The technology world greatly relies on hydraulic press brakes to make precise bends in metals and other materials. Industries such as automotive manufacturing and airplane engine production utilize these machines extensively. In this blog, we will discuss what is a hydraulic press brake, its components, applications, and the advantages associated with its use. We will also explore the costs involved in acquiring one of these essential pieces of equipment, providing valuable insights for anyone looking to purchase or learn more about hydraulic CNC press brakes.
Table of Contents
What Are the Types of Press Brakes
Hydraulic press brake
Hydraulic press brakes use hydraulic cylinders to apply force to the ram, which bends the material. They are known for their power, precision, and ability to handle a wide range of material thicknesses and lengths.
Mechanical press brake
Mechanical press brakes operate using a flywheel powered by an electric motor. The flywheel stores energy and releases it to move the ram and bend the material.
Pneumatic Press Brake
Pneumatic press brakes use compressed air to drive the ram. These machines are generally smaller and less powerful than hydraulic and mechanical press brakes.
Servo-Electric Press Brake
Servo-electric press brakes use an electric servo motor to drive the ram, offering high precision and energy efficiency.
CNC Press Brake
CNC (Computer Numerical Control) press brakes can be hydraulic, mechanical, pneumatic, or servo-electric, but are equipped with CNC systems for automated control of the bending process.
Each type of press brake has its unique characteristics and is suited to particular tasks and industries. When choosing a press brake, consider factors such as the type and thickness of materials you will be working with, the complexity of the bends, production volume, and energy efficiency requirements. This will ensure you select the right machine for your specific needs.
How Does a Hydraulic Press Brake Differ from Other Press Brakes?
While press brakes are universal in their aim to bend metal, the way they apply force significantly varies across different types.
In contrast to the mechanical press brake, which operates via a crank mechanism, and the electric press brake, that uses an electric motor, the hydraulic press brake utilizes hydraulic pumps to generate pressure. This hydraulic pressure then actuates the synchronized hydraulic cylinders to exert force on the material, allowing the machine to bend it to the desired angle. The use of hydraulics translates to a smoother operation, greater control, and overall bending length accuracy, even for larger, more complex parts.
They are known for their:
- Precision: Hydraulic press brakes can produce consistent and accurate bends.
- Flexibility: They are capable of handling various materials and thicknesses.
- Safety: Modern hydraulic press brakes are equipped with safety features, including light curtains and laser systems.
- Efficiency: They typically require less manual labor and can increase production speeds.
Types of Hydraulic Press Brakes
Hydraulic press brakes are categorized based on the synchronization of their bending process. They are essential tools in metal fabrication shops for bending sheet and plate material, most commonly sheet metal.
Synchronous Hydraulic Press Brakes
Synchronous hydraulic press brakes, also known as synchronized press brakes, employ a servo-electric motor to ensure the synchronized movement of the press beam. Typically, these machines use a CNC (Computer Numerical Control) system for high precision. They are characterized by:
- High Precision: Utilizing CNC systems for control of the ram position.
- Smooth Operation: Servo motors provide smooth and quiet operation.
- Efficiency: Capable of complex bending with reduced waste.
Asynchronous Hydraulic Press Brakes
Asynchronous hydraulic press brakes operate without the precise synchronization found in their synchronous counterparts. The key aspects of these machines include:
- Simple Design: More straightforward construction compared to synchronous brakes.
- Cost-Effective: Typically lower in cost due to their less complex mechanism.
- Broad Application: Suitable for various bending tasks that don’t require the high precision of CNC control.
What Is A Hydraulic Press Brake? Definition and Structure
A hydraulic press brake is a machine tool used for shaping sheet metal and metal plates by clamping the workpiece using hydraulic pressure between a matching top tool (punch) and bottom die thereby making precise bends. The main components that make up a hydraulic press machine include:
Frame: The frame is the main structural element of the press brake, providing stability and support to the entire machine. It is typically constructed from high-strength steel to withstand the substantial forces exerted during the bending process.
Ram: The ram is the moving part of the press brake that holds the upper punch. It moves vertically, driven by hydraulic cylinders, to press the punch into the die, thus bending the material.
Bed: The bed is the stationary part of the press brake that supports the lower die. It provides a surface against which the material is bent when the ram presses the punch into the die.
Hydraulic System: The hydraulic system consists of hydraulic cylinders, pumps, fluid reservoirs, and valves. It generates the necessary force to move the ram. The system uses hydraulic fluid pressure to achieve precise and powerful movements.
CNC Control Unit: The CNC (Computer Numerical Control) unit allows operators to program and control the press brake’s movements with high precision. It stores bending parameters and sequences, ensuring consistent and accurate bending operations.
Back Gauge: The back gauge is an adjustable component used to position the workpiece accurately before bending. It can be manually or automatically adjusted and ensures that the material is correctly aligned for each bend.
