What Is Press Brake Software? How It Works?

With advancements in technology and production processes, CNC press brakes have become crucial machines for many enterprises, offering precise and efficient metal sheet bending. At the heart of this operation lies the press brake software, which plays a pivotal role in ensuring both accuracy and productivity during the metal forming process. The precision and efficiency provided by press brake software not only enhance manufacturing quality but also significantly reduce production costs. In this article, we will delve into the working principles, benefits, and accuracy of press brake software, while addressing common issues and providing tips on how to select the best software for your needs.

What Is Press Brake Software

Press brake software is a tool used to calculate and simulate metal sheet bending, which provides a comprehensive solution for sheet metal bending. It controls and guides the press brake machine by generating programmable codes and providing accurate instructions for operators.

Press brake software has offline calculation tools for setup and bending sequence, as well as the ability to simulate bending.

Specifically, press brake software generates accurate bending data through advanced algorithms, including factors such as the best bending sequence, material characteristics, bending parameters, tool selection, etc.

Press brake software not only optimizes the bending process but also minimizes errors. It can precisely control the bending angle, shape of the workpiece, and back gauge position, thus ensuring better accuracy and consistency of the workpiece.

The 3D simulation function of press brake software can also visualize the finished product and simulate the bending process before actual production.

All these benefits translate into higher quality products, shorter delivery cycles, and better overall efficiency. It can be said that press brake software comprehensively promotes manufacturing productivity.

How Does Press Brake Software Work?

1. Detailed Technical Details

Actually, press brake software mainly operates based on finite element analysis (FEA) and numerical simulation technology.

Firstly, the CAD file is converted into a 3D model, and then calculations are made based on FEA and numerical calculation methods. Finally, the final bending parameters are obtained through simulation and optimization to achieve efficient and accurate metal material processing.

Here are the general steps for operating press brake software, although different types of press brake software have different functions and operational details. Detailed operation steps still need to be referenced from the user manual of the press brake software.

• Import CAD files: Import the CAD file of the parts (usually in DWG, DXF, etc. formats) into the press brake software.
• Material and parameter setting: Input material characteristics, elastic modulus, etc., as well as relevant parameters of the press brake, such as clamping force, bending angle, and bending radius.
• Layout and setting: Arrange the 3D model in the software and select the appropriate bending sequence according to requirements, which determines where to bend, use punches and dies, and bending order, etc.
• Numerical calculation: After all parameters are set, the software performs numerical calculations on the entire model, typically using the FEA method. This method discretizes the raw sheet metal parts into many small pieces and then analyzes and calculates the mechanical properties of each small piece, obtaining its deformation and stress state.
• Simulation and optimization: Use the simulation function provided by the software to simulate the part bending process based on the calculation results and perform model acceptance. If there are problems with the model, it can be adjusted and optimized until it meets design requirements.
• Output results: After completing the simulation, optimization, and other operations, the software outputs all the required parameter information for the bending process, which can be used for on-site operation in the factory.

2. Example of FEA Application in Press Brake Software

Meshing: The software divides the workpiece into a finite number of elements. For instance, a frame might be divided into 30,170 units, as shown in the following.

Load and Boundary Conditions: The software applies the load and boundary conditions to the model. For example, the top beam might experience a maximum bending force of 1000 kN, distributed among three cylinders.

Stress and Displacement Analysis: The software calculates the displacement and stress distribution across the workpiece.

Optimization: Based on the analysis, the design can be optimized. For instance, changing the fillet radius in the C-shaped throat of the side plate can reduce the maximum stress from 169 MPa to 149 MPa, improving the design’s robustness.

Main Functions of Press Brake Software

1. CAD/CAM Integration:

Press brake software seamlessly integrates with CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing) systems, bridging the gap between design and production. This integration enables operators to import 2D drawings or 3D models of the parts to be bent directly into the software. By doing so, designers can work in familiar CAD environments, while the press brake software interprets these designs for production. The accuracy of this integration helps eliminate manual input errors and ensures that complex geometries are executed flawlessly. Additionally, many press brake software systems offer automatic unfolding of 3D designs, making it easier to program and execute even the most intricate part geometries.

2. Bend Sequencing:

One of the most critical aspects of efficient press brake operation is determining the correct sequence of bends, especially in complex parts with multiple bends. Press brake software automatically calculates the optimal bending sequence, ensuring smooth workflows and minimizing potential collisions between the workpiece and the machine components. By taking into account factors like part orientation, tooling, and machine capacity, the software optimizes production, ensuring high-precision bends. This feature is particularly valuable in automated environments where minimizing downtime is essential to maintain production efficiency.

