A Guide to Maintaining Press Brakes

If you work in the metal fabrication industry, you must be knowing that Press brakes are an important part of any equipment. Thin sheets of metal and sheet metals made to particular specifications using CD/CAM are widely in use in the construction and manufacturing industries. Press brakes help bend these sheets of metal in a number of different ways.

If you are just starting in the industry, here’s all you will need to know:

Types of Press Brakes

Mainly there are three different forms of Press Brakes. Hydraulic, mechanical, and pneumatic. In the market, a hydraulic press is a superior quality press brake providing best quality results. Because of the difference in trigger mechanisms. There are different types of parts in Amada press brake including precitec parts. Each part refers to a different use. In the mechanical brakes, it uses a spring-loaded trigger. Pneumatic brakes use an air trigger. When you press the trigger in these brakes, the machine will start working.

With the hydraulic press brake, you can stop it at any point even after its stroke. In this case, the operator will have a greater degree of control over what they are doing. Thus, it helps in achieving more precise results. You can also operate Hydraulic presses at a slower pace. It gives the operator time to fine-tune the piece to their liking. 

Bends and Dies

You can change the parts of the press brake. You can take them out and replace it with precitec nozzles or any other required part. Just as you changing the function and capabilities of a drill by changing the type of drill bit, changing the bends and dies in the press brake will change what it is supposed to be doing.

Precision Control

In order to run the press brake efficiently, a skilled operator is a must-have. When it comes to CAD and CAM, they have their made place in manufacturing and construction. But even when you implement them in your system, you will need a skilled operator to monitor the work and make sure that there is no defect in the final outcome.

Maintenance

If you as a fabricator are considering to buy your own press brake, it is important to understand the steps of maintenance. The good thing is, the maintenance is not that complicated compared to other machinery. Make sure to follow the manuals and keep checking the machinery on a regular interval, you might not get many issues.

Regularly clean the press brake. Make sure to remove any oil and dust which might have made their place. Doing it on a weekly basis is a great thing. All the oil filters will need changing on a yearly basis at least.

Make Sure to Take Precautions

Before performing any operations using press brake, it is necessary to support the ram of the machine. You can place the ram on two equal size wooden blocks. You can also lower the ram by the tooling. 

Review it Mechanically

It is important to review piston bolts, chain sprockets, precitec nozzles, and guides of the press brake. Make sure to check the connection between the pistons and ram on a regular base. Also, to calibrate or realign the back gauge and stops.

Lubrication at a minimum number of points in modern press brake is also important. Keep moving components such as back gauge, guiding systems, and ball screws clean. Don’t forget to grease them to extend the press brake’s function and life.

Here are the components which require weekly lubrication:

• Ram guiding system
• Ball screws
• Guide encoders, encoder guiding system
• Gear segment
• Rack and pinion system
• Guides and rails

Press brakes are a simple piece of machinery. In order to maintain it and leverage the functionality over a long period, follow the right steps to maintain it. Even the highest quality press brakes like Amada press brake need maintenance on a regular basis. It is a common equipment for a variety of reasons. It soon will be working with materials like graphene and other synthetic metamaterials. Make sure you make it an excellent investment for your metal projects.

Should Manufacturers Consider Buying Laser Cutter?

What do you do when you need a promotional logo for an event in under two weeks. You must be paying high rush rates and hefty shipping charges to a promo company. But how about firing up your own laser and make 100 pieces quickly? Isn’t the second option more convenient? Now, you must be thinking about costing.

Back in the day, most small to medium-sized businesses outsourced laser engraving. With the largely spread development in technology in the market, it removed the economic barrier for the in-house capabilities of laser engraving and cutting.

Laser cutting and engraving is making a buzz in the market for many reasons. With the increasing volume of outsourcing, there comes a point when the monthly spend on custom laser services is not cost-effective.

Sometimes it can stretch your production schedule and can lead to delays. If you are a manufacturer then installing laser equipment having Amada replacement parts or Trumpf spare parts in your own factory can be a cost-friendly option. You won’t be having any delivery time pressure. Plus, whenever you have to satisfy unpredictable customer demands, you can minimize the cost by taking control of laser cutting and having those resources on-premise.

