When it comes to metal fabrication, investing in the right equipment, such as when you buy hydraulic press brake, can significantly boost productivity, precision, and overall business efficiency. Whether you're a small workshop upgrading your tools or a large-scale manufacturer expanding production capabilities, choosing the right machine is crucial. There are numerous factors to consider, including the type of material you work with, your production volume, and specific requirements like tonnage and bending length. This ultimate guide will walk you through everything you need to know to make an informed decision when you buy a hydraulic press brake.
Introduction
Press brakes are one of the most essential metal forming machine tools in the shop, offering manufacturers the capability to do the simplest and most precise metal bends. The most advanced models can perform precise bends on a variety of materials in a wide range of sizes. Basic models execute easier bends on thinner materials, efficiently completing projects on budget.
Today’s press brakes also come equipped with features that improve productivity and allow these workhorses to make the most precise bends. It can be difficult to sort through the models and features; this buying guide explores the types of press brakes, things to know before buying, key advances in press brake bending, factors to consider during the purchase, and features to consider so you can get the best press brake for your projects and budget.
Types of Press Brakes
Press brakes come in various types, each tailored for specific manufacturing requirements and applications. Below are some of the most common types of press brakes:
Mechanical Press Brake: These machines utilize a mechanical flywheel to generate the force needed for metal bending. Known for their durability and reliability, mechanical press brakes may have limitations in terms of speed and flexibility compared to newer technologies.
Hydraulic Press Brake: Hydraulic press brakes rely on hydraulic cylinders to apply force for bending operations. They offer precise control and can handle a wide variety of materials and thicknesses. Due to their high accuracy and capacity, hydraulic press brakes are ideal for high-volume and precision-demanding applications.
Servo-Electric Press Brake: These press brakes use electric motors and ball screws to manage the bending process. Recognized for their precision, speed, and energy efficiency, servo-electric press brakes are well-suited for applications that demand fast setups and high accuracy.
CNC Press Brake: Equipped with computerized controls, CNC (Computer Numerical Control) press brakes allow for the precise programming and automation of bending operations. Their versatility and ease in handling complex tasks make them a common choice in modern sheet metal fabrication.
Synchro Press Brake: Synchro press brakes utilize multiple hydraulic cylinders that work in sync to ensure parallelism and maintain even bending along the entire length of the workpiece. This design ensures uniform bending results across long sheets of metal.
Pneumatic Press Brake: These machines use compressed air to apply bending force. While they are often employed for lighter sheet metal applications, pneumatic press brakes may not provide the same level of precision and power as their hydraulic or servo-electric counterparts.
Press brakes can also be optimized for maximum productivity, such as in bending cells or tandem configurations. Tandem press brakes involve multiple press brakes arranged side by side to handle longer and heavier sheets or plates. This setup is typically used when the length of the workpiece exceeds the capacity of a single press brake.
What to Know Before First Buying
Several factors affect the price of a press brake, such as bed length and tonnage capacity. To ensure you choose the right machine without overspending on unnecessary features, it’s essential to gather the following information:
Type of Metal Being Formed: The type of metal you plan to bend—whether it's steel, aluminum, or another material—plays a crucial role in selecting the right press brake. Materials with higher tensile strength may require a machine with greater ram stroke or higher tonnage to handle the bending process effectively.
Maximum Metal Thickness: For thicker metals, a press brake with a higher tonnage is necessary. It’s advisable to overestimate the required tonnage to avoid potential machine damage and reduce the risk of workplace injuries. Underestimating tonnage needs can lead to costly accidents and equipment failure.
Size of Metal Sheets: The size of the metal sheets is another key factor in determining the appropriate bed length. Larger sheets require machines with longer beds for proper bending. Additionally, if you are working with larger or heavier sheets, consider opting for a press brake with front support arms or sheet lifters. These features help manage the material during the bending process, increasing productivity by reducing the number of operators needed and minimizing the risk of workplace accidents. Both support arms and sheet lifters can be purchased separately and added to the machine if not included. For extremely large sheets, multiple press brakes can be set up in a tandem configuration to handle the bending process efficiently.
