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Clamping down on costs
Find the right clamping system for your press brake
- By Steve Brown
- August 21, 2017
- Article
- Bending and Forming
Setup time adds costs to every part that goes out the door. Finding and implementing adequate practices to help minimize costs while elevating production efficiencies can cause headaches on the shop floor, not to mention budget frustrations. Clamping systems are one solution that fabricators have been implementing for decades to bring faster setup times and reduce costs. But with so many choices – hydraulic, air, manual – what really is the best option?
Numerous clamping systems are available for the press brake, but production managers often are put off by the potential cost of having to purchase a new brake to fully utilize a new clamping system. By looking at ways to refurbish an existing press brake, along with the different clamping options available, fabricators can make decisions that best suit their work flow, production schedules, and budget.
Refurbish an Old Brake
A new press brake is a significant investment, one that should last for decades. With costs for a small brake running between $50,000 and $120,000 and large brakes hitting half a million dollars, weighing the benefits of such an investment isn’t a light decision, nor one that is always within the budget.
The thought of purchasing a new brake shouldn’t scare fabricators away from purchasing a clamping system for an older brake. Refurbishing an existing press brake can deliver the right setup for the system.
Over time it is common for press brakes to experience wear and tear on the upper and lower beams. A worn beam with uneven surfaces and other disfigurements not only poses challenges for clamping systems, but also just about any type of application performed on the brake. If the frame of the brake is still in good shape and the stroke is repeatable, the brake most likely has years of life left. Simply grinding the upper and lower beam surfaces can make all the difference.
The cost for grinding press brake beams is approximately $10,000 to $14,000, which is a far cry from purchasing a new machine, even one that’s smaller. Adjustments are necessary in the brake control to account for the change in open height – a minor change and cost to help improve repeatability and operator efficiency and add years to the machine’s life.
Types of Clamping Systems: The Pros and Cons
A clamping system is another option for extending a press brake’s useful life. Any type that replaces the need to tighten set screws manually is a good investment. The choices now include high-speed power clamping using hydraulic- and air-powered systems, as well as quick-change manual clamping systems. Learning more about the pros and cons of each and aligning those features with specific applications and production requirements can help fabricators make the best choice for their operations.
Power Clamping. Delivering high-speed clamping at the touch of a button, power systems are designed to clamp and seat each punch section at the same time. The entire process is operated by a wireless, hand-held control.
Power clamping provides precise alignment and the maximum open height for large flanges or parts. Available with either air- or hydraulic-power options, they can be installed utilizing existing power sources within the shop.
A power-clamping system naturally costs more than a manual system, but the cost is considerably lower than that of a new press brake. Requiring less changeover time, these systems often are a good choice for shops that have numerous changeovers throughout the day.
Quick-change Manual Clamping. Another option that eliminates the need for manually tightening set screws for each punch in the press brake, the quick-change clamping system secures the tools using a quick-change lever. The operator inserts short, long, or sectionalized tools into the clamp and then slides the removable lever to clamp the tools securely into place.
Most tooling manufacturers offer quick-change manual clamping systems for virtually all types of press brakes. While the manual lever still requires slightly more time to clamp the tooling by hand, the system has an extremely low chance of failing, since there is no power source connected. For shops that routinely run high-volume parts or repeat jobs, a quick-change manual clamping system can deliver a quick return on investment.
Standard Manual Clamping. Sometimes speed just isn’t a concern. That’s why tooling manufacturers still offer standard manual clamping systems with various punch and die holders that can convert tooling styles or extend bend clearance. These systems require operators to tighten traditional set screws or clamp plates for each tool, but the time-tested option continues to deliver accurate results at a considerably cost-effective price.
While the cost of a standard clamping system is upfront, changeover time is a factor fabricators should keep in mind when considering the best choice for the shop to ensure efficient operations.
The Extras
Tooling manufacturers offer a variety of clamping tools for most press brakes. While selecting the type of product and finding the right price are key factors in making a decision, service and quality are company differentiators that tooling manufacturers use to set themselves apart from the competition and can often prove beneficial for shop managers.
Tool quality is an important consideration when researching clamping systems. Fabricators should ask tooling manufacturers about hardening practices they use to make longer-lasting, more durable tools and the additional costs associated with these types of features. Identifying the proper fit of the tools for each application also is an important consideration, and many tooling manufacturers offer support to help fabricators ensure the tooling works the first time upon receipt.Finally, following installation instructions that come with a system can be a simple process. However, extra help from the manufacturer may be necessary. If a fabricator is uncertain about installing a new clamping system, it can ask the manufacturer if service technicians are available to install it, or if it offers phone or chat availability for troubleshooting during a DIY install.
Selecting the Right Clamping System
There’s no need for fabricators to watch profits fly out the door by performing complicated, time-consuming setups on the press brake. With a variety of options that can suit just about any type of shop and any type of press brake, fabricators can do the research to determine the best clamping system for their operations. Whether refurbishing a press brake beam and installing a clamping system or simply upgrading to a quick-change manual system, fabricators have options available to help curb costs and add a competitive edge to production.
About the Author
Steve Brown
12912 Farnham Ave.
White Bear Lake, MN 55110
866-752-6531
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The Fabricator is North America's leading magazine for the metal forming and fabricating industry. The magazine delivers the news, technical articles, and case histories that enable fabricators to do their jobs more efficiently. The Fabricator has served the industry since 1970.
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