When there is a development in the technology, there are many features available in large-scale cutting and engraving machines you can find on smaller desktop models. Today’s laser cutters provide speed, productivity, and efficiency for improved output and reduced scrap rates. Due to constant improvement in design and manufacturing process, there are systems which became more durable and requires less maintenance than the older models.

Major Benefits of having an in-house laser cutter:

• The laser marking process produces a crisp, detailed design which allows you to engrave images up to 1000-1200 dots per inch.
• It also provides an extremely fast way to customize products. You can easily engrave multiple pieces at once.
• This makes it easier for a laser system allowing users to create a quick jig to hold items in place and engrave as many pieces as per the area capacity in the laser’s work area.

While there might be some manufacturers concerned about the availability of in-house expertise to develop a particular laser job configurations and engineering. Bringing an in-house laser system allows manufacturers to brand their own promotional products. They can craft their own clothing, laptops, mobile phones, and so on. They can also design their own internal/external signage and other products as employee recognition products. Engraving custom graphics on MP3 players, iPods, iPads, and cell phones is an incredibly popular application which helps deter theft.

Hence, the next time when you are facing such deadlines to customize your products, having your in-house laser cutting systems having Amada replacement parts or Trumpf spare parts could help you deliver results on time.

Some of the useful tips to help you before you place your first order:

Material: Make sure that the materials you use involve steel tubes. Also, if your materials contain high reflective metals, aluminum, red copper, etc. then choose a laser cutter which is suitable for processing of such metals.

Size: It is key to the fiber laser cutting selection. Be careful while taking a measurement on them and decide the size of the work table.

Thickness: To achieve cutting effect with efficiency, it is important to consider the thickness of materials with the wattage of fiber laser cutting machine. Plus, it will help you choose the most effective solution.

The Finance Factor

While some manufacturers pay cash for a laser, the majority of them would use the finance method. Other than the bank sources you have OEM with their own financing plans. Also, make sure you are not compromising on quality while investing in the laser cutter to save money. Higher quality parts like Amada replacement parts will not only increase the lifecycle of the cutter but will also need lesser maintenance. 

But in order to get full services, you need to get a successful delivery and installation. Decide what type of foundation you will require. After that, it is important for a laser cutting machine to be in the right place with a facility away from harsh environmental areas. Also, make sure that you choose an efficient flow of laser-cut banks to downstream manufacturing process.

5 Avoidable Mistakes of in Laser Engraving

Utilizing heavy machinery demands its proper usage to avoid pitfalls. Whether a novice or an experienced engineer, it is important to learn how you can avoid common mistakes while operating heavy machinery like Laser engraving. It may harm its sensitive parts as not all the parts come with a great resistance power except for Mitsubishi spare parts and Fanuc spare parts.

When issues occur, you might end up just guessing what went wrong while using it. So, to help you we have come up with common mistakes you might be making.

1. Using Wrong Fabrics

Using laser on a fabric which cannot withstand with it will end up burning. Research and understand which fabrics can combat high power settings during the process. Denim, leather, canvas can resist high power settings. When you use delicate fabrics, set your settings at high speed and gradually lower the power to 5%-10%. And to avoid wasting any material, test a small piece, in the beginning, to see if the fabric can withstand. Adjust the power until you get the results.

While attempting direct-to-garment engraving, lower the DPI (dots per inch). Engraving at a lower DPI will ensure the laser vaporizes the top layer and doesn’t burn entirely through the fabric. General engravings work best at 150 to 300 DPI.

2)Using the Wrong Acrylic

There are two types of acrylic used in laser engraving.

1. Liquid Acrylic
2. Extruded Acrylic

Liquid acrylic is best when producing cast acrylic sheets and objects. You pour it into the molds to set into various shapes and sizes. It is the perfect type of acrylic for engraving as it turns frosty white color while engraving. It won’t give your projects flame-polished edges on cutting it with the laser.

Another type of acrylic used for engraving is Extruded acrylic. A machine turns extruded acrylic in sheet format. And because of the high-volume manufacturing technique, it is less expensive.  It cuts clean with smooth outputs and produces a flame-polished edge. And when used for engraving, it provides you with clear engraving. So, if you want a frosted white finish, do your engraving project with liquid acrylic.

3) Inconsistent Glass Engraving

While you are using laser engraving on glass, sometimes it does not get through it properly. As a result, it fractures the surface. Eventually, it will produce the fractured glass surface with a frosted appearance. Rough and chipped.

