A Guide to All the Parts of a Press Brake Machine and Their Uses

The metal sheet bending machine is a critical metal processing equipment widely used in manufacturing. Its efficient and precise bending capabilities make it an indispensable component on production lines. In this blog post, we will delve into the composition, working principles, and crucial consumable parts of the bending machine, along with insights into maintenance. Recommendations are also provided regarding material selection and customization of bending molds.

1. Working Principles and Components of the Bending Machine:

1.1 Working Principles

The bending machine operates based on hydraulic or mechanical systems. The hydraulic system provides power, driving the ram’s up-and-down motion to bend the metal sheet. The CNC system enables precise control of bending angles and shapes, ensuring the produced items meet design requirements.

1.2 Key Components

The main components of the bending machine include the frame, bed, ram, bed axis, beam, upper and lower dies, hydraulic system, electrical system, and CNC system. Each part plays a specific role in collaboration to accomplish the metal sheet bending task.

1.2.1 Frame: The frame, made of robust steel, serves as the supporting structure for the entire bending machine, ensuring stability and rigidity.

1.2.2 Bed: The bed is the platform for placing the metal sheet, supporting and securing it for processing. T-slots on the bed facilitate clamping and fixing of molds.

1.2.3 Ram: Connected to the frame, the ram is the movable component equipped with the upper die. It moves up and down, bending the metal sheet through hydraulic cylinders or mechanical drive systems.

1.2.4 Bed Axis: The bed axis controls the up-and-down movement of the worktable and is usually driven by hydraulic cylinders or screw mechanisms.

1.2.5 Beam: The beam connects the frame and the ram, providing support and guidance. It is typically a sturdy structure to ensure smooth ram movement.

1.2.6 Upper and Lower Dies: The upper and lower dies are tools used to bend the metal sheet. The upper die is mounted on the ram, while the lower die is fixed on the bed. Their shapes and sizes determine the final bending shape of the metal sheet.

1.2.7 Hydraulic System: Most modern steel sheet bending machines use hydraulic systems to provide power, employing hydraulic cylinders to drive the up-and-down motion of the ram. The hydraulic system includes components like oil pumps, tanks, hydraulic cylinders, valves, etc.

1.2.8 Electrical System: The electrical system controls various machine movements, including the up-and-down motion of the ram and the worktable. It typically comprises an electrical control cabinet, control panel, sensors, etc.

1.2.9 CNC System: Advanced bending machines are often equipped with CNC systems, enabling automated operations through pre-programming to enhance production efficiency and accuracy.

2. Maintenance of Consumable Parts:

Among the main components of the bending machine, some parts are susceptible to wear and damage and require regular inspection and maintenance. Here are common consumable parts:

1. Dies (Upper and Lower): Dies, in direct contact with the metal sheet, are prone to wear. Frequent bending operations can lead to surface wear, affecting bending quality. Regular inspection and replacement of heavily worn dies are necessary.
2. Hydraulic Cylinder: Responsible for driving the ram’s up-and-down motion, the hydraulic cylinder is a crucial component under heavy pressure and frequent movement. Seals and piston rods are prone to wear, causing hydraulic system leaks. Regular inspection and replacement of damaged parts in the hydraulic cylinder are part of maintenance.
3. Beam: The beam connecting the frame and ram bears significant stress. Due to its unique structure, fatigue cracks may occur after prolonged use. Regular structural checks and necessary repairs are crucial.
4. Guides and Bearings: The machine’s slider and beam often use guides and rolling bearings for guidance. These parts are susceptible to external factors such as dust and metal debris, leading to increased friction and wear. Regular cleaning and lubrication are necessary.
5. Electrical Components: Switches, sensors, cables, and other electrical components in the electrical system may be affected by environmental factors, leading to malfunctions. Regular checks, cleaning of electrical components, and replacement of damaged parts are essential.
6. Hydraulic Oil: The hydraulic oil used in the hydraulic system can get contaminated and aged over time, affecting system performance. Regular replacement of hydraulic oil and ensuring the cleanliness of the hydraulic system are part of maintenance.

Regular maintenance and timely replacement of these parts are crucial to ensure the normal operation of the bending machine, improve production efficiency, and extend equipment life.

3. Bending Machine Molds:

3.1 Selection of Mold Materials:

Common materials for bending machine molds include high-speed tool steel, alloy tool steel, and carbide. Different materials have different characteristics suitable for processing various types of metal sheets. Here are some common bending machine mold materials and their applications:

1. High-Speed Tool Steel: Good wear resistance and rigidity; suitable for processing general cold-rolled and hot-rolled sheets, as well as less hard stainless steel. It is a cost-effective choice for bending tasks with medium to low material strength.
2. Alloy Tool Steel: Contains multiple alloy elements, providing higher hardness and wear resistance. This type of mold is suitable for processing high-strength metal sheets such as high-strength steel and stainless steel.
3. Carbide: Carbide has extremely high hardness and wear resistance, making it suitable for processing high-hardness and high-strength metal sheets. Carbide molds excel in handling materials with high wear-resistance requirements, such as carbide steel and wear-resistant steel.
4. Hardened and Tempered Steel: These molds undergo quenching and tempering treatment, providing a certain level of hardness and strength. They are suitable for general metal sheet bending, offering a relatively low cost.

Selecting the appropriate bending machine mold material depends on the nature of the work material, hardness, thickness, and specific processing requirements. Typically, flexible choices based on different bending tasks and metal sheet characteristics are needed in practical applications.

