Plate bending machine VS Pres brake in forming automation

Different specs, different forming automation systems. This is the rule you must take into consideration before fabrication. There are certain factors that affect your choice of machinery, two of the most important being the highest quality, and the better cost per time.

Both press brakes and plate rollers are able to handle many materials, create several shapes, and produce mar-free, aesthetically pleasing products. Press brakes can work with acute, 90, and large angles. Accompanied by the right tooling, they can form thin and thick materials, even roll cylinder shapes. So why plate rolling machines are still needed?

In this article, we will specify what forming automation system is better for you, according to these variables.

Material Design

One of the main differences between press braking and roll forming is that the first one is a one-hit process, whereas a plate rolling machine can bend materials with one passing or multiple passings through the roll.

Because of this fundamental working principle, complex works and cross-sections would finish faster in a plate rolling machine, while the press brake would need more time. If you were to do complicated shapes with a press brake it would require too much time, slowing the production down and raising costs.

Press brakes can do a limited number of bends, and each of them requires a separate hit. On the other hand, roll forming can bend the material progressively, meaning it can form complex linear shapes in a single pass. This reduces the costs and downtime dramatically. Roll forming eliminates several steps of metal processing, improving lead times and efficiency.

Workpiece length

Press brakes can’t handle long parts. This is a derivative of the problem we mentioned earlier. Because press brakes work with separate hits and long parts require secondary operations, press brakes manufacturing a long workpiece means increased costs and product labour, as it increases product weight. In a roll forming machine, long workpieces can go into fabrication without fasteners. The production is also less wasteful, as it produces fewer scraps.

After the length part, think about other specifications like yield and tensile strength, thickness, radius, etc. You will consequently learn what is the needed pressure for this operation and the deflection rate to be expected.

Another difference between these machine systems is how you are supposed to feed the workpiece. To work metal in a press brake, it has to be sheeted, slit, and cut to length. So there is a number of pre-fabrication operations to be completed which take time and additional costs. Meanwhile, in a rolling machine, you can insert a slit coil directly.

Material Selection

What material you choose determines how manufacturing is going to turn out and how much money are you going to save or spend in the process.

Press brakes and rolling machines both can form lighter metals. These type of materials are a good choice because they use less content and are very durable. This feature helps to maintain the structure of the material and allows dropping gauge. Press brakes find it difficult to process high-strength material because they can’t control spring back very well.

Material selection is crucial, especially on large radii workpieces, as spring-back and radius go hand in hand. Large radii amplify spring back and other variables. Look for consistent material, that will help you achieve consistent results.

Deflection

Deflection is the degree to which a structural element is displaced under a load. Crowning methods account for machine deflection, which means that when deflection occurs, the pressure disbalances, creating a deflection control or “compensation”. This is a much-needed upgrade for operators, and it has improved considerably the bending accuracy, in both press brakes and plate rolling machines.

In press brakes, crowning happens with the help of strategically placed wedges below the press brake bed or hydraulics. In roll forming, the crowning is in the rolls. A crowned roll has a slightly larger diameter in the middle. Dynamic crowning systems are now available, integrating pressure detecting sensors that perform the compensation automatically.

Tooling and Amortization

The cost and variety of tooling cannot be measured by comparing the machine type, as it is something that has to do more with the specs of the project. However, if we are asked to make an estimate, tooling costs are almost the same. Then it all depends on the volume.

Besides tooling expenses, there are other added costs that come to play, like amortization costs. Amortization allows you to keep full ownership of your tooling. This will help you as you won’t have recurring payments, and you will be able to use them anytime, for every task, guaranteeing a fast ROI.

Best of both worlds

When comparing these two machines, we cannot forget to mention that there also exists a mix between press brakes and rolling machine, called the press roll bending machine. This model has normally six rolls, divided equally in top and bottom rolls, that work synchronized in forming operations.

But the options are not limited to press brakes, plate rolling machines, and their hybrid version. Manufacturers use also metal folders, panel benders, and other forming machine systems. The ultimate choice will also be the most efficient and effective machine of all.

Conclusion

Plate rolling machines and press brakes each have their highs and lows. Roll forming promises speed while press brakes promise versatility. In the end, think about what’s important for your plant. Which machine from the two will raise the bar for better performance?

Before making your final decision, we advise you to take a professional’s opinion from a trusted manufacturer and distributor.

To discuss in detail, schedule a call with us.