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Common faults and solutions of press brakes

Common faults and solutions of press brakes

Press brakes are a common metal processing equipment, often used to bend and form metal sheets. However, during use, press brake may have some common faults. This article will analyze these faults in depth and provide corresponding solutions, hoping to help the majority of users. Possible causes of inaccurate bending angles:The angle adjustment device of the press brake is damaged or unstable, and the operator operates improperly.Solution:First, check whether the angle adjustment device is damaged. If damaged, it should be replaced or repaired in time. Second, the operator should be familiar with the use of the press brake to ensure accurate operation. 2. Possible causes of wrinkles after bending:The upper and lower molds of the press brake are not symmetrical, the material is too thin or too hard, and the bending speed is too fast.Solution: First, adjust the symmetry of the upper and lower molds to ensure their flatness. Second, for thinner or harder materials, you can increase the upper mold strength or reduce the bending speed to reduce the generation of wrinkles. 3. Possible reasons for abnormal noise or vibration of the press brake:The base of the press brake is not stable, the upper die is not fixed firmly, and the mechanical parts are worn.Solution:First, check whether the base of the press brake is firm. If it is not firm, adjust or fix it.Second, check whether the upper die is installed correctly and check whether the fastening bolts are loose. Finally, regularly inspect and maintain the mechanical parts, and replace them in time if they are worn. 4. Possible reasons for the press brake to fail to start or stop:Poor contact of the power cord, damage to electrical components, and control system failure.Solution:First, check whether the power cord is in good contact. If there is a problem, it should be repaired or replaced.Second, check the electrical components and replace them in time if they are damaged.Finally, if there is a control system failure, professional technicians should be asked to repair it. 5. Possible reasons for insufficient or excessive pressure of the press brake:Failure of the hydraulic system, insufficient or contaminated hydraulic oil, inaccurate pressure regulating valve.Solution:First, check whether the hydraulic system is working properly. If there is a failure, contact professional technicians for repair.Secondly, check the quality and level of the hydraulic oil. If there is any problem, it should be replaced or added in time.Finally, adjust the pressure regulating valve to ensure that the pressure of the press brake is within the specified range. In summary, the common faults of the press brake mainly include inaccurate bending angle, wrinkles after bending, abnormal noise or vibration, inability to start or stop, and insufficient or excessive pressure.For these faults, we can solve them by adjusting the angle adjustment device, symmetrically adjusting the mold, fixing the base, repairing electrical components, replacing hydraulic oil, and adjusting the pressure regulating valve.For some more complex faults, professional technicians should be asked to repair them.In daily use, the press brake should also be inspected and maintained regularly to ensure its normal operation and extend its service life.

