Introduction
If you are interested in metalworking, chances are that you must have heard something about metal bending and cutting. They are two highly important ways of manipulating metal. Manufacturing metal tools and parts requires a high level of precision. It is necessary, therefore, that bends and cuts be accurate and error-free.
Two state-of-the-art machines deliver the high performance required by industries: press brakes and shearing machines. A metalworking shop is incomplete without them. But do you know the differences in their capabilities and applications? If you don’t, worry not. We’ll tell you everything about them.
Overview of the Press Brake
Press brakes are used by fabricators for metal forming tasks. Let us go over the definitions, functions, and capabilities of these machines.
Definition of Press Brake
A Press Brake is an industrial machine that bends metal sheets into a desired shape. It consists of a machine frame to which two components are attached vertically. The top part is known as the ram, and the bottom part is known as the bed.
The ram ends in a horizontal piece called a punch. Similarly, the top part of the bed is a long section which is called the die. The workpiece is inserted into a slot between these two. When the press brake operates, the punch slams down into the ram, squeezing the metal sheet. This bends it at an angle specified by the operator.
Types of Press Brakes
Modern press brakes are very varied, so it’s necessary to group them. The differences in press brakes arise from how they generate power and how they are controlled.
The simplest kind of press brake is the mechanical press brake. It has a motor and a flywheel. The flywheel is used to generate the energy that drives the ram up and down.
In hydraulic press brakes, hydraulic oil stored in hydraulic cylinders is the transmission medium for energy. Hydraulic pumps use this to move the pistons, which in turn power the ram.
Pneumatic press brakes also use cylinders, but they don’t use hydraulic oil. The cylinders contain pressurized gas that is used to generate force through the pistons.
CNC press brakes are high-tech machines that automate the bending process. They use software tools and sensors along with a human-machine interface to simplify the operation of the press.
Another type of press brake is the electric press brake, which uses servo motors to generate the force that drives the punch.
Overview of Shearing Machine
Nowadays, the shearing machine has become synonymous with metal cutting. But why is this machine used so much? Let us try to understand why metal workshops prefer this industrial tool.
Definition of Shearing Machine
The shearing machine is an industrial device that cuts metal sheets. It consists of a machine frame that holds the various components. The main cutting tools are a vertical blade and a horizontal blade that is placed roughly perpendicular to each other. Cylindrical clamps are used to hold the metal sheet in place during operation. Additionally, it contains supports for the sheet metal, slotted guards, a control panel, and a covered pedal to start the operation.
When a metal sheet has to be cut, it is placed over the lower blade and clamped in position by the hydraulic cylinders. The upper blade is driven down into the metal sheet at an angle known as the rake angle. This results in a clean and accurate cut on the metal sheet.
Types of Shearing Machines
Shearing machines are classified based on their cutting tools and power generation methods. Broadly speaking, the main categories are pneumatic, hydraulic, mechanical, and manual shearing devices.
Manual shearing machines are hand-operated cutting tools. The operator exerts physical effort to move the blade up and down. They are simple to operate and budget-friendly. However, they are unsuitable for complex cutting tasks.
Mechanical shearing machines have a flywheel in addition to the motor. The motor powers the cutting edge, while the flywheel reduces the motor’s energy consumption.
Hydraulic shearing machines use oil stored in hydraulic cylinders for power generation. Hydraulic pumps supply the energy required to operate the blades. This is further categorized into guillotine and swing beam shearing devices. The tool rest is oscillated during the cutting procedure of a swing beam shearing machine. Guillotine shearing machines employ a vertical assembly of an upper and lower blade to cut metal.
A pneumatic shearing machine is similar to a hydraulic shearing machine but uses air pressure instead of oil to power the cutting assembly. The pressurized air is stored in gas cylinders and generates energy by powering hydraulic pistons.
Advantages and Disadvantages of Press Brakes and Shearing Machines
Now that we know a little bit about these versatile industrial tools, let us analyze their strengths and weaknesses.
Advantages of Press Brake
Press brakes are specialized industrial tools that excel in providing high precision in sheet metal bending operations. They can drastically improve factory output compared to manual bending.
A press brake allows you to work with several kinds of metals. Working with harder metals requires greater tonnage, achieved by an appropriate punch and die combination.
CNC press brakes boost factory production in several ways. With the use of Human Machine Interfaces, they are easy to use. They are able to perform complex bending operations in rapid succession. They are particularly useful for meeting batch production requirements.
Press brakes also offer different bend types. Choosing the appropriate bends can reduce operational costs and achieve complex results. The bending options available to manufacturers are air bending, bottom bending, and coining.
Disadvantages of Press Brakes
Press brakes are complex devices with heavy machinery and working parts. They are challenging to operate and service. Skilled operators are required to work the machine. Bending operation is more complex than cutting, requiring planning and design.
Press brakes are also energy-intensive. The tonnage required to shape hard and thick metals requires more energy. The generation of this force, in turn, demands a lot of power consumption.
Advantages of Shearing Machines
Shearing machines are fast and efficient at cutting metals. They are well-suited for large product batches and can process various materials. Shearing machines can cut ductile metals like aluminum and harder ones like stainless steel and copper.
Shearing is a low-temperature process that keeps tools safe from overheating.
