HARSLE offers a wide range of automation productions. Yet, despite the fact that the machine does the hard work, the human factor matters to gain the most of the automated production. For instance, CNC system has been the norm for press brake machines ensuring high levels of accuracy, which is impossible in case of manually handled systems.
However, no matter how accurate this system is when it reaches certain bending angles, they still need the contribution of human operators to realize how to bend deeply. Skillful experience is needed to understand how various metal alloys get in the reaction with bending applications as well as the complications connected with the CNC press brakes to gain the most of the machines preventing wastes. The following factors determine the essence of experienced and trained operators.
1. Determining Bending Inner Radii.
Some restrictions exist on the metal bend tightness prior to its breaking. One more factor affecting bending is the back spring, that is about how much metal pieces bend back upon being exposed to bending.
At this point CNC brake operators` work gets double complicated:
- Certain restriction exists on metal bending deepness.
- Operators must consider the return in metal forms, making the primary bending deep for compensation. Operators have to determine the inner radii of every bending to prevent metals from breaking and to make the back spring effects slight providing proper tolerance for work pieces.
For various metal materials possess different tightness level and extensible force, compensating the mentioned factors will be quite challenging for a person with little experience and practice. Here is an offered list of formulas on spring back calculation for various metals:
[(Inner radius in mms/2)/
Material thickness in mms] x extensible factor
Extensible factor = Material extensible force in PSI/60,000
In case of less than 100 percent precision, these formulas will provide proper estimation of back spring for many materials.
Much more mathematics exists in this procedure, though it gives you a common idea of how complicated the task of calculating the internal bending radius of sheets is, that CNC press brakes can`t carry out for operators.
2. Calculation Tonnage Restrictions for Press Brakes
CNC press brake operators with little or no experience and training will overload and finally damage the machine.
I will refer to the case when store used the entire tonnage of a 600-tons press brake for 8 inches. part in the center of the machine. This brought to a serious plunger distortion (constant deformity) in the plunger core. Producing total strength on the area causes tonnage increase in inch limits leading to distortion. How is tonnage for each inch calculated? The side beam distances must be multiplied and have the outcome divided by the equipment tonnage. Thus, in case press brakes of 600 tons and 10 feet amongst the side beams of the brake, 120 inches should be multiplied by 60 percent, the outcome will be 72 in. Then 600 tons should be devided by 72 in. and you will get 8.3 ton for each inch. This implies not applying strength above 66.6 tons for 8-inch parts.
3. Equipment Maintenance.
A press brake machine may function long hours with no break. Yet, it needs to be cared and maintained regularly to work at its top of capacity. Hydraulic system requires changing oil and filters, the equipment must be cleaned from dirt, machine parts require lubricating. Machine level should be regularly checked and adjusted to produce proper bending.
Operators must be aware of various applications their machine is able to carry out as well as tools needed for various operations. Tools also require careful maintenance, since no proper part is possible to produce if tools are improper.
Thus, properly experienced and trained knowledgeable operators are capable of accounting for such important factors as:
- Tightness of materials
- Phenomenon of back spring in bend for variously thick metal materials
- Part tonnage limitations
- Maintainaing of the machine.
All these ensure precise bending of parts through press brakes from the very beginning and reduce the tuning and maintenance time.