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Optional Flattening die 60mm European Amada Promecam Press brake Tooling System
Some mistakes could be made on all press brakes, but how to prevent it?
Sometimes all most of common issue of basic mistake for running one press brake is have not keep the bending machine clean, which it bring dirt and grime to accumulate causes excessive wear to gibs and tooling. It do not need too much dirt can scratch parts as they are formed if metal scraps stuck in the space between top punch and lower dies, also if metal dusts enter the control panel or cabinet, it may cause serious electrical problems. So fabricating workshop must be issure press brake bending conditions to wipe dirts for every bending shifts. Any oil residue should be removed to prevent shop dust from being attracted to the machine. The practice of keeping the press brakes clean, not only prolongs using life of the bending machine and also can makes the sheet bending machine faster and safer.
Y1&Y2 cylinder downward not equal. All kinds of press brakes are designed with a deflection limit under full bending pressure loading. main frames Deflection refers to the tendency of the ram to bend upward in the center and the bed to bend downward under full tonnage loading. If the bending loading is too concentrated and top&bottom beam overdeflects, they take on a permanent upset in the center of the bending machine. If this happens, normally you will get very big bending angle in the middle than 2 ends of machines, unless you need to refabricating the top beam and lower beam again, that's required professional equipemnts and experience, only pres brake manufacture can do this.
So press brake operator must be running material pressing very carefully and using only a sufficient amount of tonnage to make the part with reasonable bending tonnage.
Proper lmechanical parts ubrication is another serious issues. All moving mechanical parts should be lubricated frequenctly with recommend schedules. Two sides of ram guides are a critical area and should be kept lubricated if required. in press brakes. Some bending machines have nonlubricated gibways, some have grease fittings, and some have manual or automatic oiling systems. If the gibs require lubrication, failing to do it may cause them to freeze and/or become so badly worn that costly replacement is necessary.
Top beam must be parallel so that the ram does not operate with a twisting motion. An out-of-level beam forms imperfect parts, and if the unequal angle is too bigger, it will cause big problem for cylinder rods.
Another causes of imperfect parts is bad tooling.
The clamps area of the punch and shoulders of the die are subject to wear; if much work is done at the same place on the bed, the resulting wear causes erratic bends. Inconsistent bends and crooked flanges usually are caused by worn tooling.
Parts profiles specificitions determine the top punch and bottom dies to be used, provided that the press brake is compatible with the bending tooling. Like a bending radius larger than metal thickness and an angle tolerance between 1 and 2 degrees, you can air-bending with almost any press brakes.This type of bending requires the least bending loading and helps to protect the press brake from overload.
Even you ahve a CNC press brake with an accurate ram repeatability must bottom-bend for small inside radius. Using the incorrect style of tooling results bad bending parts and possibly damage to the press brake.
Unaligned press brake Tooling. It commonn sense that the punch and die are properly aligned to produce accurate parts. Thecenter line of top punch and bottom dies should be in the same plane for the entire length of the bending machine table.
Also The flange width of the part is affected by wrong linked. The press brake back gauge is positioned from the center of lower die, while the final sheet profiels flange width is determined by the center of the top punch. Misalignment can occur when the die or the die rail moves on the press brake bench.
Determine Required Bending Loading Tonnage,It is important to know the loading required to make a bend. The load is based on the sheet thickness and type of material, the length of the bending and the full tooling packages.
There are some special conditions for hydraulic press brakes, the top beam drifts down on one or both ends when the machine is stopped with the ram raised and left under pressure with the power off. This condition is caused by an internal oil leak in the cylinder. Oil leakage on main cylinders can relief some pressure of one side of cylinder to push the beam down. The cylinder oil leak can be corrected by replacing the oil seals. If the internal oil leak is allowed to continue, it will get worse and eventually decrease the bending pressure in the affected cylinder, it's like bending 6mm mild steel sheet with 10ft, 160T bending pressure can ge easily get the job done, cnc press brake controller also input 160T pressbrakes, but problem is oil leakage with less actual bending pressure, so can not bending the sheet properly.
Another case for hydraulic press brake, not all hydraulic press brakes can adjust the bending tonnage, Using the minimum tonnage required to bend a part is good for the tooling and the machine.
Forget To Change Hydraulic Oil In time. Hydraulic oil must be changed in time by regular schedule, or press brake operator need to remember to check the oil situations by eye, normally just need to open the tank to see the status of oil; but if you have not chnage the oil regularlly, it will be cause serious problem, like stuck valves or damaged pump, which will be need big money for replacing or fix this kind of hydraulic problems.
It also can break down if the machine is run at high temperatures for too long. All of these conditions can damage valves, cylinders, and hydraulic blocks.
When will you need to replace the oil, it all depends on how much the machine is used, but should be check very carefully after 6-8 moths bending cycle.
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