The choice between press brakes and rolling is a big decision that needs to be considered with many factors. The method of production you choose will usually depend on which method will give you a quality result at the lowest possible cost.
We will give you some details about press brakes and rolling and we will consider some aspects that you need to consider before deciding on a sheet metal production method. Hydraulic Press Brake
What is a pressure brake?
Compression braking is the process of deforming a metal that aligns a piece of sheet metal or sheet metal to an axis. This is achieved by using a machine pressing tool (press brake) to clamp a metal piece between the punch and a set of dies for pre-prepared bends.
The pressure brake ensures very precise metal bending for certain types of parts. The pressing process has different shapes, some of the most common shapes are 90 ° rib shape, bottom V, channel, closure, double shape, hat channel, offset, open hat channel, etc.
Some types of press brakes include:
Mechanical press brake: Designed to convert circular movements into linear motion.
Pneumatic press brake: acts by air pressure to move the ram. Hydraulic press brake: Hydraulic oil and a hydraulic pump are used as the energy source.
Servoelectric press brake: Uses a servomotor that forces the ram to move vertically.
Marlin Steel uses the Trumpf TruBend 5230 hydraulic press brake for faster precise sheet metal turning.
What is Roll Forming?
Rolling is a type of metal bending in which long strips of sheet metal are continuously rolled to fill the desired cross-section. The blade edge passes through a set of rollers, which are usually mounted on two stands.
Each set of rollers forms another part of the bend until the ideal profile is reached.
Roll shaping is a simple process by which complex shapes can be created. It has always been a cost-effective and sensitive alternative to stamping and pressing.
The types of rolling machines include:
Single-purpose roll forming machines: Use strategically placed rollers to machine a specific cross-section of the profile attached to each spindle. Standardized rolling machines: Uses outbound support that is easily accessible to operators. The spindle can be easily removed.
Side-by-Side machines: Equip multiple profiles with different rolling tools.
Double-headed machines: consist of two separate sets of rolling shafts and housings.
Raft motors: Cabinet and spindle shafts with standard rolling valves are available. 4 factors to consider when choosing a production method
Here are four things to consider before deciding between press brakes and rolling.
The length of your parts is important for the production method you choose. Higher parts are best used when rolling over press brakes. This is because press brakes are not able to produce higher parts. The press brake material must be cut, covered and cut lengthwise before being inserted into the press. Tall parts, such as a slot coil, can be added directly to the rolling line.
2. Metal Fabrication Design
Before choosing a production method, think about your production design and the shapes you will need. Pressure braking and rolling go through different processes, and each process has a different duration depending on the complexity of the shapes you bend. For example, the pressure brakes can only handle a certain number of revolutions and each requires a separate intervention. But rolling can create complex linear shapes in a single stream, reducing production time and costs.
Other manufacturing processes work better on specific materials. The material you choose will make the most of your production process and can even save you money. Pressure braking and rolling can be lighter materials such as flat rolled steel or high strength low alloy steel (HSLA). The high-strength material makes it difficult to maintain the shape of the brake and cylinder.
4. Tool costs
The application costs are always the same between press brakes and rolling. The price usually depends on the type of project you are doing. In general, the larger the volume you use to create a roll, the lower the cost of the tools for each piece. If the volume is small, then it is probably the cheapest option to press the brake tool.
How do panel benders differ from pressure brakes?
While the press brake has been a bending machine for many years, depending on the component, the panel bender can have many advantages over a traditional press brake.
The most visible difference between a press brake and a panel bender is in the physical way of bending the sheet. In a traditional hydraulic press brake, the clamps secure the hinges used to hold the upper punch and lower attachment with a V-die. The punch comes to the plate to create a bend in the V-shape using the operator on the foot pedal. V-dies, the most common type of die, have different hole sizes depending on the sheet thickness and the required radii and bending angles. There are many other specialists who have died, which may be necessary depending on the job. Similarly, it may be necessary for the punch to differ from a standard punch, such as a gooseneck to form a U-profile, or a narrow punch if space is limited when performing the final bend.
However, investing in various tools can be costly and hamper the project. In addition, the crimping tool needs to be replaced over time because the tool wears out and changing tools for different parts can also be laborious and time consuming. The panel bender works differently and will probably be automatic. At the panel bender, the blade is held firmly by a counter knife and an empty holder. The machine has high and low universal bending knives that generate a lateral bending force to fill the sheet. Because countersinks, blade holders and bending blades are more versatile, they can be adapted to the size and thickness of the material, eliminating tool change and slight production interruptions between orders.
In addition to the tool’s advantage, the panel bender has the advantage of a traditional brake pedal in terms of speed, flexibility and consistency. Both benefit from CNC functions, but press brakes require manual sheet metal handling from bending to bending. Large boards can be difficult for operators to maneuver or require many people to complete a turn. Operator fatigue can also affect quality and efficiency.
In contrast, the panel bender uses a side manipulator to move the metal. Once the blade is inserted against the positioning device, the entire piece is formed without the operator having to reach it until it is ready. Intelligent sensors measure thickness, material size and ambient temperature and adapt the panel bending tool to changes, eliminating punctures, errors and defects.
The Bender panel can rotate a part two to three times faster than a brake pad and has a much higher consistency. For example, the Salvagnini P4 Panel Bender can complete an average of 17 revolutions per minute. The automation of this machine also allows you to turn off the lights when strict deadlines are required.
One problem that has arisen with press brakes eliminated by bending panels is rear cornering. Back-bending results from the material behind the press as the mold runs, which usually leads to whipping as the material attempts to catch up with the press. Reversing is more common on very large panels, where the operator cannot keep up with the speed of the press because the material is lifted manually during the forming process itself. The result is a slight inverted bend or bend at the edge of the animal.