A press brake is an essential tool in the metalworking industry, primarily used for bending sheet metal. By selecting and utilizing various dies, it can bend, stretch, round, and punch metal sheets. Widely used in light industries, aviation, shipbuilding, metallurgy, instrumentation, electrical appliances, stainless steel products, steel structure construction, and decoration industries, press brakes play a critical role in manufacturing. This article will guide you through the safe and effective operation of a press brake.
Overview of Press Brake Operations
1. Turning on the Press Brake:
- Connect the power supply.
- Open the key switch on the control panel.
- Press the oil pump start button to begin operation.
2. Adjusting the Stroke:
- Always test the machine before starting a bending operation.
- Adjust the stroke to ensure there is a gap equal to the thickness of the sheet metal between the upper die and the workbench when the upper die is at the lowest point.
- Stroke adjustments can be made using electric quick adjustments and manual fine-tuning.
3. Selecting the Die Slot:
- The width of the die slot should be eight times the thickness of the sheet metal.
- For example, if bending a 4mm sheet, select a die slot approximately 32mm wide.
4. Adjusting the Back Gauge:
- The back gauge can be adjusted using both electric quick adjustments and manual fine-tuning, similar to the settings on a shearing machine.
5. Starting the Bending Operation:
- Use the foot pedal to control the bending process.
- The press brake can stop at any time by releasing the pedal and will continue bending when the pedal is pressed again.
Safety Procedures for Operating a Press Brake
1. Pre-Operation Checks:
- Adhere strictly to machine safety operation procedures.
- Wear appropriate personal protective equipment.
- Check the motor, switches, wiring, and grounding to ensure they are functioning correctly.
- Ensure that all control elements and buttons are in their correct positions.
2. Machine and Die Inspection:
- Verify the alignment and stability of the upper and lower dies.
- Ensure all positioning devices are set according to the processing requirements.
- Run the return-to-origin program if the upper slide and positioning axes are not at their starting points.
3. Initial Operation:
- Run the machine idle for 1-2 minutes.
- Move the upper slide through its full range of motion 2-3 times.
- If abnormal sounds or issues are detected, stop immediately to investigate and resolve the problem before resuming work.
4. Operational Safety:
- Ensure one person directs the operation to maintain coordination among all personnel.
- Firmly press the sheet metal to prevent it from lifting during bending, which could cause injury.
- Cut off the power before adjusting or changing dies.
- Ensure no materials are in contact with the lower die when changing the die opening.
- Do not allow anyone to stand behind the machine during operation.
- Avoid bending overly thick or high-strength materials that exceed the machine’s capacity.
5. Post-Operation:
- Regularly check the alignment of the upper and lower dies.
- Verify that the pressure gauge readings meet the specified requirements.
- Place wooden blocks under the lower die and lower the upper slide onto them before shutting down the machine.
- Exit the control system program and then cut off the power supply.
Setting Up Dies on a 530 System Press Brake
1. Machine Preparation:
- Clean the machine thoroughly to remove any dust, metal shavings, or other debris from previous operations.
- Check the die thickness and ensure the upper and lower dies are proportional and properly aligned.
2. Adjusting Die Position:
- Raise the upper die to its highest position.
- Set the limit switches correctly to maintain die positioning.
3. Measuring and Adjusting Die Gaps:
- Measure the gap between the upper and lower dies.
- Adjust the gap as needed to ensure proper bending.
4. Setting Bending Angles:
- Set the bending angles to ensure they are greater on the sides than in the middle.
- Use a pressure gauge to calculate the correct pressure needed to avoid damaging the dies.
FAQs
What is the first step in operating a press brake?
The first step is to connect the power supply, open the key switch on the control panel, and start the oil pump.
How do you adjust the stroke on a press brake?
Adjust the stroke to ensure a gap equal to the sheet metal thickness between the upper die and the workbench when the upper die is at its lowest point. Use electric quick adjustments and manual fine-tuning.
Why is it important to firmly press the sheet metal during bending?
Firmly pressing the sheet metal prevents it from lifting during bending, which can cause injury and result in inaccurate bends.
What should you do if abnormal sounds or issues are detected during operation?
Stop the machine immediately to investigate and resolve the issue before resuming work.
How do you set up dies on a 530 system press brake?
Clean the machine, check die alignment, raise the upper die, measure and adjust the die gaps, and set the bending angles to ensure proper bending.
Conclusion
Operating a press brake safely and effectively requires careful setup, precise adjustments, and adherence to safety procedures. By following the steps outlined in this guide, you can ensure accurate and consistent bending operations while maintaining a safe working environment. Regular maintenance and proper handling of dies will also extend the life of your press brake and improve productivity.
