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All You Need to Know about  for V Die for Press Brake

The most frequent type of press brake die is the V-die.

V-die for press brake is very important for the operation of press brake. Depending on the punches utilized and the depths to which they drop into the die during an air-bending operation, a set of V-dies with varying-sized die apertures can be used to bend a variety of materials in different bend angles.

Advantages of Using V Die for Press Brake:

Improved Bending Accuracy

Although it hasn’t been the subject of prior research, the V-die bending force is a crucial factor to consider when choosing the capacity of press machines. Moreover, even if the different modified formulas suggested in earlier studies were computed using V-die bending theory, they are not adequate to forecast the real V-die bending force.

A new V-die bending force formula has been developed based on the real V-die bending mechanism. According to this formula, bending occurs on the legs next to the bending allowance zone in addition to the bending allowance zone itself. The bending force in these zones needs to be properly taken into account as a result.

The types of v-die are divided into the following categories:

T-Die
T-Die
1V-Die
1V-Die
2V-Die
2V-Die
4V-Die
4V-Die
Multi-V Die
Multi-V Die
Flattening Die
Flattening Die

Enhanced Efficiency in Production

The real V-die bending mechanism as well as the modification and creation of a new V-die bending force formula were both successfully ascertained through the application of the finite element method (FEM). To verify the accuracy of the novel V-die bending force formula that was suggested and to validate the findings of the FEM simulation, laboratory experiments were conducted.

As test materials, two different workpiece kinds were utilized: medium carbon steel sheet-grade SPCC (JIS) and aluminum AA1100-O (JIS). The findings unequivocally demonstrate that, when compared to forecasts made using previous formulae, the new V-die bending force formula provides greater accuracy in V-die bending force prediction.

Versatility in Applications

Press-brake forming is a craft that heavily relies on the operator’s proficiency. As such, it is anticipated that two distinct operators will attain differing degrees of productivity and quality. As a result, variable outcomes are also tolerated and require further care to ensure uniformity. Higher differencing components are either moved on to the next phase, reworked, or eliminated.

It is a great tool for bending sheet metal. After that, the sheet metal that was created will be helpful for a variety of uses in the manufacturing sector. These manufactured sheet metals are employed in automobiles, heavy machinery, and home appliances, therefore they are undoubtedly useful in people’s daily lives.

However, to generate suitable sheet metal, sheet metal benders must first think about the appropriate die design. With the appropriate die design, these can be utilized for a wide range of forming tasks, including V dies, rotary bending dies, acute angle dies, radius dies, and more.

An electric motor adds energy to a flywheel in a mechanical press. The ram is moved vertically by a crank mechanism that is powered by a clutch that engages the flywheel. The mechanical press brake has the advantages of accuracy and quickness. Two synchronized hydraulic cylinders on the C-frames move the upper beam in the hydraulic press brake’s operation.

Mechanical press brakes provide a rigid ram level, making it easier to overload and more difficult to bring the ram near to the material for scribed line work. To adjust, the skilled operator is required to slip the clutch. Mechanical brake buttons do not allow you to modify the stroke length. One must finish the revolution and cycle the machine completely.

Hydraulic press brakes are both safe and more expensive. These brakes are slower and have more precision bend work, giving you better control when inching down and setting up for your bend; they can return to the top at any point. These are simple to use and offer straightforward settings for optimal output and increased operator efficiency.

Choosing the right V die for press brake to finish your Job:

Understanding Project Requirements

Press brake operators frequently use their own “rule of thumb” when selecting the V opening on a particular job application. These guidelines may have evolved based on their individual experiences, but they don’t account for the real behavior of industrial sheet metals, which might occasionally result in defective finished products.

Steel, for instance, is an alloy made by heating iron, carbon, and other minerals. The mechanical properties of that steel can vary due to variations in the quantities of each component. This implies that no two pieces of steel are alike and that they won’t all behave the same after they are produced.

Because commercial steels frequently have a set composition, all we can say about their behavior is that they will usually be consistent. There isn’t just one ideal V opening for a given thickness or material. While there are optimal V-openings for varying thicknesses, the right one is simply the right one for the particular bending method we use. As a result, you must first comprehend the project requirements.