3. Tool Setup:

In modern press brake software, tool setup is automated, streamlining the preparation process for each job. The software allows operators to select and configure the appropriate punch and die combinations based on the material type, thickness, and desired bend radius. It ensures accurate tool alignment, positioning, and clamping, reducing manual adjustments and enhancing production efficiency. Moreover, advanced software can recommend tool changes on the fly if a certain tool set is not suitable for the job, ensuring optimal performance. This function helps reduce machine downtime and improves workflow efficiency, especially in environments with frequent job changes.

4. Angle Calculation:

Achieving consistent and accurate bends requires precise calculations of the bending force, angle, and material springback. The press brake software takes these variables into account and automatically calculates the necessary force and angles for each specific material and thickness. By using pre-defined material databases, the software adjusts for different properties such as aluminum, stainless steel, or mild steel. This feature minimizes operator guesswork, reducing scrap and improving repeatability. Additionally, the system compensates for any material variations in real-time, further ensuring accuracy in mass production.

5. Offline Programming:

Offline programming is a game-changer in modern manufacturing environments. With press brake software, operators can create and test bending programs remotely on a computer without tying up the machine. This means that production can continue on the press brake while new jobs are being programmed and tested in the background. Once the program is ready, it can be loaded into the press brake via USB or network, minimizing machine downtime. Offline programming not only increases productivity but also allows for greater flexibility in managing multiple projects, reducing bottlenecks in production schedules.

6. Simulation:

Advanced press brake software provides highly accurate simulation capabilities that allow operators to visualize the bending process before running the actual part. This simulation helps detect potential issues such as part collisions, incorrect sequences, or tool interference, all without wasting material. Operators can adjust parameters in the software to correct any problems, ensuring a smoother and more efficient production run. Some systems even provide 3D simulations of the entire bending process, offering a comprehensive preview that aids in training operators and troubleshooting complex operations before the press brake is engaged.

7. Data Management:

Press brake software also functions as a robust data management system. It stores and organizes bending programs, machine settings, and material specifications, making it easy for operators to recall and reuse previous jobs. This feature is especially valuable in environments with high product variety, as it reduces the need to recreate programs from scratch for recurring jobs. Additionally, the software can track machine performance metrics such as cycle times, tool wear, and job histories, offering insights that can be used for predictive maintenance and continuous improvement initiatives. With proper data management, press brake operators can maintain consistent quality while optimizing production throughput.

How to Improve the Accuracy of Press Brake Software?

Using a press brake for bending, even the slightest angle and size deviation can lead to rework or a scrap of workpieces. The advanced features of press brake software greatly guarantee the accuracy and efficiency of workpiece bending.

Firstly, press brake software can predict modelling. Operators can model the bending process through tools such as CAD/CAM and 3D simulation software before actual processing.

By analyzing different simulation scenarios, problems can be discovered before the actual operation, and parameters, processes, tools, and materials can be optimized in time. This can eliminate workpiece bending errors caused by design factors and reduce costs.

Secondly, press brake software has the function of automatic measurement and synchronized adjustment. Sensing technologies such as laser scanners, cameras, or weighing sensors can be integrated with press brake software.

Real-time measured bending angles, positions, and bending forces can be fed back to the control system, which adjusts parameters according to predetermined targets. This is more timely and accurate and ensures consistency and repeatability throughout the entire process than manual measurement in the past.

Finally, press brake software can analyze and optimize data. All data can be saved in the software. By collecting and analyzing previous bending operation data, press brake software can improve programs.

This optimizes the bending process and improves the accuracy, efficiency, and quality of workpiece bending.

When using press brake software, the following points should also be noted to maximize the optimization of the bending process.

1. Choose the bending angle and curve shape reasonably. Improper setting of the bending angle and curve shape can still cause problems with the workpiece.
2. Conduct sufficient testing. Before using press brake software for bending processing, it is necessary to conduct sufficient testing of relevant programs to ensure that they can operate normally and produce accurate tooling setups and workpieces.
3. Continuously optimize and upgrade. The press brake bending software is a constantly evolving and maturing technology, and we need to constantly optimize and upgrade it to improve its performance and stability.

Advantages of Press Brake Software

In the past, bending operations mainly relied on experienced press brake operators to adjust manually. This method may lead to bending errors. With the development of technology, the emergence of press brake software has changed the traditional sheet metal bending pattern.

Press brake software achieves automated, efficient, high precision, and high-safety production methods through digital control. Compared with the previous press brake operation mode, press brake software has many advantages.

1. Higher Automation

Press brake software is an automated computer tool that can achieve automated operation through offline software programming. It provides standardized tools, programs, and shape libraries and simplifies the process of integrating different machine types.

By selecting the bending program, tool, bending parameters, and controller, the bending sequence can be automatically generated. This reduces labor and time costs and can also improve bending accuracy and consistency.