Punch and Die: The punch and die are the tools that come into contact with the workpiece to create the bend. The punch is attached to the ram, while the die is mounted on the bed. Different shapes and sizes of punches and dies are used for various bending operations.
Hydraulic Cylinders: The hydraulic cylinders are part of the hydraulic system and are responsible for converting hydraulic fluid pressure into mechanical force. They drive the ram’s movement, enabling the bending process.
What Are the Advantages of Hydraulic Press Brakes?
Hydraulic press brakes have transformed the metal forming industry by offering numerous benefits, from cost-efficiency to unmatched precision and accuracy. These machines significantly enhance productivity in metal fabrication processes, making them indispensable for both small workshops and large manufacturing facilities.
Understanding these benefits will help you make informed decisions when investing in metal forming equipment. Let’s delve deeper into how hydraulic press brakes can elevate your metal fabrication operations.
Cost-Efficiency
Hydraulic press brakes are an essential tool in the manufacturing industry, providing cost-efficient solutions for bending and shaping metal sheets. These machines offer precision and versatility, allowing businesses to create a wide range of products with ease. The cost-efficiency of hydraulic press brakes lies in their ability to reduce material waste, increase productivity, and improve overall workflow efficiency.
One key factor that contributes to the cost-efficiency of hydraulic press brakes is their high level of accuracy. These machines can bend metal sheets with incredible precision, ensuring that each product meets the desired specifications. This accuracy helps to minimize errors and rework, ultimately saving businesses time and money in the long run.
Another advantage of hydraulic press brakes is their versatility. These machines can handle a variety of materials and thicknesses, making them suitable for a wide range of applications. This versatility allows businesses to streamline their production processes and eliminate the need for multiple machines, reducing overall costs and increasing efficiency.
Additionally, hydraulic press brakes are known for their durability and reliability. These machines are built to withstand heavy use and provide consistent performance over time. This reliability helps businesses avoid costly downtime and maintenance issues, ensuring that production remains smooth and uninterrupted.
Precision and Accuracy
Precision and accuracy are key factors in the manufacturing industry, especially when it comes to using a hydraulic press brake. These machines are essential for bending and shaping metal with extreme precision. The ability to control the pressure and speed of the hydraulic system ensures that every bend is accurate and consistent.
When it comes to working with a hydraulic press brake, operators must pay close attention to detail to ensure that each bend meets the required specifications. Even the slightest miscalculation can result in a part that doesn’t fit properly or a product that doesn’t meet quality standards.
That’s why manufacturers invest in high-quality hydraulic press brakes that are known for their precision and accuracy. These machines are designed to deliver consistent results, time after time, ensuring that every part meets the exact specifications set by the designer.
In a competitive market where quality is key, manufacturers understand the importance of using equipment that can deliver precise and accurate results. By investing in a hydraulic press brake with a reputation for reliability and accuracy, companies can ensure that their products meet the highest standards of quality and consistency.
Increased Productivity
Increased productivity is crucial for any business looking to stay competitive in today’s fast-paced market. One way to boost productivity in manufacturing processes is by investing in a hydraulic press brake.
A hydraulic press brake is a versatile machine that allows for precise bending of sheet metal. By utilizing this technology, companies can streamline their production processes and reduce the time it takes to complete each task. This results in faster turnaround times and increased output.
In addition to speeding up production, hydraulic press brakes also offer high levels of accuracy and consistency. This means fewer errors and rework, leading to higher quality products and ultimately, increased customer satisfaction.
Furthermore, the efficiency of hydraulic press brakes can help businesses save on costs in the long run. With faster production times and reduced waste, companies can improve their bottom line and reinvest those savings into other areas of the business.
How Hydraulic Systems Work
Hydraulic systems use liquid to create pressure. Liquid particles are close together, meaning a liquid is almost incompressible. When the particles move, they strike each other and also bump against the walls of the container. Because the pressure in a liquid transfers in equal measure in every direction, a force applied at one point on a liquid transfers to other points on the liquid. You work out the pressure using the equation F ÷ (P x A), where P is the pressure in pascals, F is the force in newtons and A is the cross-sectional area in meters squared. This is known as Pascal’s law.
In hydraulic systems, a small force across a small cross-sectional area transmits pressure and creates a large force over a larger cross-sectional area. Essentially, if you connect two cylinders, a large and a small one, and apply force to one cylinder, it generates equal pressure in both cylinders. Because one cylinder contains a larger volume, the force the larger cylinder produces is higher, although the pressure in the two cylinders remains the same.