These machines are easy to operate and maintain. They can drastically increase the production rate in workshops. The initial investment is high but covered by profits from high product output.
Disadvantages of Shearing Machines
Shearing machines may be inadequate for cutting super-hard materials like tungsten, and the blade may chip or crack.
They are repetitive machines with just a single operation mode. This means that they can only cut in straight lines.
The cuts made by shearing machines are not free of deformation. They leave burrs and irregularities at the edges of the workpiece, which makes them unsuitable for applications that require perfect edges.
Press Brake and Shearing Machine: What is the Difference Between Them?
Having reviewed the fundamentals of press brakes and shearing machines, let’s dive a bit deeper. We will discuss the different aspects of these two industrial juggernauts in detail.
Working Principle
Press Brake
A press brake bends metal by exerting vertical force on it. The workpiece is placed on the workbench between the punch and die. It is aligned using the back gauge. A punch and die combination is selected based on the tonnage required to bend the sheet. When the operation begins, the punch slams into the die and shapes the workpiece at the desired angle. After completion, the operator removes the workpiece and inspects the angle made by the press brake.
Shearing Machine
A shearing machine cuts metal pieces by applying shearing force. It contains two blades placed roughly perpendicular. The operator sets the rake angle before operating the machine. A positive rake angle is used for ductile metals, while a negative rake angle is used for brittle metals. Hydraulic cylinders clamp the workpiece in position. The back gauge precisely aligns the workpiece. The operator sets the blade clearance and starts the procedure using the control panel. Upon completion, they inspect the metal using measurement instruments.
Structure
Press Brake
The press brake is composed of an outer frame that holds the machine parts. The workbench is in the middle section. It holds the punch, die, clamps, and supports. The upper section consists of the ram, motor, flywheel, or hydraulic cylinders. The lower portion consists of the bed, which holds the die and the workpiece. The back gauge is behind the die.
Shearing Machine
The shearing machine comprises an outer frame, a work table, vertical and horizontal shearing blades, cylindrical clamps, baffle guards, a control system, and electricals. A motor is present to convert electrical energy into mechanical work. Depending on the type of shearing machine, it may use a flywheel, hydraulic pumps, or pneumatic pumps. The workpiece is held in position using cylindrical clamps. Vertical shears perform the cutting.
Application
Press Brake
Press brakes can build automobile doors, bumpers, chassis, body parts, and panels.
They are important manufacturing tools in the construction industry, which requires many metal sheet products, such as beams, decks, and facades.
Furniture factories use press brakes to manufacture cabinets, doors, metal frames, brackets, and reflective surfaces.
The aerospace industry requires metal sheet work of aluminum, titanium, and stainless steel. It requires press brakes for precisely manufacturing parts like body frames, turbines, and engine covers.
The electronics industry requires press rakes for precise and detailed metalwork. They are used to manufacture CPU frames, laptop bodies, TV cases, stands, etc.
Shearing Machine
Shearing machines are a blessing for metalworking factories and workshops. They offer fast, efficient, and cost-effective metal plate cutting.
Aeronautic manufacturers use shearing machines to cut high-strength aluminum and titanium plates.
Shearing machines enable cutting and shaping metal sheets in the automotive sector. They are used in manufacturing doors, handles, body frames, interiors, etc.
Shearing machines are widely used in the shipbuilding industry. They cut stainless steel and carbon steel sheets for use in ship hulls and bodies.
In industries requiring large batch processing, shearing machines are the ideal choice.
Which is Better, the Press Brake or the Shearing Machine?
Are you still considering which of these two machines is better? The following points will help you decide:
Do you want to bend or cut?
Fundamentally, the choice between a press brake or shearing machine will come down to this question. Do you want to bend or cut metal? If you want to bend metal, then press brakes are better for you. Shearing machines cannot perform metal bending. However, if you primarily want to cut metal sheets, go for the shearing machine.
Faster operation or precise control?
Shearing machines are fast, efficient, and cost-effective industrial tools. They make processing large batches of parts easy. However, shearing machines leave burrs and irregularities at the edge of the workpiece. They also do not offer a high level of precision.
Press brakes are slower, more complex, and expensive. However, they are highly precise machines suitable for smaller product batches and complex metal-forming tasks.
Versatility
Press brakes enable fabricators to achieve a variety of metal-forming goals. They can bend metals like aluminum, iron, and stainless steel to achieve various angles and profiles.
Shearing machines are simpler in their performance. They can only create linear cuts on metal sheets. In terms of metal variety, they can work with a broader range of brittle metals like copper, bronze, carbon steel, and stainless steel.
Cost
The press brake is an expensive industrial device that requires a substantial initial investment. Its operational cost also varies according to the tonnage. In addition, press brakes require skilled operators to run them.
Shearing machines have lower initial investment and operational costs than press brakes. In addition, they do not require highly skilled operators to run.
Conclusion
The press brake and shearing machines are indispensable tools for industrial manufacturing and secondary processing. They have distinct features and applications.
If you require a tool that can help you cut a wide range of metal sheets and process large batch sizes, go for the shearing machine. Go for the press brake if you want to bend metal sheets and create complex structures like boxes, lids, panels, and frames.
Do you have questions about these machines? Contact us! Our professional team would be happy to consult you on metalworking machines.