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Everyone will agree that technology advancement comes with its perks, and the press brake machines are proof of that.
Press brake machine are mostly used for bending sheet metal materials, and you need a proper understanding of how it works to use them correctly.
So, if you have a workshop, having a press brake machine is a “must”. However, there are different types of bending machines and they all have their unique mode of application.
What is a Press Brake Machine?
A press brake, sometimes known as a bending machine, is a manufacturing machine used for bending and folding plates and sheet metal into various angles and shapes
It works by clamping the metal between a punch and a die, and applying force to create the desired bend.
What Are The Different Types Of Press Brakes?
Bending machines are utilized in metalworking industries, and they come in different types and specifications.
This section will highlight the various types of press brakes and help you understand their distinctive features.
Mechanical Press Brakes
Mechanical brakes have been around since the beginning of press brake machines, and they are known for their high tonnage capacity. It operates with a clutch system and mechanical flywheel that stores kinetic energy and transfers it through a system of gears.
What types of materials are best suited for
Mechanical bending machines are suitable for bending a wide range of materials. As bending machine operators, it’s important that you are familiar with operating a bending machine when working on specific materials.
Some of the materials commonly used for mechanical brakes are;
Stainless steel
Mild steel
Copper and Brass
Aluminum
Common Applications
Mechanical press brakes are commonly used in metalworking and fabrication industries to bend and fold metal sheet to different sizes and shapes.
However, they are also essential in other applications like;
Automotive and Aerospace Industries
HVAC Ductwork
ADVANTAGES
Enhanced productivity
Precise control
Ideal for high-tonnage applications
DISADVANTAGES
Limited speed control
High maintenance
Hydraulic Press Brakes
The hydraulic bending machine is easily the most used brake now due to its hydraulic system, and it’s driven by two hydraulic cylinders.
Hydraulic press brakes work by using two synchronized hydraulic cylinders on the C-frames to move the upper beam. They are a better option than the mechanical variant because they offer more flexibility in terms of speed control and retraction.
Hydraulic brakes can fold sheets up to 8 meters, plus they can be both down-acting and up-acting.
Also, the hydraulic press brake comes with independent cylinders; meaning folding and bending of your workpiece at different angles can be done in a single operation.
What types of materials are best suited for
Hydraulics are typically used to get accurate designs and shapes. And they are best suited for materials such as;
Copper and Brass
High Strength Alloys
Stainless Steel
Aluminum
Common Applications
Application for hydraulic press brakes include;
Heavy Plate Bending
They are great energy-saving options.Aluminum Extrusion Bending
Pipe and Tube Bending
ADVANTAGES
Hydraulics are user-friendly and come with intuitive controls that make programming easier, and allow operators to set up bending parameters.
Hydraulic press brakes have high bending force and accuracy
Can sustain high levels of power: The industries working with bigger metal parts require huge amounts of energy, which can easily extend over 250 metric tonnes. Hydraulic machines tend to be a better option in such cases.
Great energy-saving options: Most of the modern hydraulic press brake systems come with built-in energy-saving times and pump mechanisms.
DISADVANTAGES
They are quite expensive compared to other press brakes
Hydraulics take up more floor space and are significantly heavier than other bending machines
What are the Different Types of Hydraulic Bending Machines
The hydraulic bending machine is classified into two;
Nut-stop hydraulic
This variant of hydraulic uses a nut-stop as a mechanical stopper during the bending process, to guarantee precise control.
It’ll come in handy when working on a project that requires detailed precision.
Synchro hydraulic
The synchro hydraulic has a digital control system that facilitates the movement of multiple hydraulic cylinders to create an accurate shape. It’s also known for its high precision, so you can use it to achieve different shapes on a variety of workpieces.
Which is Better Mechanical or Hydraulic Press Brakes?
A hydraulic press brake is a better option as it easily performs complex tasks, has more precision bends, and is a safer press brake.
Pneumatic Press Brakes
Pneumatic press brakes known as ‘air press brakes” use pneumatic (air) power for bending metal sheets.
What types of materials are best suited for
Pneumatic bending machines work best with light gauge materials like;
Thin Sheet Metal Work
Plastics
Non-Ferrous Metal
Common Applications
Typical applications of pneumatic brakes are;
Forming and Shaping Operation
Precision and Delicate Parts
ADVANTAGES
They are more affordable compared to hydraulics
Pneumatics offers fast set-up and adjustment time
It requires minimal training to operate
DISADVANTAGES
They cannot bend any thick material due to their low force capacity
It’s noisy compared to hydraulic press brakes
All-electric press brakes
The currently available electric bending machine systems are the most effective and modernized edition of all press brake machines in history.
Apart from simply making the process more effective and promoting fast functioning and manufacturing, an electric bending machine has also shown great progress in the overall safety of the working.
They are also highly accurate when compared to relatively older methods of functioning.
How does it work?
An electric bending machine system is completely free from any form of hydraulic support and run entirely on electricity. That being the case, it is relatively eco-friendly and offer greater levels of safety and accuracy.
This is all thanks to the recent advances and progress in the mechanics field.
In the electric bending machine, the movable part is solely operated by electricity rather than any form of direct force, which is the case in hydraulic systems. This is brought about with good precision with the help of several in-built attachments and software control.
Benefits
With such high degrees of innovation and automation, these devices greatly decrease production costs. They also help reduce production costs, as well as energy expenditure.
As a result of the above, they are considered highly economical options compared to the others in the line.
CNC Press Brakes
A CNC bending machine is a new model of press brake and uses servo or electric motors as its primary source of power for its various machine movement.
CNC bending machines have the highest precision, as it utilizes computer technology to achieve optimum efficiency.
Plus, you don’t have to worry about oil leaks as there’s no use of hydraulic oil.
What types of materials are best suited for
CNC press brake is capable of bending various metals like;
Stainless Steel
Aluminum
Exotic Metals and Alloys
Mild Steel
Common Applications
Some applications of the CNC machineinclude;
Heavy Plate Bending
Customized Fabrication
Complex and Multi-Bend Parts
ADVANTAGES
CNC brakes offer consistent bending quality throughout production runs
It often has built-in data-logging capabilities
CNC brakes reduce material waste and scrap
DISADVANTAGES
It’s expensive to purchase
It requires more specialized maintenance
Operators must have a certain level of technical expertise to perform any task using the CNC brakes
Conclusion
Press brakes will forever take the front stage when it comes to bending and folding metal materials. However, you should know that not all metals have the same level of thickness and width, hence your choice of bending machine will highly depend on that factor.
In the end, make sure to do your research before making a choice.