Hydraulic System Examples
A hydraulic system most every driver uses every day, without thinking about it, is the brake system in your vehicle. Other examples include lifting equipment, such as hydraulic jacks and wheelchair lifts, lifting and excavating arms on backhoes and other heavy equipment, hydraulic presses, which produce metal components, and some parts of aircraft and boats, including wing flaps and rudders. Every hydraulic system follows the same basic principle. For example, a hydraulic jack lifts heavy loads with a pump plunger, which moves oil through both cylinders. Pulling the plunger back opens a suction valve ball and takes the fluid into the pump chamber. Pushing the plunger forward sends the fluid into an external discharge check valve, then into the cylinder chamber, closing the suction valve as it builds pressure inside the cylinder.
Hydraulic System Advantages
A hydraulic system is an efficient transmitter of power for many reasons. Firstly, its simple levers and push buttons make it easy to start, stop, accelerate and decelerate. This also allows for control accuracy. Also, because it is such a fluid system, without any cumbersome gears, pulleys or levers, it easily copes with a huge weight range. It provides a constant force, regardless of changes in speed. For the most part, hydraulic systems are simple, safe and economical because they use fewer moving parts compared to mechanical and electrical systems, which makes them easier to maintain. Hydraulic systems are safe to use in chemical plants and mines because they do not cause sparks.
Hydraulic System Disadvantages
Hydraulic systems also have some drawbacks. Handling hydraulic fluids is messy, and it can be difficult to totally get rid of leaks in a hydraulic system. If hydraulic fluid leaks in hot areas, it may catch fire. If hydraulic lines burst, they can cause serious injuries. Take care when handling hydraulic fluids, as too much exposure can lead to health issues. Hydraulic fluids are also corrosive, but some types are less so than others. For example, two main types of brake fluid are available for hydraulic mountain bikes, DOT fluid and mineral oil. Due to its non-corrosive properties, mineral oil is less likely to destroy a bike’s paintwork. To keep your hydraulic system in its prime, periodically check hydraulic systems for leaks, lubricate when necessary, and change filters and seals as required.
Where Are Hydraulic Press Brakes Used?
Automotive Industry
The automotive industry is one of the largest consumers of hydraulic press brakes. These machines are crucial in the manufacturing and assembly processes of automobiles, as they can shape and bend large pieces of sheet metal into various components.
- Bending and shaping chassis parts
- Forming automobile bodies
- Fabricating internal structures such as dashboard frames
- Producing smaller parts like brackets and supports
Aerospace Industry
The aerospace industry, known for its stringent standards for precision and quality, also heavily relies on hydraulic press brakes. The creation of various parts for aircraft requires exact bending and shaping, which these machines consistently deliver.
- Manufacturing airplane wings and fuselage sections
- Fabricating internal structural components
- Forming landing gear parts
- Creating smaller parts like brackets and mounts
Construction Industry
In the construction industry, hydraulic press brakes are utilized for creating structural elements, metal frames, and other parts required in building infrastructures.
- Production of steel frames and structural supports
- Fabrication of roofing and wall panels
- Creating HVAC components
- Shaping gutter and drainage systems
Shipbuilding Industry
Hydraulic press brakes are extensively used in the shipbuilding industry. Their ability to handle heavy and large pieces of metal sheet makes them ideal for forming the hull and other components of a ship.
- Bending and shaping large plates for ship hulls
- Creating internal structures and supports
- Fabricating parts for the ship’s propulsion system
- Manufacturing smaller parts like brackets and mounts
Hydraulic Press Brake Cost
A hydraulic press brake can cost anywhere from $5,000 to $200,000 and upwards. The price of a hydraulic press brake depends on various factors, including the size and complexity of the machine and the ongoing costs of operating it.
What Factors Influence the Cost of a Hydraulic Press Brake?
Several elements affect the price of a hydraulic press brake, including its capacity (tonnage), bending length, CNC capabilities, brand, and whether it is new or used.
Size
The size of the machine is often directly proportional to the cost. Larger machines with higher tonnage capacities typically come with a higher price tag as they can handle thicker materials and larger workpieces.
- Entry-Level Hydraulic Press Brakes: These can cost anywhere from $5,000 to $20,000. They are typically smaller machines with less complexity and tonnage.
- Mid-Range Hydraulic Press Brakes: Machines in this category typically cost between $20,000 and $50,000. These machines often offer greater tonnage and length, as well as more advanced controls and features.
- High-End Hydraulic Press Brakes: Top-of-the-line machines can easily cost $50,000 to $200,000 or even more, depending on the specific model and its features. These machines are used for heavy-duty applications and feature advanced control systems, high tonnage, and long bed lengths.
Complexity of the Machine
The complexity of the hydraulic press brake also impacts its cost. Machines equipped with advanced features like CNC controls, a back gauge system, or a variety of press brake tooling options will be priced higher due to their increased functionality and precision.
What Are the Ongoing Costs of Operating a Hydraulic Press Brake?
