RS Machinery Group

How to choose the right press brake based on your production volume

Choosing the right press brake is a journey that requires knowledge, experience, research, and setting clear goals. Finding the right machine and then finding the right manufacturing company are two key stages that will determine the product you’ll end up with.

In our previous articles we have talked about the three factors you need to consider before making your final decision. We explained the importance of the material you work with, the nature of operations you undertake in your plant, the tonnage, and tooling. Today, we will dive further into this topic.

Let’s discuss some press brake selection criteria based on your workspace and workload.

 

Configuration

A factor you should consider is the setup and configuration of the press brake. A typical setup procedure starts with planning and reviewing the drawing, which presents what operations you will perform. Then, you select the right tooling and determine the tonnage or required bending force. (we have talked about tooling and tonnage in our previous article; read more here)

After these first steps, you choose the press brake that fits the task, implement the tooling and position on the bed, and finally program. The desired product will turn out if all these steps are taken correctly before running parts.

Depending on what you want to achieve, there are different configuration types. For example:

    • the tandem press brake

This press brake is suitable for long and thick parts. Tandem press brakes are a combination of two press brakes synchronized to perform aligned operations. If you have to deal with large, thick metal parts and have quick turnover times, you might consider this type of press brake for your workshop. But this doesn’t mean that they can’t handle small materials. The main advantage of tandem press brakes is that you can use them separately for shorter pieces.

    • the robotic press brake

This type of press brake is extra automated with robots that help the bending process. Paired with a robotic system, press brakes can automatically decide on the right bend, releasing the need for an operator to determine it. Robots can detect the type of material produced, the specs of the sheet metal part, and the production volume, resulting in increased productivity on the shop floor.

Press brake Tooling

We have mentioned tooling several times as a crucial factor to carry flawless press brake operations. Furthermore, they greatly affect production time too. If you have a big production volume, pay attention to your operators’ tools.

For faster tool changing, consider hydraulic clamping, as they are easier to replace and implement. Make sure to respect the rules on what tools to use every time. Even if tool changing looks like it will waste time in production, the right toolset will give you a more accurate product that will require less running in the machine for perfecting.

The best tools need to have around a 0.0004-inch range of tolerance. Also, the workflow should install tools from the front of the machine, reducing setup time.

Working area

Another problem is planning to buy a new and advanced press brake without being mindful of the space that you have available in your workshop. Before deciding on a press brake, think about:

  • the square area available in your workshop
  • where exactly are you going to place it/how much do you have to alter the workshop (as every machine system needs to stay close to complementary machines)
  • how much workspace is left for your operators to move comfortably around the workshop

Daylight

Also called “open height”, this factor can influence or determine the brake of your choice. It is the distance between the upper beam where the punch is incorporated and the table’s surface. Some operators consider “daylight” the distance between the upper beam and the bottom of the die. Discuss with your press brake provider to clear this up beforehand.

When considering this factor, make sure to opt for a big enough opening that operators can easily install and extract the big tools. As we said earlier, this process should be done from the front, so this is a criterion too. If you typically bend large parts, a standard opening won’t be effective.

If you need a press brake with a customized open height, you can order it at your chosen manufacturer. RS Machinery provides customized sizes for every type of machine according to our client’s specific needs. If you want to learn more or order your personalized press brake, contact our team here.

Technology

Today’s automation has helped to increase the production speed and the quality of performance drastically. When searching for a new press brake, have a look at these features:

    • setup time

Automated press brakes need fewer manual setups.

    • quality control

Advanced quality control means fewer mistakes, more accuracy, and faster turnover.

    • software

Chose a system that can take autonomous decisions and needs minimal operator overseeing.

Think Green

If your plant has a high production volume, consider investing in a green, safe choice for the environment. The manufacturing industry is one of the biggest polluters, producing everyday hazardous waste that affects the quality of our surrounding environment. Think about an option with less energy consumption, less oil waste, or less noise. Try to contribute by making a healthier choice with this investment. Our Morgan Rushworth machine systems have:

  • Approx. 50% less energy use
  • Approx. 30% faster cycle times
  • Approx. 75% less servicing costs than hydraulic machines
  • Quiet operations

Finding the right press brake is a process where several variables have to be taken into consideration. These criteria will help you have a clear vision and direction when starting your purchasing journey. 

Get in touch with our technical sales team, and we will provide you with more information.

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