In the realm of metal sheet and mechanical engineering, the press brake is a key tool for transforming sheet metal into intricate shapes and designs.
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This powerful machine can achieve precise bending and folding, utterly change the industry, and create mass products ranging from simple rackets to complex mechanical components.
However, it has restrictions too. Its series of specific advantages and disadvantages must be taken into consideration when manufacturers balance its usage.
Our passage aims to delve into the world of press brake to explore its pros and cons, making you understand the press brake comprehensively
in the metal sheet industry.
A press brake is a machine specially designed for bending sheet metals, also one of the indispensable devices for the sheet metal industry.
The frame and bed are the fundamentals of the press brake. They are made of heavy steel and withstand the force produced in the bending process. The bed is a horizontal surface on which the workpiece is placed. And the frame supports the ram and die.
The ram and die are essential parts of a press brake. The ram is a vertically moving part, which leaves pressure on the workpiece and makes it bend surrounding the die. Die is a changeable tool designed for ensuring the angle and parameters of the press brake.
The back gauge is also an important part of the press brake, which ensures the accurate location of the workpiece to bend. It is composed of many stop fingers aligned with curved lines and guides the workpiece to the correct location. The back gauge can be adjusted by hand or automatics to accommodate different bend sizes.
The main function of the controller includes bending parameters, monitoring pressure, and ensuring the machine operates within its specifications.
Mechanical press brake
This is the most common type of press brake. The mechanism is operated by the electric motors inside them.
The motor offers energy to the flywheel and rotates the big flywheel at high speed. The operator controls the flywheel via the clutch.
The mechanical press brake is simple to operate especially in electronic equipment. It makes maintenance and operation easier.
Once the ram is connected, it must undergo the whole process. If the gate stroke is too large, the press brake may be locked, which is a potential hazard.
Pros: low cost, easy operation
Cons: restrictions on precision, power, and control
Hydraulic press brake
The hydraulic press brake uses hydraulic to push the oil cylinder down instead of a mechanical setting.
It can be equipped with multiple cylinders, which provides much convenience for operators to control the elbow, thus achieving high custom and precise bending.
Compared with the mechanical press brake, the hydraulic press brake offers more accurate bending and better control.
It can be easily adjusted to fit various thicknesses of metal and achieve intricate bending at steady movement. It is usually more expensive but is popular because of its higher performance and versatility.
Pros: higher precision, control, and force, and fits various materials
Cons: high cost, more complex operation and can&#;t exceed its rated tonnage
CNC press brake
The CNC press brake is highly custom and accurate and is controlled by computer technology to improve efficiency and control accuracy.
The skilled operators can input the data like bending angle, sheet thickness, and width to the controller to control the machine.
Pros: high accuracy and precision, easy operation and handle various shapes and angles
Cons: high cost, limitations with highly reflective or brittle materials
Press brake features lots of advantages, making it indispensable for the metal sheet industry. And it plays a pivotal role in the metal sheet industry.
Easy operation: press brake is one of the most simple devices. Compared with other machines, it does not require highly skilled operators.
High accuracy: accuracy is the key to handling metals. The press brake can offer higher accuracy compared with other metal bending machines because it uses a punch and dies to form the metal, achieving metal bending at a precise angle.
More flexible: compared with other machines, the press brake can bend small components and large masses of metals. It features large flexibility in various applications due to its compatibility with multiple sizes of metal sheets.
Improve productivity: the press brake is more efficient than other methods of bending metals. It can bend many metals at one time, thus improving productivity.
Reduce material waste: compared with other devices, the press brake offers high accuracy and precision. This means less material waste, making it more efficient and cost-effective.
Low cost: the cost of the die used by press brake is relatively low, but has a long life span, which increases the economical accessibility in the process of metal sheet forming and bending.
Improved security: the press brake is safer than other metal bending methods. Because there is no need to heat the metal before bending, thus lowering the risk of injury. The modern press brake is equipped with many protective measures, such as laser sensors. When the operator gets hurt, the sensors will stop the metal operation process.
Versatility: the modern press brake can handle many shapes of elbows. What&#;s more, it can bend different thicknesses of metal sheets.
Used for prototyping: A key advantage of press brakes is their ease of setup and tool changeover, allowing for quick changeover and testing of different designs and shapes during prototyping.
Intelligent technology: CNC press brake offers advanced automatic solving solutions for bending metals, which makes modern press brake a very intelligent technology.
Crowning: when bending a long workpiece, there may be a noticeable deviation between the forming angles in the middle and the sides, causing uneven bending angles. However, the press brake features a crowning function to adjust each location of the angle, ensuring line bending and decreasing the requirement for manual adjustment and maintenance.
High initial cost: the press brake needs mass initial investment due to purchase and maintenance. Also, the machine requires specialized equipment and training, which may increase the initial cost of setting up the machine operation. It needs more energy and may improve the operation cost apparently. The press brake with automatic is expensive, which can reduce the small company to order High-end models.
Require high pressure: press brake needs high pressure to operate. This means press brake may be not suitable for thin materials due to high pressure may cause material deformation. Besides, the high pressure is dangerous. The press brake must be operated by skilled operators to use, thus the potential risks may be reduced.
