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Precision is not only the aim of metal fabrication, but a necessity. Although it is understandably much more devoted to the press brake machine itself, its programming, and proficiency of the operator, there is one basic element which is frequently disregarded: the press brake die. The choice of the right die is not an incidental thing, it is a very serious issue that determines the precision, stability and quality of each individual bend that you make. This relation is the most important to understand the art of precision bending.
The Direct Link Between Die Geometry and Bend Formation
A bend is formed on the basis of the press brake die. Its physical properties are immediately implicated in the workpiece, its geometry becoming the main determiner of the bend result.
V-Opening and the Forming Process
The most important factor is the width of the V-opening of its die. A too-wide V-die used on material with a thickness that is too thin will result in an inconsistent and poorly-defined bend, and excessive inner radius that is not up to specification. On the other hand, a too-narrow V-die raises the risk of ruining the machine, the tooling and even the material itself, by excessive tonnage. The severe marking or shearing of an material surface can also occur. The right V-width will assure the precise leverage applied in a clean and efficient manner producing an accurate bend radius and angle.
The Critical Role of the Die Angle
One of the most frequent mistakes is to think that the die angle has to be equal to the end bend angle. As a matter of fact, to obtain a perfect 90-degree bend, e.g. a die with a 2-degree aperture (88 or 85) is commonly employed. This is what allows the material to have a natural springback, i.e. to tend to partially to reopen once the bending pressure is released. A die of the same angle as your target, with no adjustment to springback, will produce a constant, and over-angulated bend. The die angle should be picked in a manner that will purposefully over shape the material in such a way that it returns to the precise angle.
How Die Material and Condition Influence Results?
The make and maintenance of your tooling is equally essential as is its shape. Dies of poor quality or worn condition are incapable of giving good parts.
Managing Material Springback and Consistency
Hardened steel dies of high quality offer extreme durability and consistency. Less expensive or run-down dies may wear on their surfaces, form nicks, and deformities with time and usage. Then these defects are pressed into each new workpiece, resulting in scratches, irregular bend lines, and variation in angle and dimension. The hardness of a high end die assures that the pressure of the punch is distributed consistently and consistently throughout length of the flex, and this is important in ensuring that a uniform flex in a very long strip of sheet metal is accomplished.
Surface Finish and Part Quality
The surface of die is finished in direct contact with the material. A die surface that is smoothed and polished reduces friction and removes the appearance-marring appearance of the finished part. It is of great concern where bending of pre-finished or fragile materials such as polished aluminum or coated steel is involved. A coarse or pitted die will mark and vulcanize the material resulting in expensive rejects and further finishing.
A Foundation for Precision
The selection of bending press braze die is a core element of the bending process. It is a choice that combines material science, machine parameters and intended results. It is not a universal answer but rather an exact estimate which takes into consideration the type of material, material thickness, tensile strength and end results bend needs. Spending time in choosing the appropriate die geometry and spending resources in keeping high quality tooling is not an overhead- it is a direct investment in the accuracy, efficiency, and reputation of your fabrication work. Any accurate bend starts with the base that you lay it on.
