“Finn-Power is the only machine builder that took a position on the ...

FOCUS ON TOOLING
Selecting a Press Brake
Tooling System for <strong>the</strong> Future
In purchasing one of today’s highly productive CNC press brakes, <strong>the</strong>
buyer will have to make several important dec<strong>is</strong>ions. One of <strong>the</strong>m
involves determining which tooling system will be used in <strong>the</strong> new
<strong>machine</strong>. While it may seem logical to have <strong>the</strong> new <strong>machine</strong> equipped to
utilize <strong>the</strong> style of tooling <strong>that</strong> was previously used, making <strong>the</strong> dec<strong>is</strong>ion to
go with an older, possibly outdated tooling system could actually prove to
be very costly and might place severe limitations on <strong>the</strong> <strong>machine</strong>s
capabilities.
Due to its accuracy and speed of set-up, <strong>the</strong> European or
Promecam”style tooling system formerly represented <strong>the</strong> state of <strong>the</strong> art.
However, usage of th<strong>is</strong> tooling system <strong>is</strong> now in a fairly severe state of
decline worldwide due to <strong>the</strong> fact <strong>that</strong> most of <strong>the</strong> punches are fairly short
in working height, thus limiting <strong>the</strong>ir versatility. In addition, <strong>the</strong> working
surfaces of <strong>the</strong> punches and dies are often hardened to HRC-43 to 48,
which provides an inferior level of wear res<strong>is</strong>tance when compared to <strong>the</strong>
more advanced heat treatment processes <strong>that</strong> are currently available.
O<strong>the</strong>r problems include <strong>the</strong> fact <strong>that</strong> it requires a variety of costly die
holders and die rails to utilize most of <strong>the</strong> various die styles <strong>that</strong> are
common to th<strong>is</strong> tooling system. These die holders and rails must also be
removed from <strong>the</strong> press brake when using dies with large V-openings and
Hemming Dies.
North American style press brake tooling has long been <strong>the</strong> most
comm<strong>only</strong> utilized tooling in North America. While versatile and easy to
use, it too has its limitations. Th<strong>is</strong> includes <strong>the</strong> fact <strong>that</strong> <strong>the</strong> end user <strong>is</strong>
limited to a narrow range of punch and die heights, which limits versatility
when forming deep parts and parts with long down flanges, as well as <strong>the</strong>
capability of press brakes with large amounts of open height.
Most North American style tooling in use today <strong>is</strong> of <strong>the</strong> nonprec<strong>is</strong>ion
type and <strong>is</strong> produced on planer milling <strong>machine</strong>s to a tolerance
<strong>that</strong> <strong>is</strong> several times <strong>that</strong> of <strong>the</strong> press brake itself. Consequently, it
comprom<strong>is</strong>es <strong>the</strong> <strong>machine</strong>s accuracy, repeatability, and overall productivity.
It also makes it difficult to take advantage of <strong>the</strong> flexibility and low
tonnage requirements provided with prec<strong>is</strong>ion air bending. Due to its lack
of prec<strong>is</strong>ion, planer made press brake tooling cannot be reordered with any
assurance <strong>that</strong> it will match <strong>the</strong> original tooling <strong>that</strong> was purchased.
North American style tooling <strong>is</strong> offered with a variety of working
surface treatments. Much of it <strong>is</strong> soft, and subsequently, does not last very
long. As punch tip radii and die shoulder radii break down, accuracy
suffers and <strong>is</strong> most often overcome by shimming <strong>the</strong> dies. Th<strong>is</strong> leads to
reduced productivity, lower part quality, and longer set-up times. Options
available to combat tooling wear include flame hardening of <strong>the</strong> working
surfaces, which will provide longer tool life but can be very incons<strong>is</strong>tent,
coatings, which are <strong>only</strong> approximately .020" (0.5 mm) deep, and laser
hardening which <strong>is</strong> approximately .039" (1.0 mm) deep. These processes
work very well for so long as <strong>the</strong> treated area remains intact. However, any
breach of <strong>the</strong> coated or laser hardened area will lead to rapid deterioration
of <strong>the</strong> working surface in <strong>that</strong> area of <strong>the</strong> tool.
Today, <strong>the</strong> state of <strong>the</strong> art in press brake tooling technology <strong>is</strong> defined
by <strong>the</strong> Wila New Standard tooling system. Th<strong>is</strong> system <strong>is</strong> prec<strong>is</strong>ion ground
to a tolerance of +/-.0004" (.01mm), making it <strong>the</strong> most accurate press
brake tooling system available. Most punches are available in four different
24
by David B<strong>is</strong>hop, Business Development Manager, Wila USA
heights with <strong>the</strong>
tallest being 7.874"
(200 mm), enabling
<strong>the</strong> operator to take
maximum
advantage of <strong>the</strong>
<strong>machine</strong>s open
height and stroke
length. Most New
Standard dies are
available in heights
of 2.165” (55 mm)
and 3.937”
(100 mm).
Like all Wila
press brake tooling,
our New Standard
tooling <strong>is</strong> CNC
Deep-hardened on
<strong>the</strong> working
surfaces to HRC-
60 to a depth of
.118" (3.0 mm),
making it <strong>the</strong> most
durable line of
press brake tooling
available. When used with our New Standard clamping and crowning
systems with hydraulic clamping, all Wila New Standard tooling <strong>is</strong>
clamped, seated, centered, and aligned with <strong>the</strong> push of a single button,
and <strong>the</strong> need for die shimming <strong>is</strong> totally eliminated. Th<strong>is</strong> results in a
drastic reduction in set-up time and eliminates <strong>the</strong> need for cumbersome,
time consuming wrenches and levers.
All Wila punches are available with our patented Safety Clicks,
making it possible to load and unload <strong>the</strong>m vertically, eliminating <strong>the</strong>
need to slide <strong>the</strong>m in and out <strong>the</strong> end of <strong>the</strong> <strong>machine</strong>.
Finally, our taller more versatile tooling profiles are extremely flexible
making it possible for <strong>the</strong> end user to use less tooling to produce a much
wider variety of parts.
The purchase of a new press brake <strong>is</strong> a dec<strong>is</strong>ion <strong>that</strong> you will most
likely have to live with for at least <strong>the</strong> next ten years. The same <strong>is</strong> true with
<strong>the</strong> tooling, clamping, and crowning systems <strong>that</strong> will be utilized on th<strong>is</strong>
<strong>machine</strong>. When viewed from th<strong>is</strong> perspective it <strong>is</strong> easy to see just how
important it <strong>is</strong> for you to make <strong>the</strong> right dec<strong>is</strong>ions.
For more information, please contact:
WILA USA
9135 Guilford Road
Columbia, MD 21046 USA
Tel: 888-696-9452
Fax: 301-490-3991
Press Brake Productivity Web Site: www.wilausa.com