Restricted to simple geometries: press brakes are also limited in the geometries they can create. Although they can create simple bends, they cannot create more complex shapes such as curves or spirals. Thus, if complex geometrical shapes need to be created, different methods may be required, such as stamping or hydroforming.
Need professional training: the press brake can be safely and effectively operated by professional training. The operator must receive proper training to know the working principle of the machine and how to set the material correctly. Additionally, the operators must know the related risks to high-pressure operations and how to escape injury.
Space requirement: the press brake has large sizes, thus more workshop area must be spared for machine placement.
Noise: there may be some noises produced when the press brake is operated. Thus, the operator needs an ear-protective device. Also, it can rouse vibration on the working spot.
Maintenance: the press brake needs regular maintenance and should be often cleaned to ensure the quality of products.
Risk of breaking during bending: during the bending process, the edges and corners of the material will develop burrs or oxide layers, which may cause the material to crack or break during the bending process.
In a nutshell, a press brake is an excellent tool for precision, accuracy, and low labor-cost manufacture.
Please take the advantages and disadvantages of press brake into consideration before using this machine to meet your manufacturing needs, thus, you can make a wise choice for satisfying your business needs.
ADH is a company that has over 20 years of metal sheet fabrication and boosts press brakes. You can browse our products to choose the suitable machine or consult our sales to learn detailed information.
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Gone are the days of shaping metal through forging. Over the decades, metal rolling/bending processes and machines have evolved. Fabricators are using metal forming machines for several reasons. Most importantly, to make the process easy and affordable.
The two types of bending/ rolling machines that metal fabricators currently use are manual plate rolling machines and automatic plate rolling machines.
This blog explains the differences between both machines while highlighting their respective advantages and disadvantages.
So, let's dive right in, but before that, let&#;s briefly look at both machines.
What is a Manual Plate Bending/ Rolling Machine?
A manual plate rolling machine, also called a manual sheet bending machine, is a tool used to bend metals into shapes and curves. You must have seen artisans create intricate metal artwork and sculptures using these machines.
As the name suggests, manual plate bending machines operate manually and don't require electricity or hydraulic power. Small-scale fabricators generally use these. It is a versatile tool used in industries like construction and agricultural equipment.
The machine consists of several parts working together to bend metal sheets. The key manual bending machine parts include the bending blade, the clamping bar and the handle. Each part performs its task - from bending to applying the required force on the metal sheet.
Manual Plate Bending Machine
What is an Automatic Plate Bending/ Rolling Machine?
An automatic sheet metal bending device is also called a computer-controlled (CNC) plate rolling machine. Used worldwide by metal fabricators to shape metal sheets into cones, cylinders, and curved shapes.
These automatic bending machines deliver sophisticated, cutting-edge and unique products. Designed to shape heavy metal products that require precision and accuracy, including ships and metal containers.
Different automatic plate bending machines, such as a 3-roll plate bending machine or a 4-roll plate rolling machine, have their own mechanisms and working principles. For example, a 3-roll machine has three rollers.
Automatic Plate Bending Machine
Difference Between Manual Plate Bending and Automatic Plate Bending Machine
Have you ever seen sugar-cane vendors on the streetside? Some have traditional sugarcane crusher machines - manually churning sugarcanes with handheld churners. At the same time, some vendors use automatically operated machines.
Both machines work the same, with the same product and output. But each one has its pros and cons. In the same way, manual and automatic plate bending machines work the same but have respective advantages and disadvantages.
Let&#;s take a look.
Manual Plate Bending Machine: Advantages and Disadvantages
Manual plate rolling machines are increasingly popular in small-scale operations, proven to save money. However, like every tool, these machines also have certain limitations. Below are some important advantages and limitations.
Advantages of a Manual Plate Rolling Machine
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Budget-Friendly: One of the key advantages of using a manual bending machine is that they are cost-effective. They are cheaper when compared to hydraulic plate bending machines. Ideal for small-scale workshops.
Simple to Use: These machines are simple to use due to their relatively simple design and operations. Making them suitable for beginners and operators without technical expertise.
Portability: Manual plate rolling machines are lightweight and do not require electrical power. Transportation of manual machines becomes easy with their compact design.
Versatile: Fabricators can use the machines to bend metal sheets into shapes as required. They are suitable for shaping metals, including aluminum, copper and stainless steel.
End Applications: Civil construction companies, Mining Industries, and Cement Plants
Certification: In order to buy these machines, you do need your seller/ company to be ISO-certified.
Disadvantages of a Manual Plate Rolling Machine
Less Precision: One of the main limitations of a manual sheet metal bending device is that they are unsuitable for obtaining complex bends. Thus, they may not be as precise as automatic bending machines.To
Time-Consuming: Manual bending machines need manual labor. From inserting a sheet into the machine to re-rolling. For example, three to four people unscrew the rolls for re-rolling a plate.
Moreover, manual plate rolling machines cannot perform pre-pinching. A process of bending the metal plate before rolling by placing it between the rolls in a plate curving machine.
