Press brake dies are an essential component of any metal fabrication operation. They help shape and bend metal into the desired shape and size.They are responsible for shaping and cutting the material, and their lifespan can have a significant impact on the productivity and profitability of any metalworking operation. However, press brake dies are not immune to wear and tear, and they will eventually need to be replaced. The lifespan of a press brake dies can vary greatly, depending on several factors. In this blog post, we will discuss how to calculate the life of a press brake dies and ways to extend its lifespan.
Factors That Affect The Life of Press Brake Dies
Several factors can affect the lifespan of a press brake dies. These include:
Material hardness – The hardness of the material being bent affects the lifespan of the die. Harder materials will cause more wear and tear on the die and reduce its lifespan.
Material thickness – Thicker materials require more force to bend, which can cause more wear and tear on the die.
Bend angle – The angle of the bend also affects the lifespan of the die. Sharp bends can cause more wear and tear on the die.
Number of bends – The number of bends the die makes also affects its lifespan. The more bends it makes, the more wear and tear it will experience.
Press brake tonnage – The tonnage of the press brake affects the lifespan of the die. Higher tonnage presses exert more force on the die, which can cause more wear and tear.
Maintenance – Proper maintenance of the press brake and die can help extend its lifespan. Lack of maintenance can cause premature wear and tear on the die.
Calculating The Life of Press Brake Dies
Step 1: Determine the Material Type
The first step in calculating the life of press brake dies is to determine the material type. Different materials have different properties and require different amounts of force to be shaped and cut. Therefore, the material type will have a significant impact on the lifespan of the die.
Step 2: Calculate the Tonnage
The next step is to calculate the tonnage required for the material you’re working with. Tonnage refers to the amount of force required to bend or shape the material. You can use a tonnage calculator to determine the required tonnage for your specific application.
Step 3: Calculate the Press Brake Dies Width
The die width is the distance between the two flanges that hold the material. It’s essential to calculate the die width accurately to ensure that the material is held securely and that the die doesn’t deform during the bending process.
Step 4: Determine the Die Clearance
The die clearance is the distance between the punch and the die. It’s crucial to determine the proper die clearance to ensure that the material is bent or shaped correctly without causing any damage to the die or the material.
Step 5: Determine the Material Thickness
The material thickness is the thickness of the material you’re working with. It’s essential to determine the material thickness accurately to ensure that the die can handle the material without deforming or cracking.
Step 6: Calculate the Press Brske Dies Life
Once you have determined the material type, tonnage, die width, die clearance, and material thickness, you can use a die life calculator to determine the expected life of the press brake dies. The die life calculator takes into account various factors such as the material type, tonnage, die width, die clearance, material thickness, and other variables to calculate the expected lifespan of the die accurately.
Step 7: Maintenance and Inspection
Finally, to ensure that the press brake dies last as long as possible, it’s crucial to perform regular maintenance and inspections. Regular maintenance can help prevent premature wear and tear and extend the lifespan of the die. It’s also essential to inspect the die regularly for any signs of wear, cracking, or deformation, and replace it if necessary.
Extending The Life of Press Brake Dies
Several measures can be taken to extend the life of a press brake dies. These include:
Proper maintenance – Regular maintenance of the press brake and dies can help extend its lifespan. Maintenance should include cleaning, lubrication, and inspection for wear and tear.
Proper storage – The die should be stored in a dry, clean place and protected from damage.Use appropriate packaging: Bending machine molds should be packed in appropriate packaging to protect them from damage during transport and storage. The packaging should be sturdy enough to support the weight of the mold and prevent any damage from external forces.
Proper use – The die should be used only for the intended purpose and not subjected to excessive force or bending angles.
Material selection – The material of the dies should be selected based on the material being bent and its thickness. Harder materials may last longer, but they may also cause more wear and tear on the press brake.When selecting the material for a bending machine die, it is essential to consider the type of material being bent, the thickness of the material, and the number of bends required. By choosing the right material, you can ensure that your bending machine dies will last longer and produce high-quality products.
Die design – The design of the die.A well-designed mold that is made from the appropriate material, has the right shape and size, and is properly lubricated can last for many thousands of cycles, reducing costs and improving production efficiency. On the other hand, a poorly designed mold can wear out quickly, leading to production delays and increased costs. To ensure that your press brake molds last as long as possible, it is important to work with a knowledgeable and experienced mold designer who can help you choose the right materials, shapes, and sizes for your specific application.
Other factors that can affect press brake dies life include the design of the tooling itself, the thickness and quality of the material being formed, and the type of lubrication used during the forming process. Proper lubrication can reduce the friction between the mold and the material, reducing wear and tear and extending the life of the mold.
In conclusion, calculating the life of press brake dies is crucial for maximizing their usefulness and getting the most out of your investment. By following the steps outlined above and performing regular maintenance and inspections, you can ensure that your press brake dies last as long as possible and help increase the productivity and profitability of your metalworking operation.