Matching Die Characteristics to Application Needs

Press brake operators frequently use their own “rule of thumb” when selecting the V opening for a particular work application. These guidelines are based on experience, but they don’t always account for the way that commercial sheet metals “behave,” which can occasionally result in poorly executed finished products.

Iron, carbon, and other minerals are combined with heat to create steel. The mechanical properties of that steel can vary due to variations in the quantities of each component. As a result, no two steels are alike and will react differently. Commercial steels frequently have a common composition, which causes them to react similarly when manufacturing and bending.

Before formulating our own “Empiric rule” for identifying a V opening in a given application, let’s examine the factors that influence this rule and how the selected V will impact other aspects of our bending procedure.

Material, thickness, and pressures

Steel is an alloy, hence different steels have different resistance levels. Stated differently, the fact that some steels are stronger than others must be taken into consideration while bending those steels. We will not go into how the elements in the alloy determine higher or lower resistance, nor will we show how that resistance is calculated, but we will say that such resistance is known as traction resistance and is expressed as UTS (Ultimate Tensile Strength), a specification that we should all be aware of when purchasing from steel suppliers.

What should we do if the uts is higher?

UTS(Ultimate Tensile Strength)

Typically, we do nothing. Mild steel has an average UTS of 42 kg/mm2, whereas stainless steel is around 70 kg/mm2. However, we must remember that the higher the UTS, the greater the pressure necessary to bend a material.

Recall that the units of measurement for bending pressure on press brakes are t/meter or t/ft. Remember that a bigger V is required for thicker materials. This is merely because our sheet metal will not slide into a tiny V opening otherwise.

Profile radius

The bend’s radius is among the most important factors that the V opening affects. Some shop workers find it difficult to accept that the V opening, not the punch, will decide the part’s radius. Imagine a dangling bridge over a precipice to gain an understanding of this concept. The bridge will hang farther and have a wider radius the farther away both sides of the cliff are.

The part’s radius will increase with the size of the V opening. Yet the radius will also be impacted by the UTS. Why? Because a stronger material will resemble a wooden hanging bridge rather than one that is solely constructed of rope. Using the same V opening, we may conclude that the radius will be bigger for stronger materials.

It is established through empirical experience that the resultant radius R is typically 1/8 of a V opening. When bending mild steel, this is true, at least for thicknesses up to ½”. This establishes the general formula that most operators use:

R=V/8

Which can be then adjusted for other materials such as:

R x 0.8 for aluminum (lower UTS)

R x 1.4 for stainless steel (higher UTS)

Minimum leg

Finally, the leg or flange length that the part requires is the easiest to determine when choosing the appropriate V opening. Remember that during the bending process, our sheet metal needs to be in direct contact with the die shoulders at all times. The smaller-than-necessary leg will fall into the V opening and disrupt our bending operation if we don’t accomplish this.

Therefore, the minimum leg or flange that we need to have on a profile is larger the wider the V opening. This minimal leg length can be calculated using a geometrical formula. If we take a 90° bend into consideration and define b as the internal minimal leg length and V as the die opening, we can conclude that the least internal leg is:

Minimum internal leg = V x 0.67

This can then be adjusted for different angle bends as follows:

b x 1.6 for bends at 30°

b x 1.1 for bends at 60°

b x 0.9 for bends at 120°

b x 0.7 for bends at 150°

Budgetary Considerations

Select a minimum quantity of lower dies that will accommodate the full range of metal thicknesses that your company forms to obtain the most value for your money. Shops with limited funds, unplanned uses, and little tribal knowledge should attempt to use the 8×2 rule to select lower dies.

Choose the range of metal thicknesses that you wish to bend first. For instance, material that is 0.250 in thick through 0.030 in. may need to be bent. Then, multiply the thinnest metal by 8 to determine the smallest v die for press brake required. The lowest die would be required in this instance for 0.30-in. material, therefore we’ll round up to 0.25 (0.030 × 8 = 0.24). After that, double the thickest metal by eight to determine the greatest V die required. Here, the largest die would be required for the thickest material, which is 0.250 in. (0.250 × 8 = 2).

