Press brake malfunctions: How to identify and avoid them

How to detect

Workers can detect over deflection when a larger angle is visible in the centre of long parts and at its ends. The only solution is to re-machine the bed, the ram, or both.

Ram drifting

This is a specific problem for hydraulic press brakes. Since hydraulic press brakes have become a common choice for manufacturers worldwide, this is a problem that often occurs in production shops. Ram drifting means that there is an internal oil leak in a cylinder of a hydraulic press brake. What happens is that when the machine stops and the ram is raised and left under pressure while the power is off, it drifts down on one or both ends.

How to detect

When only one cylinder is affected, the ram will drift on that side, becoming non-aligned with the bed. So, if you have the upper and lower side of the press brake out-of-parallel, they are not synchronised and precise when working.

You can solve this by replacing the internal oil seal to stop the leak. It is essential to stop the leak on time, as it can travel in other parts of the machine and affect it greatly by decreasing the bending pressure in the cylinder. To prevent non-alignment from happening in the future, workers can place a block under the ram after shutting down the machine.

Another problem that may occur with the ram in hydraulic press brakes is the adjustment of ram tonnage. Many workers don’t adapt the tonnage according to the workpiece by over concentrating the load. Some press brakes have an adjustable tonnage feature, and if your machine has it, too, it is better to take advantage of it.

Press brake Tooling complications

Press brakes have several tool changes to carry out their whole array of processes. When working with tools, workers can stumble upon three problems that can all sort out more training and better collaboration with the machine. Better use and knowledge can prevent these complications from happening and lead to a more healthy and long-lasting machine.

Misalignment

As we mentioned earlier in this article, not aligning the punch correctly and die in the same plane harms the precision and accuracy of the production. Misalignment also affects the flange width. The back gauge is positioned from the centre of the die, while the centre of the punch determines the final flange width. The punch position is fixed, while the die position is adjustable to the centreline of the punch. When the die or the die rail move, then misalignment happens.

Worn out Tooling (exhaustion)

When workers conduct most of their work at the same place of the bed, the wear leads to erratic bends. In a press brake, the parts that are most prone to wearing out are the nose of the punch and the shoulders of the die. Worn tooling crooks the flanges and inconsistency in bending operations. Make sure to conduct weekly and monthly inspections of your tooling and re-machine if needed.

Wrong tooling in press brake operations

Every workpiece has its specifications, so it is vital to know what we’re dealing with before starting an operation on the press brake. According to the part’s specs, workers need to implement the right tooling. This is very important not only in the effectiveness of the bend but also in the longevity of the machine parts. Make sure your press brake operators know the features and the machine’s model to use compatible tooling and prevent damages.

When you purchase an RS machine, we make sure to help you determine your press brake’s benefits and features and guide you for better operations and maximum output. If you’re interested in more information, please contact us, and our sales team will help you out.

Press brake Maintenance

Some other complications happen because of infrequent maintenance, like improper lubrication or negligence in cleaning. It would help if you lubricated moving parts frequently and properly, according to the machine type. Skipping lubrication can make the parts freeze or worn out to the point where you need to replace them inevitably.

Lubrication and keeping a clean machine are crucial steps to avoid bigger problems. By not cleaning press brakes or any other machine in general, dirt and external particles gather in different areas, causing excessive wear, scratching parts, or in the worst cases, lead to machine breakdowns.

After lubricating, you should clean the machine, as too much oil makes dust easier to stick. Proper maintenance is healthy for the machine’s performance, reduces downtime and makes operating the machine easier.

To conclude

Malfunctions are always a part of workshops and production plants. If you plan on investing in a new press brake, make sure to rely on a manufacturer that will help you through your journey until the final purchase.

We at RS Machinery have crafted a beneficial experience that will guide you and train your team on how to get the most out of your machine. Feel free to contact us for more information regarding our press brake catalogue.