10-28-2024

Adjustment and use of Press Brake

Adjustment and use of Press Brake

1. Adjustment of the machine tool(1) Adjustment of the parallelism between the slider and the worktableIf the machine tool is a torsion axis synchronization, a turbine box is installed on the upper end of the cylinder, and the left and right cylinders have a detachable synchronization shaft, and two hexagonal tubes are added to connect the left and right cylinders. The cylinder worm rotates clockwise for one circle, and the cylinder piston rises 0.2mm. The cylinder piston rod drops 0.2mm when it rotates counterclockwise for one circle. In the case of long-term bending or irregular sheet metal, if there is an error in the parallelism between the slider and the worktable plane, the hexagonal tube can be removed and the worm of any cylinder worm box can be manually adjusted (the error distance of parallelism needs to be found before adjustment). After the adjustment is correct, the synchronization shaft is connected. (2) Adjustment of the clearance of the machine tool guide railThe machine tool is equipped with a guide rail seat, guide rail, adjustment iron and adjustment screw at both ends of the slider. The guide rail seat is fixed on the slider, and the guide rail is connected to the column. When the machine tool is frequently used, the gap between the guide rail seat and the guide rail increases. Please use a wrench to adjust the screws, but do not adjust them too tight to avoid damaging the guide rail seat and the guide rail. (3)Pressure adjustment of the machine toolOrdinary machine tools have a bending pressure table installed on the right side of the column of the machine tool. When bending, please refer to the table to select the mold notch and adjust the pressure (the maximum pressure of the machine tool is 25Mpa, and the rated pressure is 31.5Mpa). If it is a 51 CNC machine tool, the CNC system can automatically calculate the bending pressure and the bottom dead point position according to the actual workpiece shape. In theory, no manual calculation and adjustment are required. However, since there are many factors that affect the bending accuracy, each batch of bending angles needs to be repeatedly debugged through the program until it is debugged to the bottom dead point position and the bending requirements. (4) Machine tool molds and splintsOur company's bending machine can install standard upper and lower molds according to user needs and the actual situation of the machine tool. The upper die is equipped with a die clamp, which has three forms: one is a direct-connected upper die configuration, which has a simple configuration structure and low cost. It relies on adjusting the deflection compensation of the lower crossbeam to achieve the bending requirements. When installing, it directly clamps the upper die and links the slider; the second is the upper die configuration with ordinary inclined iron compensation clamping; the third is the upper die configuration with inclined iron compensation and quick clamping. (As shown in the figure) (5) The clamping configuration structure has the following characteristics:a. When installing the upper die with ordinary clamping, pay attention to the upper die slipping to prevent personal injury.b. The ordinary clamping inclined wedge type and the quick clamping inclined wedge type can adjust the compensation amount of the non-parallel upper die and lower die to achieve the basic optimal effect of the bending angle.   Preparation before trial run: (1) Be familiar with the contents of the manual, understand the chain structure, operation method and safety maintenance precautions of the machine tool. (2) Clean the oil tank before refueling. No impurities are allowed in the oil tank. When refueling, unscrew the nut of the air filter on the oil tank cover, and inject filtered new hydraulic oil (see the oil gauge) (the filtration accuracy of the oil dispenser shall not be less than 5um) until the oil level reaches more than four-fifths of the position indicated by the hydraulic gauge. Mobil AFT-25 hydraulic oil can be used for better results. In winter, when the temperature is low (about 5 degrees Celsius), it is recommended to use YB-N32 anti-hydraulic oil. To ensure the long-term service life of electrical and hydraulic components, the following requirements are made for the operating and storage environment: It is generally recommended not to operate the machine tool at low temperatures (below minus 5 degrees Celsius). If it must be used, the machine tool must be operated under no-load for a period of time. If necessary, a cylinder heater can be installed in the circuit. The temperature required for the use of the electrical box shall not be lower than 5 degrees Celsius. If it is lower than 5 degrees Celsius, the electrical box must be in the "on" state so that the electrical components and circuits can be in a normal temperature environment. The maximum temperature shall not exceed 50 degrees Celsius. Under normal working conditions, the oil temperature should not exceed 70 degrees Celsius. Otherwise, a cooler should be installed according to the actual situation, with a relative temperature range of 20% to 75%. (3) Add lubricating grease to the moving parts according to the lubrication label (generally install an oil ring or oil nozzle on the lubrication part). (4) Turn on the power (do not start the oil pump motor first), and check whether the hydraulic valves and related electrical components are operating correctly according to various process specifications and related operating methods. Machine tool test run and operation (1) Slider idle run test After turning on the power, start the oil pump motor and check whether the rotation direction is correct. Otherwise, swap any two power lines: After the slider jog specification moves normally, make the slider move continuously within the specified slider travel range, and then use the foot switch for a single operation. (2) Movement of the back gaugea. For ordinary machine tools, after the slider of the machine tool moves according to the regulations, press the two buttons on the operating surface to control the front and rear of the back gauge and make sure that the digital display on the display is consistent with the actual bending size. If there is a loss difference, it can be adjusted by pressing the handwheel installed in front of the workbench to make the digital display consistent with the actual number (because the screw is an ordinary screw, it is necessary to frequently check whether the actual distance from the stop rod to the center of the mold is consistent with the digital display). b. During the load test, select the V-groove opening according to the operating instructions, and bend the sheet metal, with the load from small to large until full load.4. Inspection before useBefore using the machine, first inject hydraulic oil into the oil tank and observe the oil mark. The hydraulic oil should occupy more than four-fifths of the oil mark space. Fill all lubrication points with corresponding grease or lubricating oil, see the lubrication of the machine for details.Check whether the center line of the upper die is symmetrically coincident with the center of the lower die. If not, see the adjustment of the machine for details.Determine the thickness of the bending plate and the opening of the lower die. Generally, the opening of the lower die is selected to be eight or ten times the thickness of the bending plate. 5. Use of the machineBefore using the machine, hydraulic oil must be injected and each lubrication point must be lubricated. Hydraulic oil should be replaced every six months to one year depending on the specific usage. When using the machine, you should first check the machine's movement by jogging, and then perform single and continuous movements. When all parts of the machine are checked to be normal, you can perform the following operations:(1) Calculate or check the table to confirm the bending tonnage and the lower die opening size.(2) Align the center position of the upper and lower dies.(3) Determine the front (rear) stopper position.(4) Adjust the stroke module to calibrate and determine the upper limit and the fast and slow speed shift position.(5) Determine the action specification. (Generally jogging and single).(6) Test the workpiece pressure, adjust the lower dead center position and the upper die wedge block to make the bending angle meet the accuracy requirements.