3.2 Types of Molds:

3.2.1 Upper Die:

1. Position and Installation: Mounted on the bending machine’s ram, the upper die moves up and down through mechanical or hydraulic systems, applying bending force directly to the metal sheet.
2. Shape and Design: The upper die’s shape and design depend on the desired bending shape. Common upper die shapes include V-type, U-type, semi-circular, etc., determined by the metal sheet’s bending requirements.
3. Material: Typically made of high-speed tool steel, alloy tool steel, or carbide to ensure sufficient hardness and wear resistance. Material selection considers the hardness, thickness of the metal sheet, and bending task requirements.
4. Bending Radius and Angle: The upper die’s design considers the bending radius and angle, taking into account the metal’s elastic deformation. Setting specific pre-bending angles and bending compensation may be necessary.
5. Replaceability: To accommodate different bending tasks, some bending machines have replaceable upper dies. This allows operators to choose different shapes or sizes based on their needs.

3.2.2 Lower Die:

1. Position and Installation: The lower die is mounted on the bending machine’s worktable and is typically fixed. It provides support and positioning, working in conjunction with the upper die to complete the metal sheet bending.
2. Shape and Design: The lower die’s shape coordinates with the upper die to ensure proper support during bending. The lower die’s shape is usually V-type, U-type, or other specific shapes depending on the upper die’s design and bending task.
3. Material: The lower die’s material is usually similar to the upper die, chosen from appropriate tool steel or carbide to ensure wear resistance and hardness.
4. Bending Radius and Angle: The lower die’s design also considers the bending radius and angle to ensure stable support for the metal sheet during bending.
5. Cleaning and Maintenance: As the lower die is usually fixed on the worktable, it may be more susceptible to metal debris and dirt. Therefore, regular cleaning and maintenance of the lower die are crucial to ensure proper operation.

The design and selection of upper and lower dies depend on specific bending task requirements, the nature of the metal sheet, and the bending machine specifications. Proper selection and maintenance of molds can improve bending quality and production efficiency.

3.3 Necessity of Custom Bending Molds:

In the operation of a metal sheet bending machine, standard molds may suffice for basic bending tasks. However, when faced with special shapes or complex requirements, custom bending molds become crucial.

Advantages of Custom Molds:

1. Shape Matching: Custom molds are precisely designed to match the specific shape of irregular parts. This ensures proper support and deformation during the bending process, avoiding unnecessary deformation or damage.
2. Improved Production Efficiency: With custom molds, you can complete bending tasks for irregular parts more quickly, reducing the production cycle. Compared to constantly changing standard molds to accommodate different shapes, custom molds enable a faster and more efficient production process.
3. Quality Assurance: The precise design and adaptability of custom molds ensure bending consistency and quality, reducing the rate of defective products. This is particularly crucial for the production of high-precision components.
4. High Adaptability: As production demands change, custom molds can be adjusted according to new design requirements, providing greater adaptability and reducing the frequency of mold changes.

Conclusion:

Through the scenarios outlined above, it is clear that in production environments with special shapes or complex requirements, custom bending molds not only improve production efficiency but also ensure product quality. Therefore, when choosing bending machine molds, customizing molds based on actual production needs is a wise choice, bringing greater flexibility and a competitive advantage to your production line.

3.4 Customization of Bending Molds:

When customizing upper and lower molds for the bending machine, providing a detailed set of information is crucial to ensure that the molds meet the specific requirements of the bending task. Here are key pieces of information to provide when customizing bending machine molds:

1. Requirements and Specifications of Bending Tasks: This includes specific bending angles, shapes, lengths, and other detailed requirements. Clear instructions on bending tasks help ensure that the mold design aligns with the expected bending standards.
2. Characteristics of the Metal Sheet: Providing information on the hardness, thickness, material, and other characteristics of the metal sheet is essential. Different metal sheet properties require different types of molds to ensure accuracy and quality in bending.
3. Design Requirements for Mold Shape and Size: Clearly specifying parameters such as the shape, size, bending radius, and other relevant details for both upper and lower molds. These design requirements directly impact the final bending results.
4. Specifications and Model of the Bending Machine: Ensuring accurate specifications and model information of the bending machine is crucial for aligning mold design with the machine.
5. Precise Requirements for Bending Radius and Angle: If specific bending radius and angle requirements exist for the bending task, providing precise numerical values is necessary to ensure the mold design meets the requirements.
6. Expected Production Batch and Frequency of Use: Providing information on the expected production batch and frequency of mold use helps manufacturers optimize mold design and material selection to adapt to actual production needs.
7. Special Requirements and Additional Features: If there are special requirements or if additional features are needed in the molds (such as quick-change devices or automatic adjustment functions), these should be clearly stated during customization.

By offering detailed information as outlined above, the customized upper and lower molds for the bending machine can accurately meet the specific requirements, improving bending quality and production efficiency.

By gaining in-depth knowledge of the composition, working principles, and maintenance of the metal sheet bending machine, you will be better equipped to understand and operate this critical metal processing equipment. In daily use, regular maintenance and care for consumable parts, especially bending molds, are key steps to ensure equipment operates smoothly and has an extended lifespan.

4. About METAL Industrial

Nanjing Metal Industrial CO., Limited is a manufacturer of mechanical blades from China, producing blades and accessories for industries including metalworking, converting, food, and more. We have more than 15 years of experience in the manufacture and sales of industrial machine blades, machine parts, and regrinding services. We invite you to experience the superior quality of production.