Introduction
Press brakes are manufacturing devices that bend metal. They are used to produce accurate bends on sheet metal. A press brake comprises a ram, punch, bed, die, and power assembly.
The working principle of the press brake is relatively simple. The punch pushes down on the metal sheet, forcing it into the die. The profile of the punch and die plays a crucial role in deciding the bending angle. Press brakes can bend ductile metals like aluminum and stiffer metals like stainless steel.
In the metal manufacturing industry, press brakes provide multiple benefits. They produce accurate bends with minimal waste. They simplify complex bending procedures and automate the process of metal forming.
Types of Press Brakes
To classify press brakes, we must look at their power generation and mode of operation. The manufacturing sector employs a wide range of press brakes. Let’s go over the primary types:
Mechanical Press Brakes
Mechanical press brakes generate power through a flywheel and motor mechanism. The electric motor generates power to turn the flywheel, which enables the vertical movement of the ram. A clutch controls the movement of the ram. Metal workshops often employ mechanical presses for bending metal sheets. They are efficient at straightforward bending tasks and manufacture parts like panels, enclosures, and brackets. They are simple in construction, affordable, and easy to maintain.
Hydraulic Press Brakes
Hydraulic press brakes use hydraulic oil to generate force for bending. A hydraulic pump transfers pressurized liquid into the cylinders. The pistons in the cylinders push outwards, driving the ram downwards. Hydraulic press brakes can generate great tonnage; hence, they are ideal for high-strength materials. They can process large metal sheets into plates, panels, and busbars. Hydraulic press brakes are accurate, quick, and versatile. Relying on a hydraulic system also reduces electricity bills.
CNC Press Brakes
Computer systems and control panels are the mode of operation in a CNC press brake. They offer a great amount of automation. Computerized operation means that technicians no longer rely on manual labor. CNC press brakes are set up with simulation software. They help in identifying optimal bends and potential errors. CNC press brakes are used to manufacture complex parts due to their high programmability. CNC brakes in the electronics industry manufacture computer panels, hardware devices, and cabinets.
Main Industries and Applications
Press brakes easily and precisely achieve metal forming goals, benefiting multiple industries. In the following sectors, press brakes simplify production and boost factory output.
Automotive Industry
If there is one industry that is dependent on multiple technologies, it is the automotive industry. The automotive industry combines mechanical, electrical, and hydraulic systems. Press brakes are important in this industry due to several reasons. The primary use of press brakes is to process automobile body panels and chassis. Steel and aluminum are the major materials in the automotive industry. Hydraulic CNC press brakes efficiently bend long metal plates at the desired profile.
Press brakes also process car parts like the bonnet, hood, bumper, roof rack, spoiler, doors, and interiors. Automobiles like trucks and buses often feature long metallic parts. Bending machines effectively process these long components. They have crowning systems to avoid deflection when bending more extended machine parts.
Construction and Decoration
Sheet metal is a critical component in construction and décor. Many important building parts, such as beams, columns, and stairs, are constructed from metal sheets. Metal fixtures, such as frames, lamps, pendant lights, and cabinets, are common in interior design. Some other popular elements are exposed piping and ductwork. Common materials in this industry are aluminum, copper, stainless steel, and carbon steel.
High-tech CNC machines make processing complex interior design elements much easier. Operators can program press brakes with the desired bending steps. The coning, flange width, inside radii, and angle bends can be controlled. The benefit of automation is that factories generate less waste. With savings in raw materials, time, and human efforts, it is easy to see that press brakes benefit factories overall.
HVAC Industry
Metal fabrication is important in heating, ventilation, and air conditioning. Ducts, vents, pipes, and machine shells are made with metal sheets. Common materials in HVAC are steel, copper, and aluminum. It is necessary to ensure the smooth transportation of refrigerant during the cooling and heating cycle. In addition to simple bending tasks, press brakes perform other important operations.
While making AC shells, the edges are reinforced by overlapping the metal sheets. Flanging makes these interfaces possible. Hemming is bending the edges of metal sheets into a tight loop. This method makes the joints and connections robust. Other techniques that help strengthen metal components are beading and coining. Such operations can be performed easily with press brakes.
Industrial Equipment
Companies that manufacture industrial equipment deal with large-scale B2B clients. Heavy-duty industrial machinery must be efficient, long-lasting, and reliable. The industrial equipment market is a high-value sector, valued at about $113 billion. Manufacturing strategies must produce optimal results.
