Press Brake Tooling and Shear Blades Maintenance

Introduction

A Comprehensive Guide to Extending Tool Life and Ensuring Precision

In the demand for metal fabrication, the longevity and efficiency of your machinery are paramount. Proper press brake tooling and shear blades maintenance are not just routine tasks; they are essential practices that ensure precision, enhance safety, and significantly extend the lifespan of your equipment.

Whether you’re looking for how to maintain press brake tooling or seeking best practices for shear blade maintenance, this guide provides the insights you need to keep your operations running smoothly and efficiently.

 

The Critical Role of Maintenance

In metal fabrication, precision and efficiency depend on well-maintained equipment. Press brake tooling and shear blades are critical components that directly impact:

• Product Quality – Precise bends and clean cuts
• Operational Costs – Reduced downtime and replacement frequency
• Equipment Longevity – Extended lifespan of expensive tooling
• Workplace Safety – Reduced risk of accidents and failures

Importance of Press Brake Tooling Maintenance

Press brake tooling is the direct interface with the material being formed, making its condition critical to the quality of the final product.

Regular press brake tooling maintenance is essential for fabrication operations. It directly contributes to extending the service life of your equipment, reducing operational costs, improving processing accuracy, enhancing operator safety, and boosting overall production efficiency.

• Extended Tool Life & Protected Investment: Regular maintenance significantly prolongs the operational lifespan of expensive tooling.
• Ensured Bending Accuracy: well-maintained tooling produces consistent bend angles and prevents surface imperfections.
• Reduced Press Brake Wear: Proper tooling maintenance prevents additional stress on the press brake machinery.

 

Common Causes of Damage and Wear

Ignoring proper tooling maintenance can result in damaged dies, decreased product quality, unexpected machine downtime, and significant safety risks. By adhering to a proactive maintenance schedule, you can prevent premature wear and ensure consistent bending results.

Understanding the primary factors that contribute to press brake tooling degradation is essential for implementing effective preventative measures:

1. Handling Without Gloves: Skin oils and contaminants transfer to tool surfaces, causing corrosion on precision-ground surfaces.
2. Metal Flakes and Residue: Particles from bending operations adhere to tooling, creating imperfections that transfer to workpieces and accelerate wear.
3. Improper Tool Storage: Tools exposed to elements or stored in unsuitable environments (like wooden cabinets that harbor moisture) are prone to rust and damage.
4. Improper Maintenance/Loading: Misaligned rams, faulty clamping systems, or incorrect loading can cause uneven forces and premature wear.

 

Best Practices for Press Brake Tooling Maintenance

Before initiating any press brake operations, a thorough daily inspection of your press brake tooling is crucial. This proactive step helps identify potential issues before they escalate into costly problems or safety concerns. Key areas to focus on include:

• Overall Machine Condition: Inspect the general condition of the press brake machine, paying close attention to the tooling area and worktable. Ensure there are no residues, debris, or foreign objects that could interfere with operation or damage the tooling.
• Tooling Examination: Carefully examine both the upper and lower dies for any signs of defects, cracks, chips, or excessive wear. Cracks or damage on the press brake dies can severely compromise bending quality and pose a safety risk. Look for any deformation that might affect the precision of your bends.
• Backgauge Accuracy: Test the accuracy of the backgauge and the positioning of the backgauge fingers. Ensure they are functioning correctly and providing precise measurements for consistent part production.
• Control System Check: Verify the responsiveness of all buttons, switches, indicator lights, and foot controls. Ensure they operate smoothly and without delay, as these are critical for safe and efficient operation.

Hydraulic System Maintenance

1)Leakage Inspection: Regularly inspect the hydraulic system for any signs of leaks, particularly around the hydraulic pump and connecting fittings. Even minor leaks can indicate underlying issues and lead to fluid loss and system inefficiency.

2) Oil Level and Cleanliness: Ensure that the hydraulic oil level is within the recommended range specified by the manufacturer. Maintaining the cleanliness of the hydraulic oil and the entire hydraulic circuit is vital. When cleaning valves, tank covers, and related accessories, it is generally not recommended to use
detergents, as they can introduce contaminants.

3) Oil Tank and Filter Care: The oil tank and hydraulic filters should be cleaned periodically. The filters at the oil pump inlet and outlet should be cleaned, and the air breather on the oil tank should be cleaned with compressed air. Filters and air breathers may need replacement after a certain period of use, depending on operational hours and environmental conditions.

4) Oil Quality: Use only the type of hydraulic oil recommended by the manufacturer to ensure optimal performance and system compatibility. Regularly check the oil level in the tank daily. The quality and viscosity of the oil should be checked every 4000 to 6000 operating hours, or as recommended by the manufacturer.

