AdvancedPress Brake Technologies

John KempBystronic, Inc.

FABTECH Canada 2014

What you will learn about Why is Press Brake tooling so important Why is this different than before Current trend Future trends Blank size and bend allowance Bend and flatten Short flanges Tryout tools and other home remedies Adjustable dies Tool storage

Why is Press Brake tooling so important

Press Brake bending performance ultimately is determined by the geometry of three critical points. The Upper Punch tip and the Lower Die shoulders.

These are the only items that will ever contact the material!

Why is this different than before

Recent advances in Press Brake control systems have eliminated the majority of manual operator machine tending.

Because of these high performance machines, manual operator tool tending now consumes 90% or more of the total setup time.

What is the current trend

Almost every Press Brake sold today includes some sort of precision ground, ergonomic tool handling system.

Traditional aligning and seating is eliminated!

What is the future trends

Better tool changing systems? Maybe?

Better tool shapes that are more versatile? Probable!

What difference does this make?

Blank size and bend allowance

What does tooling have to do with blank size?

This is how most systems assess bend allowance and blank size!

Here is the formula used by most CAD systems to assess the k-factor or neutral axes:

k = 0.65 + 0.5 * log (r / t)

k

r

In this formula to assess the k-factor, what 4 variables are missing?

Here is the formula used by most CAD systems to assess the k-factor or neutral axes:

k = 0.65 + 0.5 * log (r / t)

k

r

Punch radius

Die Radius

Material type

Bend angle

In this formula to assess the k-factor, what 4 variables are missing?

What difference does this make?

Example: Material Type = Cold Rolled SteelMaterial thickness = .060”Bend angle = 90 degreesPunch Radius = .060”Die opening = .500”Die radius = .060”DIN bend allowance = .118”Actual bend allowance = .114”

Results:Without taking tooling and material into consideration an error of .004” is introduced at step one!

Per bend!

Bend and flatten

Flattening operations require a significant amount of force!

Modern tooling and machine features minimize setup times

Thickness Force TPF C Force  TPF D24 ga .023" 3 .125" 10 .046"20 ga .036" 4 .125" 11 .072"18 ga .048" 6 .137" 15 .096"16 ga .060" 8 .137" 16 .120"14 ga .075" 14 .188" 20 .150"

Traditional hemming toolset method

Integrated hemming table method

How to “tool” for short flanges

The demand for lighter and more complicated products have driven some flange lengths below the traditional tool limits!

Rocker dies are an effective flexible alternative to hard tooling

Sample rocker die in action

How to “design” for short flanges

The demand for lighter and more complicated products have driven some flange lengths below the traditional tool limits!

Creative design is an even more effective alternative to hard tooling!

Relief cuts prevent bulging of the hexagonal holes during the bend process

Tryout tools

Due to the demand for rapid prototyping, Press Brake tooling is sometimes made from segments flame cut segments.

These tools are typically used for determination of special tool shapes and not ideal not for mass production.

Take this process to the highest level with

LASER cut quality and many special tools can be made

in-house, on demand.

Adjustable dies

Just-in-time, one-piece-flow and rapid prototyping effect heavy plate users too. Adjustable V-dies do offer some advantages. Cost and complexity however restrict many of their applications.

Home remedies

The demand for lighter and more complicated products have driven some flange lengths below the traditional tool limits!

Magnetic wear strips also help reduce excessive marking associated with short flanges.

Tool storage

With tooling setups consuming the majority of the total Press Brake setup time, small improvements in tools handling can represent huge productivity gains!

Many well organized and easy access systems are available.

Tools should be located at an ergonomic height.

Recessed slots should be provided to prevent tool tipping.

No drawers to open/close.

Visualization and random access to all tools at once.

Door can remain open during production without obstructing operator workspace.

What to look for?

Thank You

John KempBystronic, Inc.