What is the Advantage and Disadvantage of hydraulic cnc press brake supplier

May. 06, 2024

Press Brake Technology in Metal Fabrication: Pros and Cons

Investing in a hydraulic CNC press brake offers a myriad of benefits for metal fabrication shops, but it also comes with its set of challenges. According to various experts, the technology can transform the speed and quality of metal processing in any workshop, making it indispensable. However, professionals must weigh both the advantages and disadvantages before making a purchase decision.

I. Introduction

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In the field of metal sheet and mechanical engineering, the press brake plays a vital role in transforming sheet metal into intricate shapes and designs. This powerful machine can achieve precise bending and folding, significantly impacting the industry by enabling the creation of mass-produced items ranging from simple brackets to complex mechanical components. However, it also has its limitations. Manufacturers need to consider a series of specific advantages and disadvantages when balancing its usage. This article aims to delve into the world of press brakes to explore their pros and cons, providing a comprehensive understanding of their role in the metal sheet industry.

II. Understanding of Press Brake

Definition

A press brake is a machine specifically designed for bending sheet metals. It is one of the indispensable devices in the sheet metal industry.

Key Components and Functions

The frame and bed are fundamental components of the press brake. Made of heavy steel, they withstand the force produced during the bending process. The bed serves as the horizontal surface on which the workpiece is placed, and the frame supports the ram and die. The ram is a vertically moving part that exerts pressure on the workpiece, causing it to bend around the die. The die is a changeable tool designed to ensure the angle and parameters of the press brake. The back gauge, another crucial component, ensures the accurate location of the workpiece to be bent. It consists of multiple stop fingers aligned with curved lines, guiding the workpiece to the correct position. The controller's main functions include setting bending parameters, monitoring pressure, and ensuring the machine operates within its specifications.

Main Types

Mechanical press brake: This is the most common type of press brake, operated by electric motors. The motor powers the flywheel, which rotates at high speed. The operator controls the flywheel via a clutch. Mechanical press brakes are simple to operate, especially in electronic equipment, making maintenance and operation easier. However, once the ram is connected, it must complete the entire process. If the gate stroke is too large, the press brake may lock, posing a potential hazard. Pros: low cost, easy operation. Cons: restrictions on precision, power, and control.

Hydraulic press brake: This type uses hydraulics to push the oil cylinder down instead of a mechanical setting. It can be equipped with multiple cylinders, allowing operators to control the bending precisely. Compared to mechanical press brakes, hydraulic press brakes offer more accurate bending and better control. They can be easily adjusted to fit various metal thicknesses and achieve intricate bends with steady movement. Although more expensive, they are popular due to their higher performance and versatility. Pros: higher precision, control, and force; fits various materials. Cons: high cost, more complex operation, and cannot exceed its rated tonnage.

CNC press brake: This highly customizable and accurate machine uses computer technology to improve efficiency and control accuracy. Skilled operators can input data such as bending angle, sheet thickness, and width into the controller to operate the machine. Pros: high accuracy and precision, easy operation, and can handle various shapes and angles. Cons: high cost, limitations with highly reflective or brittle materials.

III. Press Brake Advantages and Disadvantages

Advantages

Press brakes offer numerous advantages, making them indispensable in the metal sheet industry. They play a pivotal role in manufacturing operations due to the following benefits:

Easy Operation: Press brakes are among the simplest devices to operate, requiring less skill compared to other machines.
High Accuracy: Utilizing a punch and die, press brakes can bend metal with high precision, ensuring accurate angles.
Flexibility: They can bend small components and large masses of metal, offering versatility in various applications.
Improved Productivity: Capable of bending multiple metals simultaneously, press brakes significantly enhance productivity.
Reduced Material Waste: High accuracy minimizes material waste, making the process cost-effective.
Low Cost: The cost of the die used in press brakes is relatively low but boasts a long lifespan, enhancing economic accessibility.
Improved Security: Modern press brakes come with safety measures like laser sensors, reducing the risk of injury.
Versatility: Capable of handling various shapes and thicknesses of metal sheets, modern press brakes are extremely versatile.
Prototyping: Ease of setup and tool changeover make press brakes ideal for testing different designs during prototyping.
Intelligent Technology: CNC press brakes offer advanced automated solutions for metal bending, showcasing intelligent technology.
Crowning: This feature adjusts each angle location when bending long workpieces, ensuring even bending angles and reducing manual adjustments.

Disadvantages

Despite their numerous advantages, press brakes also come with certain drawbacks:

High Initial Cost: Significant initial investment is required for purchase and maintenance, including specialized equipment and training.
Require High Pressure: High pressure needed for operation may not be suitable for thin materials and poses potential safety risks.
Restricted to Simple Geometries: Press brakes are limited in creating complex shapes, and alternative methods may be required for intricate designs.
Need for Professional Training: Proper training is essential to ensure safe and effective operation, increasing the initial costs.
Space Requirement: Press brakes are large and require ample workshop space for placement.
Noise: Operation can be noisy, necessitating ear protection for operators and causing workplace vibrations.
Maintenance: Regular maintenance and cleaning are necessary to ensure product quality and machine longevity.
Risk of Breaking During Bending: Burrs or oxide layers on material edges may cause cracking or breaking during bending.

IV. FAQs

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How long does a press brake last?

The lifespan of a press brake depends on factors like machine quality, maintenance practices, operation conditions, and workload. A well-maintained press brake can operate for several decades, but components such as cylinders and controllers may need regular replacement. Proper lubrication, checking and replacing worn parts, machine calibration, and maintaining hydraulic and electrical systems are essential for prolonging the machine's lifespan. Following operational guidelines and providing operator training can also extend the user's lifespan.

Is hydraulic press better than press brake?

The choice between a hydraulic press and a press brake depends on the specific application and requirements. Hydraulic presses are versatile machines that use hydraulic pressure for bending, punching, and forming tasks, offering high power for heavy applications. They are suitable for various materials, including metal and plastics. Press brakes, on the other hand, are designed specifically for bending metal sheets, providing precise bending operations for creating bends, flanges, and channels. If focused on metal sheet bending, press brakes are ideal for their design and precision. For broader metal fabrication tasks, hydraulic presses offer more potential.

What is the preventive maintenance on a brake press?

Preventive maintenance on a press brake includes cleaning and lubrication, regular checks, tooling inspection, hydraulic system checks, electrical system checks, back gauge calibration, safety system checks, software and control upgrades, new operator training, and recording maintenance activities. These measures minimize unplanned downtime, reduce repair costs, and improve overall machine efficiency and safety.

V. Conclusion

To summarize, a press brake is an excellent tool for achieving precision, accuracy, and cost-effective production in metal fabrication. Considering its advantages and disadvantages before use ensures it meets specific manufacturing needs, enabling informed decision-making. ADH boasts over 20 years of experience in metal sheet fabrication and offers a range of press brakes. Browse our products to find the suitable machine for your business, or consult our sales team for detailed information.