Ensuring the quality and accuracy of press brake operations begins with the proper inspection and adjustment of the bending dies. This article provides a comprehensive guide on inspecting new dies and adjusting old dies for optimal performance.
Inspection of New Dies
Before using new dies in a press brake, it is essential to conduct thorough inspections to ensure they meet the required standards. Here are the key inspection steps:
Flatness Inspection
1. Using a Feeler Gauge: Measure the flatness of the die surface. The permissible bend is between 0.2mm to 0.3mm.
2. Using a Vernier Caliper: Measure the flatness more precisely, with an allowable bend of up to 0.03mm.
Height Consistency Inspection
1. Using a Vernier Caliper: Measure the distance from the force plane to the tip of the die. The allowable error is 0.03mm.
Straightness of the Cutting Edge
1. Manual Inspection: Touch the joints of the die segments to ensure the cutting edge and the bevel are flush.
2. Test Bend: Bend a long piece of sheet metal and inspect the joint area of the die segments for any indentations or misalignments. Ensure the bend line is straight.
Adjusting Old Dies
When using old dies, they must be checked and adjusted to ensure they still provide accurate bends. Here are the steps for adjusting old dies:
Aligning the Cutting Edge
1. Check for Consistency: Ensure that the cutting edge of the upper and lower dies are aligned. If not, regrinding may be necessary.
2. Inspect for Inconsistencies: Look for the following issues and correct them as needed:
- Inconsistent thickness and size of the cutting edge.
- Uneven clamping surfaces and force planes.
- Inconsistent distance from the force plane to the tip of the die.
- Bends in the plane.
- Overall straightness discrepancies.
Adjusting the Template
If there is a height discrepancy in the upper die, use the template adjustment to correct it.
Setting Up Press Brake Dies
Proper setup of the upper and lower dies is crucial for achieving precise bends. Here’s how to correctly set up the dies:
Setting the Height of the Protrusion
1. Positioning the Upper Die: Stop the upper die at any position.
2. Insert a Spacer: Place a part that raises the upper die by 10mm between the upper and lower dies.
3. Adjust Protrusion Height: Adjust the height of the protrusion to ensure the part is clamped securely without compromising the quality of the bend.
Setting the Angle of the Lower Die
1. Rotate the Lower Die: Adjust the lower die to the required angle.
2. Maintain a Small Angle: Keep a slight angle to ensure the accuracy of the bending angle.
3. Pre-Processing Calibration: Calibrate the angle of the lower die before each processing operation.
Setting the Distance Between Upper and Lower Dies
1. Adjust Based on Material Thickness: Set the distance according to the thickness and strength of the material being processed.
2. Control Bending Angle: A larger distance results in a smaller bending angle.
3. Depth of Lower Die: Control the bending degree by adjusting the processing depth of the lower die.
Common Parameter Settings Reference
Here are some typical parameter settings for a press brake:
| Parameter Type | Parameter Name | Unit | Default Value | Range |
|---|---|---|---|---|
| Bending Angle | Bending Angle | Degrees | 90 | 0-180 |
| Bending Speed | Downward Speed | mm/s | 100 | 0-1000 |
| Bending Speed | Return Speed | mm/s | 100 | 0-1000 |
| Pressure | Pressure | MPa | 10 | 0-100 |
Conclusion
Proper inspection and adjustment of press brake dies are critical for maintaining high-quality bending operations. By ensuring that both new and old dies meet stringent standards and are correctly set up, operators can significantly improve the precision and efficiency of their work.
Key Takeaways
- Inspect New Dies: Conduct thorough flatness, height consistency, and straightness inspections.
- Adjust Old Dies: Check and correct any inconsistencies in alignment and condition.
- Set Up Dies Correctly: Adjust the height, angle, and distance between the upper and lower dies based on material specifications.
By following these guidelines, operators can ensure that their press brakes perform optimally, producing precise and high-quality bends consistently.