Press brakes have streamlined the process of industrial equipment manufacturing. They are excellent at fabricating outer casings for equipment like cranes, robotic arms, tanks, and mills. Many useful machine components like brackets, hinges, and corner braces can be made by press brakes. Press brakes are used to fabricate dimpled metal sheets that are used in industrial vehicles and platforms. They allow industrial manufacturers to diversify their production lines. Press brakes are proven to reduce labor and operational costs.
Aerospace
The aerospace industry requires high-precision manufacturing. Aerospace companies produce aircraft and spacecraft parts. They rely on high-tech machines that deliver peak performance. Press brakes transform metal sheets into engine casings, wing assemblies, and brackets. Aluminum and titanium are the most widely used materials. They also play an important role in rocket manufacturing. A prime example is SpaceX. They use press brakes to manufacture high-precision parts for their Starship rockets.
Due to their extensive usage, aerospace machines are manufactured with high-quality materials. Aircraft parts undergo physical stress, heating, cooling, and corrosion. Therefore, it is necessary for aerospace manufacturing to be precise and error-free. Heavy-duty hydraulic press brakes and automated CNC press brakes fulfill these rigorous demands. Bending machines also conserve R&D costs by providing rapid prototyping of new designs. Manufacturers conduct small production runs using press brakes. They can test new parts before deploying them.
Medical Equipment Manufacturing
The medical industry manufactures a diverse range of products. There are several categories of medical equipment to be aware of. Diagnostic equipment helps in identifying the patient’s condition through scanning and testing. Durable medical equipment consists of therapeutic items like wheelchairs and beds. Treatment equipment includes machines that are used for operation. Life support devices help sustain the patient’s vitals. Laboratory equipment helps scan samples for evidence of disease.
Quality and reliability are essential in all medical machines. For this reason, dedicated manufacturing norms and quality standards are important. High-tonnage CNC hydraulic press brakes automate medical manufacturing. They make both therapeutic equipment and treatment machines.
Press brakes make frames and handles for wheelchairs, hospital beds, and cylinders. They have reduced the time and cost of manufacturing costly diagnostic devices like CT and MRI scanners. CNC press brakes can rapidly produce delicate surgical instruments, such as forceps, scalpels, and clamps. Stainless steel and aluminum are the two most common metals in medical tools. They can be bent easily using bending machines.
Catering Industry
The catering and cookware industry has greatly benefited from press brakes. The advent of bending machines has enabled many small manufacturers to open shop. Consumers have more choices than ever when it comes to catering. Press brakes have streamlined the process of manufacturing aluminum and steel products. Common catering supplies include tableware like plates, trays, and cutlery. Furniture like folding tables and chairs are also popular catering items. Press brakes also contribute to producing cooking equipment like grills, microwaves, and ovens.
Press brakes have made the process of designing and manufacturing catering supplies much easier. They have increased sales for many businesses. Design and aesthetics are a huge part of catering, and press brakes help achieve them in a cost-effective way. Manufacturers can prototype new products with press brakes, 3D printing, and shearing machines. With a few modern machines, you can make coffee dispensers, trays, cans, cutlery, bins, grills, etc.
Container Industry
The container industry is a fast-growing multi-billion-dollar market. It relies on modular containers to transport cargo. Containers have standard dimensions and must follow international norms. Their construction must be robust and secure in order to facilitate transport by water, rail, or road. Containers have five parts: front plate, back plate, chassis, roof, and side.
Storage container manufacturing requires several industrial devices. Press brakes are necessary for shaping metal sheets. They create the required bends and flanges for the metal plates to attach. Shearing machines and laser tools precisely cut the metal to size. Punching machines create the necessary openings for screws and attachments.
Corten steel and aluminum steel sheets are the primary materials in shipping containers. Press brakes are an ideal choice for processing these materials. Container manufacturing begins with stamping, primarily where they come into action. Hydraulic CNC press brakes shape metal sheets into the desired angle and dimensions. Stamping is followed by welding the joints. Finally, the containers are coated with anti-dust and anti-corrosive paints. Manufacturers observe regular quality checks throughout the process. Finally, shipping containers are ready for freight and cargo transportation.
Conclusion
As you can see from the numerous examples above, press brakes have benefitted multiple industries. They automate the bending process, which allows greater efficiency and productivity. CNC press brakes enable manufacturers to produce small parts with complex bends. Hydraulic press brakes increase production speed. They help bend strong metals. Mechanical press brakes are versatile and suitable for small and large factories alike.
With such a wide range of applications, it is no surprise that press brakes are helpful in every industry that processes sheet metal. Whether you are a parts supplier or a product manufacturer, press brakes can boost your business. Contact our professional team for expert guidance. We would be glad to help you!