You now know that you require the smallest and largest dies, which are 0.25 and 2 inches. Start with the smallest V die and double its size to fill in everything you need in between. This provides you with a 0.5-inch die in this instance (0.25 × 2 = 0.5). Then, to produce 1.0 in. and 2.0 in., double the 0.5 in. die twice. This allows you to bend material ranging from 0.030 to 0.250 inches in four distinct V-die openings at a minimum: 0.25, 0.5, 1.0, and 2.0 in.

Installation and Setup:

Proper Alignment Techniques

Depending on the model of your press brake, there are a few different ways to align the toolings you use. To help you identify which and set it up safely, the three methods you are likely to encounter are listed below. This will help you set up your press brake machine correctly and safely manage the process.

The WILA Method:

A self-aligning hydraulic top and bottom clamping mechanism (WILA type) with an open and shut button is featured in some other machines, especially high-end versions.

On these versions, you can release the tool by pressing the hydraulic clamping button, and you can remove the tooling entirely by pressing another button. A second push of the hydraulic clamping button secures everything in place once you’ve fitted the appropriate tooling.

Quick-Clamp Technology:

Your model may be a fast clamp system, in which the bottom tool self-aligns and the top tool locks in place with a basic clamp. To use this system, simply select the V you need, seat it properly, and loosen the key bolts.

The top tooling will most likely feature the same quick clamping method as previously discussed, where the operator just fits the tooling and fast-clamps it in place manually. The Multi-V machines require alignment because the procedure isn’t automated.

However, for the bottom tooling, all handles are removed, a chain is looped around the ends of the lower and top portions of the machine, and the machine is set to slow speed. At this point, choose the v die for press brake you need and verify it is clean.

With that done, lower the beam using the front and rear adjusting devices while staring down the center of the machine. The goal is to line both the front and back ends, then nip the middle once you’re satisfied.

Importance of Rigorous Calibration

Observe Machine Safety Regulations:

Adhering to the manufacturer’s safety instructions is essential while using metal bending machines. This entails being aware of the machine’s safety features, limits, and capabilities. Before operating the machine, make sure you read the user handbook, and never change or delete any safety measures. Before doing any modifications or repairs, make sure the unit is turned off.

Put on Safety Gear:

Putting on the appropriate safety gear is one of the most crucial safety measures when bending metal. This consists of a hard hat, gloves, earplugs, and safety eyewear. Sparks, dirt, and noise from metal sheets can cause harm to your skin, ears, and eyes. To safeguard yourself from these risks, make sure you’re wearing the proper equipment. This is especially crucial for metal bending in Albuquerque since there’s a greater chance of coming into contact with potentially dangerous materials.

Make Use of Safe Lifting Methods:

Lifting and transporting bulky objects is frequently necessary when bending metal sheets. Using the right lifting techniques is essential to preventing back problems. This entails raising using your legs rather than your back and bending your knees. Additionally, make sure the metal sheet can be moved easily, and refrain from twisting your body when lifting.

Never Work by Yourself:

Bending metal is a risky hobby where mishaps can occur at any time. It’s imperative that you collaborate with people at all times to protect yourself. Always have a coworker or colleague on hand to help or call for help if necessary. In addition, keep a first aid kit and a phone nearby in case of an emergency.

Maintain A Clean And Organized Work Space:

When bending metal, keeping the work environment clean and orderly might help to prevent accidents and injuries. Keep your workplace clean and clutter-free. It entails cleaning up any scraps or debris from the floor and keeping your tools and equipment organized. A cluttered work environment can cause accidents, slips, and falls, resulting in significant injuries.

Troubleshooting Techniques:

Identifying Bending Irregularities

Bending Indentation

Bending indentation is the result of friction created during bending as the sheet metal gradually presses up against the inner surface of the die’s V-shaped groove, leaving visible imprints on the material’s surface.

Traditional bending is not able to meet the quality standards for items with high surface requirements, and the bending indentation is not able to meet the requirements of the procedure that follows.

The structure of the lower die and the hardness of the sheet material have the greatest effects on bending indentation. Harder materials are more resistant to plastic deformation, which makes it more difficult for the material to deform and facilitates the production of indentations.

The following is the order in which common materials are most likely to experience bending indentation: Stainless Steel > Carbon Steel > Aluminum. The indentation is shallower and larger the bigger the lower die’s opening. The indentation depth decreases with increasing die shoulder R size.