The process takes longer as you need to use a hydraulic press on both sides before rolling for pre-pinching. This limitation affects the time of operations, thus impacting overall productivity.
Not ideal for Heavy-Duty bending: Designed to shape thin metal plates, these machines take longer to bend heavy or thick sheets. Heavy or thick metal sheets also require more force to bend and people to operate the machine. By the time one roll takes its shape, you can use an automatic plate curving machine to shape approximately three to four rolls.
High-Volume Production: Manual bending machines are not the best solution for high-volume bending jobs. Due to the same reason, the machines demand more time and extra workforce.
Re-Rolling: Passing a metal sheet multiple times inside a metal plate bender to achieve the desired shape or curve. To make sure that there are no flat bends on the sheet. Indeed, manual plate bending machines perform this task.
However, after rolling a shell once, the operators need to unscrew the machine, insert the sheet and roll it back. You must repeat the process on both sides of the sheet several times to achieve the required bend.
Looking at the pros and cons of manual plate rolling machines, it is evident that they are an ideal option for small-scale businesses. They are also perfect for time-saving and less meticulous tasks.
But, if you are willing to step up your operations, consider investing in automatic plate bending machines. Ready to know about the pros and cons of automatic metal plate benders?
Let&#;s have a look.
Automatic Plate Bending Machine: Advantages and Disadvantages
The demand for automatic bending machines is steadily rising due to an increased demand for metallic components. These machines make heavy-metal-forming jobs easy. However, they have some drawbacks, too.
Advantages of a Manual Plate Rolling Machine
Efficiency, Precision and Result: Automatic plate bending machines deliver large bending projects precisely. The machines operate quickly and consistently, ensuring accurate results for complex shapes and curves.
Reduced manual labor: Since the machines are automated, each machine requires less workforce for various tasks, such as welders. One machine does it all. At most, one or two professional technicians are enough to complete the task.
Ideal for heavy-duty bending: Automatic plate bending machines can easily process thicker sheets. These machines are designed to handle heavy-metal shaping for industrial applications, such as aerospace and automobiles.
Time-Savings: One of the greatest advantages of automatic bending machines is the amount of time it saves in manufacturing. With programmable settings and features, the machines remove the need for manual fixes.
Re-Rolling: Unlike manual plate bending machines, automatic plate rolling machines perform re-rolling more precisely and efficiently. The machine's programmed process ensures that the machine accurately shapes/ bends the sheet every time.
End Applications: Shipping industry, Oil tanks, and Rocket shell
Disadvantages of an Automatic Plate Rolling Machine
Higher investment: Automatic plate bending machines need a hefty investment. The machines are more expensive to purchase and maintain than manual plate rolling machines.
Professional knowledge: Automatic machines' advanced automation and features require a skilled workforce. Operators need proper and professional technical proficiency to operate, set up and maintain the machines.,
Space and Size: Since the machines are huge, they require proper and more setup space, which is a constraint for smaller workshops. Moreover, due to their size, it becomes difficult to change locations.
Maintenance: Automatic plate bending machines are more complex than manual ones. They need intricate maintenance procedures, leading to a higher maintenance cost.
Certification: To purchase an automatic plate bending machine, you need to ensure that the seller holds an ISO certification. Similar to the one you can see below.
Himalaya Machinery is ISO Certified
Manual vs. Automatic Plate Rolling Machines: Side-By-Side Comparison
Based on the above-mentioned advantages and disadvantages, here is a side-by-side comparison of both the machines: Manual Plate Bending Machine and Automatic Plate Bending Machine.
Factors
Manual Plate Bending Machine
&#;Automatic Plate Bending Machines
Operation:
Manually operated using hands
Automatically operated using hydraulic power and programmable settings
Efficiency:
Slow speed and less consistent
Operates quickly and consistently
Precision:
Not suitable for complex bends
Ensures accurate complex shapes with precision
Investment:
More affordable upfront cost
Higher initial investment
Skill Requirement:
Suitable for beginners, and operators with less technical expertise
Require professional technicians.
Production Capacity:
Not ideal for high-volume bending jobs
Suitable for delivering heavy-duty bending jobs.
Type of Bending:
Used for bending thin metal plates
Used for bending/shaping heavy and thick metal plates.
Maintenance:
Needs manual fixes, simple maintenance procedures
Doesn&#;t require manual fixes, complex maintenance process
Space Requirements:
Compact and space-efficient
Requires more space for larger machines.
Duration:
Longer compared to automatic machines.
Faster than manual ones.
Pre-pinching:
Done outside using a hydraulic press.
Already a part of the bending process inside the machine.
Applications:
Ribbed bars and channels in the construction industry
Aerospace, Silos and Oil tanks
Conclusion
Do Consider the factors for both manual and automatic plate rolling machines before you make that purchase. Choose the one that fits your workshop needs.
Your requirements may vary depending on your specific fabrication needs, like the budget and complexity of your bending projects.
We hope this blog helped you understand the pros and cons of manual and automatic plate rolling machines. Let us know if you have any questions regarding other metal shaping products. Himalaya Machinery would love to cater to your needs.
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