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Advanced

Press Brake Technologies


John Kemp
Bystronic, Inc.

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
FABTECH Canada 2014

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)

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)

In this formula to assess the k-factor,


what 4 variables are missing?

Punch radius

Material type

Die Radius

Bend angle

What difference does this make?


Example:
Material Type = Cold Rolled Steel
Material thickness = .060
Bend angle = 90 degrees
Punch 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!

Thickness ForceTPF
24ga.023"
3
20ga.036"
4
18ga.048"
6
16ga.060"
8
14ga.075"
14

C
.125"
.125"
.137"
.137"
.188"

ForceTPF
10
11
15
16
20

D
.046"
.072"
.096"
.120"
.150"

Modern tooling and machine features minimize setup times

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.

What to look for?

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.

Thank
You
John Kemp
Bystronic, Inc.

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