5) Oil Temperature Control: The hydraulic oil temperature should not exceed 60 degrees Celsius. High temperatures can adversely affect the oil’s stability, degrade its properties, and potentially damage hydraulic components.

 

General Press Brake Maintenance

1) Keep the machine clean and apply rust protectant to susceptible surfaces
2) Regularly inspect electrical connections and tighten if needed
3) Clean or replace air filters for electrical cabinets monthly
4) Check for loose parts and listen for unusual noises during operation
5) Keep the press brake manual accessible for reference

 

Shear Blades Maintenance

Proper shear blade maintenance is fundamental to achieving high-quality cuts, extending the lifespan of your blades, maximizing production efficiency, and ensuring operator safety. Regular shear blade care prevents dullness, rust, and damage, thereby avoiding unnecessary downtime and costly replacements. Well-maintained guillotine shear blades ensure clean, precise cuts, reduce material waste, and contribute to a smoother, more reliable metal shearing process. This section provides essential tips on how to maintain and sharpen shear blades.

Best Practices for Shear Blades Maintenance

• Regular Cleaning: Shear blades must always be kept clean. Use isopropyl alcohol and a clean rag to wipe down the blade profiles. Rub the inside of the blade with a cleaning pad and then wipe it with a rag to remove metal shavings, oil, and other debris. This prevents buildup that can affect cutting performance and lead to corrosion.
• Lubrication: Lubricate the blades with a suitable oil, such as Aemovil M302 oil, as recommended by the manufacturer. Apply grease to the internal bearings of the rollers. For high-carbon steel shear blades, apply a light machine oil or specialized blade oil to the pivot screws every few months or after cleaning, wiping away any excess to prevent transfer to materials.
• Sharpening and Grinding: After prolonged use, shear blades will eventually become dull. Use a diamond sharpener suitable for carbide to sharpen the blades. Typically, it is not necessary to remove more than 0.10 mm of height during the sharpening process. For major grinding, start with a green carbide grinding wheel for rough grinding, then finish with a diamond grinding wheel for fine grinding. Regular blade sharpening maintains the sharpness of the cutting edge, which is crucial for clean cuts and reducing strain on the machine.
• Inspection and Adjustment: Regularly inspect the cutting clearance between the punch and the blade. For steel, maintain a clearance of 10% of the metal thickness, and for aluminum, 15%. Ensure that the shear blades are correctly aligned. Proper alignment between the lower and upper blades is critical for achieving optimal cutting results and preventing burrs. Adjust the blades as needed to prevent burrs and ensure a clean cut.
• Component Replacement: If necessary, replace old blade rubbers and ensure new rubbers are used during reassembly. If the distance from the cutting edge to the “die center” lip is lost due to continuous grinding, shims can be used to rework the blade. Ensure shims are burr-free, uniformly thick, and milled with holes. * Storage
  and Handling: Handle shear blades with care during storage, assembly, and disassembly to prevent damage. Proper storage protects the cutting edges from accidental impact and corrosion.

 

Trouble shooting Common Shear Blade Issues

Effective troubleshooting press brake tooling issues and shear blade problems can minimize downtime and extend tool life. Here are some common issues and their solutions:

1. Dull or Unsharp Blades: If the cutting edge becomes dull or unsharp, it’s time to either flip the blade (if it has multiple cutting edges) or replace it. When adjusting the blade, first set the blade gap to its maximum, then gradually reduce it by closing the ball valve until the desired clearance is achieved.
2. Incorrect Blade Gap: The shear blade gap adjustment should be determined based on the thickness of the steel plate being cut. Generally, it should be 5% to 7% of the material thickness. Incorrect gaps can lead to burrs, uneven cuts, and excessive wear on the blades.

Identifying and addressing common problems quickly can minimize downtime and maintain product quality:

Issue	Solution
Dull Blades	Rotate/flip blades or sharpen using appropriate grinding techniques
Burred Edges	Check and adjust cutting clearance; ensure proper blade alignment
Inconsistent Bend Angles	Verify tooling alignment; check for debris under dies
Tool Sticking	Apply appropriate lubrication to reduce friction
Tooling Misalignment	Ensure proper seating and check for worn clamping systems

Conclusion

Proactive and systematic maintenance of press brake tooling and shear blades is essential for metal fabrication operations. From meticulous cleaning and precise lubrication to proper storage and careful handling, each practice contributes significantly to equipment health.

Key Benefits of Proper Maintenance

• Increased operational efficiency through reduced downtime
• Extended equipment life that defers costly replacements
• Improved product quality with precise bends and clean cuts
• Enhanced workplace safety for operators