To avoid that and produce a smooth frosted finish, here are some tips to help you:

• User lower resolution. Up to 300 DPI. As you separate the dots you are engraving, it will produce better results.
• A DIY tip: Apply a thin, wet sheer of newspaper or a paper towel to the area to help with the heat dissipation. It improves the overall process. Make sure the paper you are applying is flat and not wrinkled.
• You can also try changing the color black in your graphic to 80 percent black.
• Polish the area with a non-scratch scouring pad.
• User better laser parts. Mitsubishi spare parts, Fanuc spare parts will increase the efficiency of your machine.
• Apply a thin layer of liquid dish soap in the area.

4) Not Getting Same Results while Wood Engraving

We see maximum engraving happening on the wood. It is one of the most laser-friendly materials available out there. As woods have different types, they might react differently to laser engraving. For example, if you make a large square from a piece of cherry, it would have a uniform appearance. If the same piece was made out of oak, it might vary in height with a non-uniform appearance.

• To smoke and debris, try engraving from the bottom up.
• Wipe off the surface of the wood with a damp cloth when engraving the stained wood.

5) Lack of Efficiency in the Engraver

When it comes to maintenance, it is important to clean the machine on a regular base. You get the manuals along with your machine. It is also important to inspect the optics on a weekly base when needed. Notice when your optics look smudgy. Because that’s when you have to clean them.

Conclusion

These are the most common mistakes you could be making. If you are a manufacturer, designer, or a layman, avoid these mistakes and increase the efficiency of your laser machine.

How to Sell Metal Scrap Material in Best Prices

Your system generates scrap material every day after the manufacturing or consumption process. And for years, you might’ve been following this procedure to scrap metal: calling a scrap company, deciding the price, sending the filled containers, and then getting paid for your metal. For you, this might be the best way to handle the scrap metal.

But, only some manufacturers know selling scrap metal the right way could be another source of profit for them. 

Everyone selects a particular scrap company for various reasons including lower prices, better services, or just transparency. But most of the scrap companies would buy very low and sell high. Hence, as a seller, it is important to understand the value of your scrap material and how to get the right value for it.

So, we’ve gathered the steps to help you make the most out of your scrap metal.

• Fix the Settled Price 

In the fabrication industry, selling scrap metal isn’t a one-time event. Therefore, it is important to make sure that you don’t end up working with a company that tempts you with an above-market price, and after that gradually lowers your per-ton rate to a below-market price.

You need to make sure that you tie the pricing to a defined commodity-market index. This way, you can protect yourself when the market falls and benefit when there the market rises. The decided upon index prices are generally not similar to the negotiated price for the scrap. So, when you negotiate, you are basically negotiating the differential price. This means there will be a difference between the market index price and the amount that the scrap company would give you. And when your prices are tied with the market-index, the scrap company won’t be able to freewill their way around the prices. So, make sure that when the index goes up to $20, the scrap price should also go up by the same amount.

• Be Aware of the Downgrades

 It is a common industry practice to pay for the least valuable scrap material in a load. If the load contains 90% stainless and 10% some other material, the less expensive material would be graded. Looking from an ideal point of view, the payment should be based on the percentage of the material in a load. For dirty loads, downgrading the scrap amount is certainly fair, especially if a dirty load increases the amount of segregation work. Hence, if a scrap company downgrade a load, ask for proper documentation. Make sure that there is an agreement to send documentation and pictures for any downgraded load. If you communicate with the scrap company about how it handles dirty loads, you will understand how it operates.

• Separate the Scrap Pieces

This technique is all about maintaining transparency. This process includes everything that happens to the scrap before it’s sent to the mill. It includes shipping, processing costs, and other value-adding process costs. For instance, you get a pallet of metal pieces after a laser cutting process from a machine containing Amada parts or Bystronic parts. Before you put them for buying, they must undergo a number of value-adding steps. You need to segregate them by type and cut down to a mill-acceptable size.

Just like that, steps may vary depending on your exact material mix and requirements. It depends on your own processes and the price increase that a scrap company is willing to give you. It might sound like a complex process, but remember that just like the production, scrap is also a revenue center, so it’s worth organizing it with a process.