Beyond the upfront purchase cost, operating a hydraulic press brake involves ongoing expenses, including maintenance costs and energy consumption.
Regular Maintenance Costs
Regular maintenance of a hydraulic press brake is essential to ensure its optimal performance and longevity. These costs can include routine check-ups, replacement of worn-out parts, and hydraulic fluid refills.
Energy Consumption Costs
While hydraulic press brakes are more energy-efficient than their mechanical counterparts, they still require a considerable amount of energy to operate. The energy consumption costs can vary depending on the machine’s size, usage frequency, and local electricity rates.
Understanding the cost of a hydraulic press brake requires considering both the initial purchase price and the ongoing operational costs. By evaluating factors such as size, complexity, and maintenance needs, you can make an informed decision that balances your budget with your production requirements. Whether you are looking for an entry-level machine or a high-end model, understanding these cost factors will help you choose the best hydraulic press brake for your needs.
Selection Criteria for Hydraulic Press Brakes
When selecting a hydraulic press brake, it’s crucial to consider factors such as machine capacity, bending length, and control capabilities to ensure the equipment meets specific production requirements.
Machine Capacity
The machine capacity of a hydraulic press brake is primarily determined by the maximum force (tonnage) it can exert. This capacity should be matched with the material type and thickness you intend to bend. Higher tonnage is required for thicker, harder materials.
- Small-scale operations: Typically require machines up to 50 tons.
- Medium-scale operations: May need machines ranging from 50 to 175 tons.
- Large-scale operations: Often require machines with a capacity of over 175 tons.
Bending Length Requirements
The bending length of a hydraulic press brake corresponds to the maximum length of sheet metal that it can bend. Ensuring that the brake’s length exceeds the largest piece you intend to bend is crucial.
- Compact components: May only need brakes with a length of less than 1 meter.
- Standard components: Often utilize brakes with lengths ranging between 1 to 3 meters.
- Large panels: Require brakes with lengths of 3 meters and above.
What Is the Difference Between Press Brake and Hydraulic Press
Hydraulic press brake is essentially different from hydraulic press machine. Although they are used for sheet metal processing, their structural principles and final machining accuracy are different.
Precision and Control
Precision and control are essential for producing accurate bends. A hydraulic press brake should offer features such as:
- CNC controls: For automating bending operations and improving repeatability.
- Adjustable speed settings: To accommodate different types of materials and thicknesses.
- Backgauges: To precisely position the workpiece for accurate bending.
Cylinders difference:
The biggest difference between the press brake machinery and the hydraulic press is that their cylinders are completely different, which determines their use characteristics. The advantage of the press brake is that he can pressurize because the press brake has stroke adjustment, if one The stroke of the cylinder is 200mm, so that he can pressurize at any point within the range below this stroke, which determines that his bending angle can be used multiple times in one set, while the press is used. It is completely manual alignment of the bending angle, and it cannot be used innumerable times.
Generally, a regular bending with a length of more than 2000 MM is a press brake machinery, and a press is mostly used for processing irregular shaped parts. This is because the press can be eccentrically and the folding machine cannot be eccentric for a long time. Longer eccentric load will cause oil leakage and wear on the cylinder. The actual press cannot be over-loaded for a long time, but the eccentric load time he can withstand is longer than the press brake time.
Throat Depth difference:
Another difference is that the bending depth of the press brake machinery is limited, and the output after bending is sometimes limited to the side discharge cannot be taken out from the front, and the throat depth of the press is far more than the press brake, and he The lifting height is also higher than that of the press brake. Many of them are completely taken from the front, which makes it easy to process. Therefore, they have their own advantages and disadvantages, and they must decide the processing equipment according to the processing requirements.
Standard or not:
Besides that, press brake is a national standard equipment and the press is a non-standard equipment. The precision of their processing is completely different. The press brake can be used as a punch, but he has no punching efficiency.
Precision or general using:
The press brake machinery has a higher precision, and the pressure has its advantages. The press can perform the eccentric machining in a certain range. He is used for many different shapes in the shipbuilding, and the press brake cannot be biased, can only be applied to more regular bending.
Finally, punching machine is more of a finishing type than the above two types of machinery, rather than sheet metal processing, and has a mechanical hydraulic type.
Conclusion
KRRASS, your premier destination where precision meets reliability in the realm of Hydraulic Press Brakes. As a leading industry manufacturer, we’re dedicated to delivering top-tier machinery that surpasses expectations, empowering businesses to thrive. With a focus on innovation, advanced technology, and impeccable craftsmanship, we stand out as the go-to choice for unrivaled precision and efficiency. Join us as we delve into the world of Hydraulic Press Brakes, unraveling their functionalities, benefits, and what sets KRRASS apart from the rest.
