What is a Press Brake?
Table of Contents
- Introduction
- The Origin of the Name “Press Brake”
- Main Components of a Press Brake
- Additional Components of a Press Brake
- How Does the Metal Bending Process Work?
- Applications of Press Brakes
- Advantages and Limitations of Press Brakes
Introduction
Metals possess several significant properties, among which their flexibility and malleability stand out. These properties enable metals to be shaped and resized to desired forms using specific tools, machinery, and equipment. The malleability of metals has contributed to the increasing use of steel, the most commonly used metal in industries. Today, one of the indicators of a country’s development is the amount of steel it produces and consumes. One of the most popular and efficient machines for shaping metals is the press brake.
Press brakes are ideal for performing specific and sequential bends. Their ability to achieve high-quality bends and execute diverse, non-uniform bends (of varying sizes and dimensions) is one of their defining characteristics.
The Origin of the Name “Press Brake”
In the past, the term “brake” referred to a tool used for “breaking or crushing.” Over time, this term became synonymous with machines.
The term “press” originates from the word “presse,” which means “to crush or compress.” It describes a device or machine that applies force through compression. Today, the word “press” is combined with “brake” to form “press brake,” effectively describing a machine designed to create various bends in metals by applying force.
Below is an image of an early press brake model.
Main Components of a Press Brake
A press brake consists of several primary components that work together to bend and shape metal sheets. These components include:
- Frame: The main structure that supports and holds all parts together.
- Ram: The moving part that applies force to the metal sheet.
- Controller: Used to control the ram’s movement and adjust bend angles.
- Punch: Attached to the ram to shape the metal.
- Die (Matrix): Works with the punch to create specific bends.
- Backgauge: Ensures precise placement of the metal sheet.
- Hydraulic Cylinders: Power the ram’s movement.
- Motor: Drives the hydraulic or mechanical systems.
- Safety Devices: Protect operators from injuries.
Frame:
The frame provides the structural integrity of the press brake, supporting all other components. Typically, it is made from heavy-duty steel to withstand the forces generated during the bending process. For our machines at Grand Dayyani Industries Machine Manufacturing , we use ST52 steel, which is stronger and tougher than ST37 steel.
Ram:
The ram is the moving component that delivers force to the metal sheet. It is connected to the punch and moves up and down to perform bending. The hydraulic cylinders generate the required force for its movement.
Controller:
Controllers, available in PLC and CNC systems, allow operators to set bending angles and depths. We recommend CNC systems for their precision and efficiency.
Additional Components of a Press Brake
Punch and Die (Matrix):
These tools shape the metal. The punch is attached to the ram and presses the metal onto the die to form specific bends based on the die’s design.
Backgauge:
Ensures precise alignment of the sheet for consistent bending and reduces operator error.
Hydraulic Cylinders:
Hydraulic systems provide the necessary force to bend the metal. Our hydraulic systems and cylinders are locally produced with high-quality materials, ensuring performance comparable to European systems.
Motor:
Electric motors are used in servo-electric press brakes for bending force or in hydraulic press brakes to power the hydraulic fluid movement.
Safety Devices:
Safety mechanisms, such as physical guards and light curtains, protect operators during operation. At Grand Dayyani Industries Machine Manufacturing , we offer customizable safety features based on client needs.
How Does the Metal Bending Process Work?
The bending process requires significant force (measured in tonnage). During the operation, the ram moves the punch downward, applying force to the metal sheet. Press brakes come in various types based on their power source, including:
- Mechanical Press Brakes
- Pneumatic Press Brakes
- Servo-Electric Press Brakes
- Hydraulic Press Brakes (e.g., CNC Press Brakes)
Among these, hydraulic press brakes are the most powerful, capable of handling thicker sheets. On the other hand, servo-electric press brakes offer the highest precision and speed, followed by pneumatic models.
Applications of Press Brakes
Press brakes are essential in manufacturing and fabrication industries for bending metal sheets into desired shapes. These machines are widely used in:
- Automotive Manufacturing
- Aerospace Industry
- Metal Art and Sculpture
- Furniture Manufacturing
- Metal Containers and Vessels
- Structural Steelworks
At Grand Dayyani Industries Machine Manufacturing , we produce high-quality press brakes that are competitive with international brands and exported to countries such as Iraq, Saudi Arabia, the UAE, Qatar, Oman, and India.
Advantages and Limitations of Press Brakes
Advantages:
- Precision bending capability.
- Versatility in handling various metal thicknesses and angles.
- Relatively low cost compared to other bending methods.
Limitations:
- Slower than some alternative bending methods.
- Requires skilled operators for optimal results.
- Needs specialized tools for specific angles and radii.
Despite these limitations, press brakes remain a versatile and cost-effective solution for metal bending in a wide range of industries. With the right tools and accessories, they can perform a variety of bending tasks efficiently and accurately.
For more information about press brakes, pricing, or purchasing options, contact us at 02155375252 or 09123775103, or complete the consultation form on our website.