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What is the difference between a press brake and a bending machine?
Hydraulic bending machine vs. press brake - Dr. Hochstrate
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Panel Benders Vs. Press Brakes - Which Is Better And Why?
How Are Panel Benders Different From Press Brakes?
While the press brake has been the go-to bending machine for many years, depending on the part, the panel bender can have several advantages over the traditional press brake.
Machine Set Up
The most noticeable difference between a press brake and a panel bender is their bending methodologies. In a traditional hydraulic press brake, clamps secure the upper punch and the lower riser, which holds the V-die. The operator engages the foot pedal to lower the punch onto the sheet metal, forming a bend into the V-die. The V-dies come in various sizes based on sheet thickness and required bend angles, while specialized punches like goosenecks or narrow punches can be used for unique bends. However, acquiring diverse tooling can be costly, and over time, these tools wear out and need replacement, adding to project expenses. It also tends to be time-consuming and labor-intensive to switch out tools for different parts.
Conversely, a panel bender employs a different and more automated approach. In a panel bender, the machine uses a counter blade and blank holder to keep the sheet in place. The universal upper and lower bending blades apply lateral force to bend the sheet without needing to change tooling for different jobs. This eliminates significant production downtime and minimizes manual intervention.
Production Efficiencies
Beyond tooling, panel benders excel in speed, repeatability, and consistency compared to traditional press brakes. Both machines can be outfitted with CNC (computer numerical control) technology; however, a press brake requires manual handling of the sheet metal for each bend. Large sheets especially pose challenges in manipulation, often needing multiple operators, which introduces inefficiencies and risks of operator fatigue.
In contrast, panel benders utilize part manipulators to maneuver the metal sheet automatically. Once the sheet is positioned against the locating device, the bending process is entirely automated. Advanced sensors measure material thickness, size, and environmental factors, adjusting the tooling accordingly to eliminate waste and errors. As a result, a panel bender can produce parts two to three times faster than a traditional press brake, with superior consistency. For instance, the Salvagnini P4 Panel Bender averages 17 bends per minute, providing a substantial boost in productivity and enabling lights-out manufacturing for tight deadlines.
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One issue that arises with press brakes that is eliminated with panel benders is back bending. Back bending results from the material lagging behind the press while the form is taking place, which generally results in a whipping motion as the material tries to catch up with the press. Back bending is more common in very large panels where the operator cannot keep up with the press’s speed as the material is manually raised during the actual forming process. The result is a slight reverse kink or bend at the die edge. Another instance where back bending can occur is when the material hits the back of the form tooling before the bend is complete. With the panel bender, the material mass lies flat on the table and does not have to follow the press action during the bending operation, thereby eliminating the risk of back bending.
In addition, the panel bender has unparalleled accuracy and repeatability numbers. The panel bender’s integrated advanced sensors measure the blank, including material thickness, for precise placement and bending. The sensors also detect any deformations caused by variations in temperature. The collected data is used to instantly calculate the correct force required to bend the sheet metal. From the inside bend line to the inside bend line, the accuracy is +/- .008″ on the overall panel dimension. The repeatability of the panel bender is +/- .004″.
What is a good part for a panel bender?
Not surprisingly, a good part for a panel bender is…a panel! There are many projects with panels that are excellent candidates for using a panel bender, including:
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- Cabinet components
- Enclosures
- Appliance components
- Lighting fixtures
- Architectural panels
- And more
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The size of the panel will depend on the limitations of the specific panel bender being used. To provide a reference, the ideal part dimensions for the Salvagnini Panel Benders used by Estes are:
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- Up to 11 gauge steel, 14 gauge stainless steel, .150″ aluminum
- Up to 85.8″ bend length
- Up to 62.9″ blank width
- Up to 98.4″ blank diagonal
- Up to 6.5″ bend height
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Even though a panel bender offers ease of setup, greater operating efficiencies, and high-quality output, there are a number of parts that fall outside the criteria and are better suited for fabrication using a press brake.
When it comes to high-quality metal fabrication, both the panel bender and press brake have a place. The decision as to which to use will depend on the type and size of the project.
Contact Estes
If you have questions or are looking for a partner with proven experience in sheet metal fabrication, Estes has the experience to deliver. Contact us today to get started!
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