Contact a knowledgeable sales person who can help you choose the right press brake for your operation.

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Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends...

Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based.

So what are the key elements to examine before signing a contract for press brake supply?

#1: the Structure

The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product.

Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles.

The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy.

#2: the Double Guide

The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing.

This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced.

#3: the Cylinders

Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part.

VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left.

#4: the Hybrid System

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If in the past there were few types of bending machines, nowadays the market offers different choices:

• hydraulic press brakes;
• electrical press brakes;
• hybrid press brakes.

These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system.

Be careful, though! 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.

It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines.

The results in numbers of this technological innovation are significant, as seen on the graph.

Advantages of the hybrid press brake compared to a conventional hydraulic bending brake

#5: Real time crowning system

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-processed 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.

The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length.

What are the advantages of this "intelligent" system? Mainly three:

1. it ensures great results even in the presence of an inexperienced operator;
2. it uniforms the bending angle without any need for operator intervention;
3. it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material).

#6: Flex

The CNC receives the data form the sensors on the cylinders. These information are then interpolated to set the correction parameters required.

Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet.

Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon "yawn" and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out.

 #7: the Back

The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities:

1. Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance;
2. Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence;
3. New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength;
4. Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference.

Ultimately

We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of:

• reducing operating costs;
• maximising productivity;
• achieving the most in terms of processing quality.

By doing so, even the end client can count on a standardised and reliable supply.

The company is the world’s best press brake machine manufacturer supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.