10-22-2024

How to debug the CNC hydraulic press brake mold. Punch and down die. The whole tools.

How to debug the CNC hydraulic press brake mold. Punch and down die. The whole tools.

  The CNC hydraulic press brake mold is composed of many parts, so special attention should be paid during installation. After completion, it should be debugged repeatedly. Machine is with special punch and blades for different shape products bending. Upper blade and punch in sections or small pcs. And down die and tools can be in small pcs and sections. Down tool can be with bottom support for adjusting. Generally, we will complete the installation and adjustment of the press brake mold in five steps. 1.Adjustment of the machine. Before installation, the performance of the machine should be adjusted first. This process should be carried out patiently and carefully. Check whether the machine has dust, used iron filings, etc., and carry out necessary cleaning to reduce the trouble in the later stage.     2.Adjustment of the slider stroke. Pay attention to check the thickness of the press brakemold and whether the ratio of the upper and lower modules is normal. Under normal circumstances, the module should be controlled at the switch point of the stroke line. This must be paid attention to.     3.Adjustment of the stroke module, that is, the adjustment of the upper limit position of the module. When the module is everywhere, the switch should be set and the stop position of the slider should be reserved. At the same time, the deceleration module should be carried out when descending, so as to better protect the machine and the press brakemold.     4.The adjustment of the gap is mainly to measure the distance between the upper and lower modules. The specific gap setting should be determined according to the plate to be folded.     5.Angle adjustment. Angle adjustment has a certain relationship with the product. The press brakemanufacturer tells you that generally speaking, when bending a 90° mold, the middle angle should be greater than the angles on both sides. Then adjust its tightness according to the adjusting screw. When bending, the pressure can be adjusted through a pressure gauge to avoid mold cracking.    

08-23-2024

There are differences between pulse laser rust rem

There are differences between pulse laser rust rem

There are differences between pulse laser rust removal machines and fiber lasers in terms of rust removal principles, application scenarios, and advantages and disadvantages.      Principle of rust removal: ‌Pulse laser rust removal machine uses the high energy density and rapid light vibration effect of pulse laser to ‌convert the laser light energy into the heat energy of the material,‌generate thermal stress or shock wave to remove pollutants. ‌The accumulated heat of this method does not exceed the melting point of the base metal, ‌which can effectively protect the base material from damage. ‌Fiber laser impacts the rust layer through a continuous beam, ‌similar to high-pressure water gun rust removal, ‌continuous impact on the rust layer to achieve the rust removal effect.     Application scenarios: Because the pulse laser rust removal machine can better control heat, it is suitable for application scenarios that require high-precision control of substrate temperature and protection of the substrate without damage, such as precision instrument rust removal. ‌Due to its continuous beam characteristics, fiber laser is more suitable for rust removal of large steel components, ‌pipes, ‌rails and other large metal parts.     Advantages and Disadvantages: ‌The advantages of pulsed lasers include long life, ‌flexible output mode, ‌high stability, ‌easy maintenance, ‌small heat-affected zone, and ‌high coupling efficiency with metals. ‌However,‌its photoelectric conversion efficiency is relatively low,‌and there are issues with internal temperature gradients that may cause thermal stress and thermal lensing. ‌The advantages of fiber lasers include good beam quality and ‌high efficiency, ‌but the disadvantage is that the cost is relatively high and ‌not suitable for applications such as precision rust removal that require higher precision control.   