• Keep Track of the Load and Tracking Reports

Usually, the truck arrives at your workplace, retrieves your scrap, and leave a pickup receipt and scale ticket at your dock. After a certain period of time, the concerned person would deliver them back to the front office. But it is not necessary that all those pickup receipts make it into the main office. You need to verify the number of loads that left the facility and for how many of them you received the payment. Keep one responsible person to take care of this process. Especially, when you scrap aluminum, stainless, or other high-value materials. Because each load can account for thousands of dollars. 

Summing it up...

Handling scrap material isn’t rocket science. But it is important to understand the process, market, and of course, having a basic knowledge of the industry prices won’t harm. If done right, just like you produce products using Bystronic parts or Amada parts, you can turn scrap into a valuable profit-making product.

7 Critical Press Brake Mistakes You Must Avoid

Machines don’t have to be brand new to produce quality desired results. But you do have to keep good care for them. With a press brake machine, producing good results won’t be a likely scenario if it has an upset ram. It is an integral part of the press brake machine. And if that has a problem, it can hinder your whole production process. Hence, it is important to practice proper maintenance practice to maximize its shelf life.

From where the problem arises?

Sheet metal fabrications, while going through the press brake machine, change its shape from a sheet into a three-dimensional shape. If those bends are not straight, the final assembly won’t go the right way. If you do not maintain your press brake machine, the bend follows a curved line rather than a straight one that is “canoeing”.

In order to avoid that, here are the seven most common press brake mistakes we should avoid to ensure its smooth working.

1. Not Taking Care of Gibs

Gibs are the small components of the press brake machines. They lead the ram and tool as it makes movements. If you neglect its regular maintenance, the ram can twist and jam. Hence, it is important to adjust Gibs regularly and provide proper lubrication from time to time.

2. Lubrication of the Machine

Apart from lubricating the gibs of the press brake, it is important to apply lubrication to other parts of the press brakes as well. If not then it may lead to metal-on-metal contact which causes wear and reduces the force available for the actual bending metal.

At the same time, lubricating does not mean slapping on too much grease. It even means not putting on the wrong type of lubricant in the wrong place. Applying excessive grease means attracting dust and metal fragments. It may cause sliding surfaces which would accelerate wear, causing seal leaks. 

The key here is to maintain a machine with a film of oil on it. Because if it is too thick, it may increase drag and not penetrate between components. 

Here are some other mistakes we should be avoiding while using, assembling or selecting press brakes.

3. Placing parts too close

Fabricators often do this to bend radius. But while putting features too close to the bend radius or at the edge of the die opening would change the features. They may no longer be able to hold necessary hardware near the bend radius. The position of the features should be according to their thickness. And lastly, if the feature has to be nearer to the bend than recommended, our advice would be you extend the opening past the bend line. And if you are already facing this problem, you can search for Amada press brake for sale or used Amada press brake on the internet to find the right part or machine.

4. Forming offsets too close to one another

If you set the Offsets that are too close to one another, they won’t be producing standard press brake tooling. Plus, these offsets would require special tooling that is not worth the extra expense for low volume orders. Refer to this image to choose the suitable standard offset size. You can contact your engineer if your measurement is outside of this table

5. Not changing the hydraulic fluid

Most press brakes have complex systems. And as time goes, hydraulic fluid would become contaminated with dirt, air, and water. It would limit the load that the press can apply. It reduces the lifetime value of the key components of the press brake. Hence, it is important to regularly change the fluid.

6. Upsetting the ram

When you apply uneven forces or if the load is too high, you can upset the ram. The root cause of this issue is its position while bending the metal which is not in the right place or not in the center. It is important to note that if the metal is too thick or not enough load is there, it could hurt the ram as well.

7. A bend radius that is too tight for the material

Keeping your radius right is paramount. If it is too tight, it can cause a permanent deformity that alerts the dimensions of the part. It is important to understand that different metals have minimum bend radius-to-thickness ratios. Hence, the harder the metal, the greater the minimum bend radius.

Machinery parts for the press brakes are sensitive. If not cared for properly, that time is not far when you would need to rebuild the whole machine.

It is a must to avoid the above-mentioned mistakes for a full-proof and versatile press brake. If you are starting over, you can try searching Amada press brake for sale or used Amada press brake over the internet to find the products which would help you put together a quality press brake machine.