In addition to increasing material hardness and changing the lower die structure, techniques such as ball-bearing lower dies and anti-indentation rubber pads can be used to address bending indentation problems.

Anti-indentation rubber cushions physically isolate surfaces to prevent indentation formation. Ball-bearing lower dies to reduce friction and minimize product damage by converting the compressive friction needed for conventional die formation into rolling friction.

V Die

Bending cracking

Bending cracking is the phenomenon in which burrs or small fractures form at the margins of materials following cutting, shearing, or stamping, causing stress concentration and cracking when bent. After bending, the HXD1C locomotive accessory’s U-shaped reinforcement groove cracked at the corners.

The primary causes of bending cracking are:

The bending direction is parallel to the sheet’s rolling direction.

Unremoved burrs on the part edges.

The sheet material has an extremely small bending radius.

Bending cracking must be addressed in the manufacturing process by specific situations. For the bending cracking problem, remedies such as adding process holes or grooves can be used.

Bending the springback

Materials can deform in both plastic and elastic ways when bent. The workpiece undergoes elastic recovery after being taken out of the bending die, which results in a change in size and form from what it was during loading. One of the primary causes of insufficient bending angles is a phenomenon referred to as bending springback.

The mechanical characteristics of the sheet material and the degree of bending deformation are two factors that affect springback. The amount of springback is inversely correlated with the sheet’s elastic modulus and directly relates to its yield strength.

The springback decreases with decreasing relative bending radius (R/t, the bending radius divided by the thickness of the sheet). The amount of springback is also influenced by the bent part’s shape; generally, V-shaped parts have more springback than U-shaped parts.

Angle adjustment is the primary technique for overcoming bending springback. This is typically accomplished by balancing the effects of springback by constructing the bending die with a slope equal to the angle of springback. A workpiece can be effectively bent to a 90° angle using a bending die with an 80° slopeure.

Bending bulge

Bending bulge is the result of sheet metal that has undergone bending and has protruded on both sides of the bend as a result of material compression, resulting in a breadth that is greater than the initial dimensions. The bending bulge’s magnitude is typically determined by the part’s thickness and bending radius; the larger the thickness and the smaller the radius, the more noticeable the bulge.

Process notches can be inserted on both sides of the bending line during the bending expansion design stage, to avoid this problem. These notches, which successfully offset the bending bulge, are usually shaped like an arc and have a diameter greater than 1.5 times the workpiece’s thickness. To repair workpieces that already have a bending bulge, hand grinding is typically used.

If you still figure out the solution or you are confused about the issue, to begin with, do not hesitate to call an expert for your v die for press brake for help.

Press brake tools are an essential component of the sheet metal bending process. A press brake tool is a precision-made tool that is designed to work with a press brake machine to form, bend, and cut sheet metal to specific shapes and angles. The press brake tooling consists of a punch and a die, which work together to create the required bend in the metal. The punch is attached to the ram of the press brake, and the die is attached to the bed of the machine.

 

Press brake tools are available in a wide range of shapes, sizes, and materials, depending on the specific requirements of the bending job. For example, a V-shaped punch and die set is commonly used for making 90-degree bends, while a radius punch and die set is used for creating curves in the metal. The tools are made of hardened steel, and the surface of the tooling is often coated with a wear-resistant material to ensure longevity and durability.

 

Press brake tooling is a critical part of the sheet metal fabrication process and plays a significant role in determining the accuracy and precision of the final product. The selection of the appropriate tooling is crucial in achieving the desired bend angle and maintaining the integrity of the metal.

WHY CHOOSE VEOELL?

Because we meet all the above conditions. We can provide quality press brake tools that meet all your requirements and help you achieve accurate and consistent results.

Availability

Press brake tools from stock, short-term production of special tools and shear blades

Availability

Press brake tools from stock, short-term production of special tools and shear blades

Regrinding Service​​​​​​​

Press brake tools and shear blades, Product quality Premium

Regrinding Service​​​​​​​

Press brake tools and shear blades, Product quality Premium

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Press brake tools, special tools and shear blades

Manufacturer

Press brake tools, special tools and shear blades

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Full Service

Design, development, production

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