08-06-2024

Press brake bending angle calculation method

Press brake bending angle calculation method

  The calculation of the bending angle of a CNC bending machine usually involves multiple factors, including material type, plate thickness, bending radius and bending coefficient. Different bending angles and material types require different calculation methods and coefficients. The following are methods for calculating bending angles for different types of materials:   1.Iron plate bending:When bending at 90 degrees, the commonly used upper mold R is 0.5, the lower mold V is 5T, and the bending coefficient is 0.4T. The formula for calculating the expanded size is L1+L2-2T+coefficient.     2.60 degree bending of iron plate (using deep insertion die) Expanded size=L1+L2+coefficient   3.30-degree bending of iron plate (use deep insertion die) Expanded size=L1+L2+coefficient   4.90-degree bending of aluminum plate: Normal bending upper die R0.5, lower die V=5T, bending coefficient 0.4T, V groove selection V=5T+R (R>0.5) Expanded size=L1+L2-2T+coefficient   5.60 degree bending of aluminum plate (using deep insertion die) Expanded size=L1+L2+coefficient     6.30-degree bending of aluminum plate (using deep insertion die) Expanded size=L1+L2+coefficient   7.Dead edge coefficient (first use the deep-insertion die to fold a small angle, then use the flattening die to press the dead edge) Above: Expanded size = L1+L2-0.55T   Above: Expanded size=L1+L2-0.55T+0.7W (W≤T)   Above: Expanded size = L1+L2+3.14* (R+m) (2R>T)   T≤2.0,m=0.4T; 2.0<T≤3.2,m=0.3T;   8.Pressure step difference coefficient A. When W ≥ 2T: the expansion is calculated as two single folds;   B. When W<2T and H≥2T: the expansion is calculated as two single folds;   C. When W<2T, H<2T: expansion size = L+(H-T)*0.7;   D.When W<2T, H=T: expanded size = L+0.15T; In addition, the calculation of the bending angle also involves the relationship between the position of the neutral layer of the material and the degree of deformation. In actual operation, it is very important to choose the appropriate calculation formula and coefficient according to the specific material, plate thickness and required bending angle.

07-18-2024

Common Faults of Bending Machines and Troubleshooting Methods

Common Faults of Bending Machines and Troubleshooting Methods

number Fault Possible causes of the fault Method of exclusion 1 The oil pump does not deliver oil or the oil supply is insufficient Oil pump reverse Change to clockwise rotation direction Coupling loose Re-secure the coupling Oil level too low Refuel to at least 80% of the tank capacity Oil pump does not start Check the electrical parts Oil pump damage Replace the oil pump The oil suction pipe or oil suction filter is clogged Clean the filter 2 Insufficient system pressure Insufficient oil supply Same as item 1 The throttling hole is blocked and the overflow valve is faulty. Check, clean or repair the relief valve The reversing valve is stuck in the middle position Check, clean or repair the reversing valve The solenoid coil of the reversing valve is damaged Replace the solenoid coil The pressure gauge and switch are damaged, and the displayed pressure is incorrect. Check or replace the pressure gauge and switch 3 Abnormal noise and vibration in the hydraulic part The oil suction pipeline is leaking and white foam appears on the liquid surface Check the pipeline to ensure tightness The oil suction resistance is too large, the oil suction filter is clogged, the oil viscosity is too high or too low Clean or replace the oil filter, replace the hydraulic oil with the appropriate viscosity The hydraulic pump input shaft is not coaxial with the motor shaft Check and readjust 4 Oil Leakage The cylinder seal, the O-ring between the valve plate and the valve are damaged or aged. Replace seals Loose pipe joints Tighten the joint or replace Hose connection is loose Tighten the joint or replace There are foreign objects on the sealing surface. Tighten the screws after removing foreign matter 5 Oil temperature is too high Insufficient oil in the tank Add hydraulic oil The oil viscosity is too high Adjust hydraulic oil type System pressurization time is too long Adjust the pressurization time The pressure control valve is too high Reduce the pressure Oil pump bearing damage Replace bearings Large internal leakage of valve group Check, repair or replace valve 6 Slider crawl Air enters the hydraulic system Run at no load for a while to exhaust the air The cylinder and guide sleeve are not coaxial Replacement of guide sleeve The clearance between the slider and the guide rail is too small, the lubrication is poor and the movement resistance increases Adjust the guide rail clearance and add lubricating oil The cylinder is seriously damaged Disassemble the cylinder for inspection and repair Relief valve stuck Check and clean the overflow valve Excessive leakage inside the oil cylinder Check the cylinder seal and replace it The center of the cylinder and the guide rail are not parallel Adjust the parallelism of mechanical parts 7 Different bending angles The slider is not consistent with the left and right free heights Adjust the height of the torsion shaft connection part on the rear side of the slider to ensure that the slider is free and at the same height on both sides. The left and right heights are inconsistent when pressurizing Adjust the fine-tuning screws on the left and right cylinders, and connect the synchronous shaft after the left and right cylinders are completely consistent. The connection between the piston rod and the slider is loose Tighten the loose bolts to eliminate the gap The mold fixture adjustment pad is loose After adjusting the upper die to be parallel, tighten the clamp screws Loose or damaged bearing Check and remove the bearing for replacement

06-11-2024

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