Whenever possible, it’s ideal to have the specifications of the parts you plan to bend before purchasing a press brake. If that’s not feasible, provide general specs to your sales team, and they can guide you toward the best press brake for your needs.
Press Brake Technology You Should Know
The first press brakes were invented in the 1920s, though today’s machines are capable of much more than their predecessors. As technology advances, press brake bending has evolved to become more efficient and precise. Here are some advanced techniques and tools that have revolutionized the industry:
CNC Control. Computer Numerical Control (CNC) systems have automated and streamlined the bending process. CNC press brakes allow computers to control the processes of the brake, offering precise control over parameters, and reducing errors and setup time.
4-Point Bending. This technique utilizes a special tool setup to achieve complex bends with minimal deformation, making it ideal for parts with stringent geometric requirements.
Offline Programming. Software solutions allow operators to program bending sequences offline (often while the machine is running). The result is optimized production efficiency and a minimized risk of trial-and-error during setup.
Material Handling Systems. Automated material loading and unloading systems increase throughput and reduce manual labor, improving overall productivity. The most advanced systems include a combination of robotics and material handling systems for a completely automated metal forming process.
Factors to Consider When Buy Hydraulic Press Brake
There are a number of factors to consider when buying a press brake, so you don’t “overbuy” and purchase capabilities and features you don’t need. In the same way, you don’t want to “underbuy” and purchase a press brake that can’t meet all your needs.
Once you have the specs for future projects, as well as an idea of the scope of the press brake technology needed (i.e. automation, offline programming, etc.), it’s time to consider the following factors.
Accessories and Automation. Support arms and sheet lifters can boost productivity, minimize workplace injuries, and even decrease the amount of labor needed for material handling. Some press brakes come with these accessories included, while others require an additional purchase. In the same way, material automation can boost productivity and improve efficiency.
Tonnage. Basically, tonnage is the force needed to bend material. Materials require more or less force because of their different tensile strengths. Therefore, it is important to have an idea of the types of materials you are bending on the press brake; a material like stainless steel typically requires a press brake with more tonnage than mild steel or aluminum. (Get more information about calculating press brake tonnage in this article from The Fabricator.)
Ram Stroke. Put simply, the larger the ram stroke, the deeper the bend. The ram stroke is the amount of space the ram has to bend. This is the area below the punch and above the die. In terms of price, a press brake with a larger ram stroke cost more.
Features. Typically, if you need more precise bends, you need a press brake with more features. This leads to the next question, “what features do you need?” This is an answer that depends on the complexity of the project. Some press brakes come with features that ensure precise bending by accounting for the spring back of the material. While many of these features are optional, the features that shouldn’t be optional are the safety features that prevent costly workplace accidents.
Control System. The right control system can impact your operations significantly, by allowing you to utilize offline programming and/or to reduce set-up errors.
Conclusion
When buy hydraulic press brake, it's essential to make a well-informed decision, as it can greatly influence production efficiency, precision, and overall cost-effectiveness. With KRRASS machinery, you can rest assured that you're investing in a machine tailored to meet your needs.
The first step is understanding the specific requirements of your operation. This means evaluating the types of materials, thicknesses, and bending angles you’ll be working with. You'll also need to determine the necessary tonnage capacity and bending length to ensure the press brake can handle your projects effectively. Additionally, considering the control system and automation features is crucial—KRRASS machinery offers advanced CNC technology to boost precision and productivity. Moreover, it's important to assess the manufacturer’s reputation and after-sales support, and KRRASS is known for providing reliable performance and responsive service.
In summary, purchasing a KRRASS press brake is a strategic investment that requires thorough research and careful consideration of your operational needs and long-term goals. Luckily, you're not alone in the process—reach out to a KRRASS sales expert who can guide you in selecting the perfect press brake for your operation.
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