2. Improving Accuracy and Efficiency

The automated process of press brake software reduces design errors and downtime and improves productivity and quality. Programming allows operators to create efficient bending settings, reducing machine setup time and workpiece delivery cycles.

Press brake software has 3D part simulation and visualization functions, which can detect potential problems in advance, such as collisions and tool interference.

Press brake software uses mathematical models and algorithms to accurately calculate the bending angle and curve shape of the sheet metal. This ensures the accuracy of bent workpieces, reduces the possibility of rework and scrap, and lowers production costs.

3. Improving the Safety of Operator

The automation of press brake software simplifies the bending process and reduces the operator’s operating time, thereby improving safety. The monitoring function of press brake software reduces the possibility of operators being injured by the machine through devices such as DSP.

Some complex steps can accelerate the design-to-production times with automated features of program settings, such as nesting parts and selecting tools, thus reducing the manual handling of heavy parts and assembly.

The powerful functions of press brake software allow operators to produce high-precision workpieces without needing to master too complex bending techniques.

4. High Production Flexibility

Press brake software can generate different programs according to different production requirements, so it can quickly adapt to different production needs.

Production management can also be achieved through remote control, improving production flexibility, efficiency, and safety.

5. Multi-Language Support

With the increasing internationalization of the manufacturing industry, multi-language support has become an important requirement.

Now, press brake software can support multiple languages, and users from different countries and regions can operate more conveniently.

Common

Common press brake software solutions are designed to optimize metal sheet bending processes, offering various levels of control, precision, and automation. Here are some widely used press brake software systems:

1. Delem: Known for its advanced graphical user interface, Delem offers real-time simulation and is widely integrated into many CNC press brakes. It is valued for its ease of use and powerful features, making it ideal for both small and large-scale operations.
2. ESA: ESA press brake software provides flexible and highly customizable solutions. It supports multi-axis control, touchscreen interfaces, and high-precision bending, making it a popular choice for manufacturers seeking adaptability.
3. CybTouch: Designed for simplicity and efficiency, CybTouch is often used in hydraulic press brakes. It offers intuitive programming, making it accessible for operators, and provides advanced control functions for accurate bending.
4. Estun: Estun control systems are known for their robust performance and user-friendly interface. The software enables real-time data processing, improving the efficiency and precision of sheet metal bending processes.
5. Siemens: Siemens press brake software is integrated into CNC systems for complex sheet metal operations. Its versatility and support for automation and multi-tasking make it ideal for industries requiring high-performance solutions.
6. LVD CADMAN®: This software is designed for advanced press brake operations, offering complete integration of bending, shearing, and punching processes. It provides 3D visualization and simulation for accurate part production.

Each of these software solutions has its strengths, and the choice depends on the specific needs of the production environment, level of automation, and the complexity of bending operations.

Factors to Consider When Choosing Press Brake Software Products

When selecting press brake software products, several critical factors should be considered to ensure optimal performance, precision, and efficiency in metal forming operations. Here are the key factors to evaluate:

1. Ease of Use: The software should have an intuitive interface that simplifies programming and operation. Operators should be able to quickly learn and use the software, reducing downtime and minimizing errors.
2. Compatibility with Machine: Ensure the press brake software is compatible with your CNC or hydraulic press brake model. Different manufacturers may require specific software integrations to fully utilize the machine’s features and capabilities.
3. Multi-Axis Control: Advanced press brake software should support multi-axis control, enabling precise management of back gauges, bending beams, and other components. This is essential for complex bending tasks that require multiple movements in different directions.
4. Real-Time Simulation and Visualization: A robust software solution should offer real-time simulation and 3D visualization of the bending process. This allows operators to preview and adjust the bending sequence, minimizing trial and error, and reducing material waste.
5. Automation Features: Software that supports automation, such as automatic tool selection, bend sequencing, and material handling integration, can significantly increase production speed and efficiency. This is especially important for high-volume production environments.
6. Accuracy and Precision: Choose software that prioritizes high accuracy in bend calculations and error correction mechanisms. Precise metal forming is crucial for maintaining product quality and avoiding costly rework.
7. Customizability: The ability to customize software settings, like material database input, tool configurations, and process parameters, can enhance flexibility and meet specific production needs. Look for solutions that allow for tailored bending strategies.
8. Support and Updates: Regular software updates are essential for keeping up with technological advancements and machine improvements. Additionally, consider the level of customer support and technical assistance available from the software provider.
9. Integration with Other Systems: If your production environment includes other manufacturing systems (CAD/CAM, ERP, MES), it’s important that the press brake software can integrate smoothly for streamlined workflows and data sharing.
10. Cost: The total cost of the software, including initial purchase, training, support, and potential future upgrades, should align with your budget while delivering the necessary functionality and performance.

By carefully considering these factors, manufacturers can select press brake software that enhances productivity, improves bending accuracy, and streamlines operations.