Brake Press Set-up Aids
Box Forming
![](http://mecon.com/wp-content/uploads/Press-brake-box-forming-2.jpg)
![](http://mecon.com/wp-content/uploads/Press-brake-box-forming.jpg)
![](http://mecon.com/wp-content/uploads/Press-brake-box-forming-3.jpg)
Standard Guage for Steel Sheets | |||||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
GAUGE | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 14 | 16 | 18 | 20 | 22 | 24 |
THICKNESS | 0.239" | 0.224" | 0.209" | 0.194" | 0.179" | 1.164" | 0.149" | 0.135" | 0.105" | 0.075" | 0.06" | 0.048" | 0.036" | 0.03" | 0.024" |
PressBrake Features
![](http://mecon.com/wp-content/uploads/Throat.jpg)
Common Types of Brake Punch Tongues – Others on Request
![](http://mecon.com/wp-content/uploads/Press-brake-tangs.jpg)
Brake Press Tonnage Chart
Tons Required Per Linear Foot to Bend Mild Steel Plate Having 60,000 PSI Tensile Strength
Thickness of MATERIAL | Width of Die opening |
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---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Gauge | Inches | 1/4" | 5/16" | 3/8" | 7/16" | 0.5 | 3/8” | 0.75 | 0.875 | 1 ” | 1.125 | 1.25 | 1.5 | 2" | 2.5 | 3" | 3.5 | 4" | 5" | 6" | 7" | 8" | 10" | 12" |
20 | 0.036 | 3.1 | 2.3 | 1.7 | 1.4 | 1.1 | ||||||||||||||||||
18 | 0.048 | 5.3 | 4 | 3 | 2.5 | 2.2 | 1.7 | 1.3 | ||||||||||||||||
16 | 0.06 | 9.6 | 7.1 | 5.6 | 4.5 | 3.8 | 2.8 | 2.2 | 1.8 | 1.5 | ||||||||||||||
14 | 0.075 | 11.9 | 9.2 | 7.6 | 6.3 | 4.7 | 3.5 | 3 | 2.5 | 2.1 | 1.8 | |||||||||||||
12 | 0.105 | 16.7 | 13.1 | 9.7 | 8 | 6.5 | 5.6 | 4.6 | 4.1 | 3.2 | ||||||||||||||
11 | 0.12 | 19.2 | 14.2 | 11.1 | 9 | 7.5 | 6.3 | 5.5 | 4.4 | 2.9 | ||||||||||||||
10 | 0.135 | 18.6 | 14.5 | 11.9 | 9.9 | 8.5 | 7.3 | 5.8 | 4 | |||||||||||||||
3/16" | 0.188 | 27.4 | 23.1 | 19.3 | 16.4 | 14.3 | 11.2 | 7.5 | 4.4 | |||||||||||||||
1/4" | 0.25 | 39.4 | 33.3 | 29.5 | 22.7 | 15.4 | 11.4 | 9 | 7.4 | 6.1 | ||||||||||||||
5/16" | 0.313 | 50.4 | 39.8 | 27 | 19.7 | 15.3 | 12.7 | 10.5 | 7.7 | |||||||||||||||
3/8" | 0.375 | 61.6 | 42.3 | 30.9 | 24 | 19.6 | 16.3 | 12.3 | 9.5 | |||||||||||||||
7/16" | 0.438 | 61.7 | 45.8 | 35.4 | 28.6 | 24.4 | 17.3 | 14.8 | 11.2 | |||||||||||||||
1/2" | 0.5 | 85.2 | 63.6 | 48.8 | 39.7 | 33.3 | 24.6 | 19.4 | 15.9 | 13.1 | ||||||||||||||
5/8" | 0.625 | 110 | 86.2 | 70 | 58.3 | 43.1 | 33.3 | 27.4 | 23.3 | 16.9 | ||||||||||||||
3/4" | 0.75 | 138 | 110 | 93 | 68.7 | 53.5 | 43.6 | 36.5 | 27.1 | 21 | ||||||||||||||
7/8" | 0.875 | 165 | 137 | 104 | 80.7 | 64.6 | 52.9 | 39.7 | 31.6 | |||||||||||||||
1" | 1 | 197 | 143 | 113 | 91.2 | 76.2 | 56.3 | 44.2 | ||||||||||||||||
Notes: The tonnages indicated in bold italics are for die openings eight times the thickness of the metal. With an 8:1 die ratio, the inside radius of a right angle bend is approximately equal to the thickness of the material. |
For other metals as compared to 60,000 PSI tensile strength mild steel adjust as follows:
- Soft brass: 50% of pressure listed.
- Soft aluminium: 50% of pressure listed.
- Stainless steel: 50% more than pressure listed.
- Chrome molybdenum: 100% more than pressure listed.
Brake Press Bending Allowance Chart
Bend Allowances for 90° Bends in Low‑Carbon Steel and Aluminum (Al)
Bend Allowances for 90° Bends in Low-Carbon Steel and Aluminum | ||||||||||
---|---|---|---|---|---|---|---|---|---|---|
Bend allowance, inches, for bends with inside radius (r) of: | ||||||||||
Metal thickness (t), in. | 1/32 in. | 1/16 in. | 3/32 in. | 1/8 in. | 1/4 in. | 1/2 in. | ||||
Steel | Al | Steel | Al | Steel | Al | Steel | Al | (steel) | (steel) | |
0.032 | 0.059 | 0.057 | 0.066 | 0.068 | 0.079 | 0.082 | 0.093 | 0.095 | 0.146 | 0.254 |
0.05 | 0.087 | 0.078 | 0.101 | 0.091 | 0.114 | 0.105 | 0.129 | 0.118 | 0.168 | 0.276 |
0.062 | 0.105 | 0.095 | 0.118 | 0.108 | 0.132 | 0.12 | 0.145 | 0.133 | 0.183 | 0.29 |
0.078 | 0.128 | 0.116 | 0.142 | 0.131 | 0.155 | 0.144 | 0.169 | 0.157 | 0.202 | 0.31 |
0.09 | 0.146 | 0.13 | 0.16 | 0.144 | 0.173 | 0.157 | 0.187 | 0.17 | 0.217 | 0.324 |
0.125 | 0.198 | 0.175 | 0.211 | 0.189 | 0.224 | 0.203 | 0.243 | 0.216 | 0.26 | 0.367 |
0.188 | 0.289 | 0.302 | 0.217 | 0.316 | 0.283 | 0.329 | 0.297 | 0.383 | 0.443 | |
0.25 | 0.382 | 0.395 | 0.409 | 0.365 | 0.424 | 0.378 | 0.476 | 0.519 | ||
0.313 | 0.488 | 0.501 | 0.515 | 0.569 | 0.676 | |||||
0.375 | 0.593 | 0.607 | 0.661 | 0.768 | ||||||
0.437 | 0.699 | 0.752 | 0.86 | |||||||
0.5 | 0.845 | 0.952 |
Bend Allowances for 90° Bends in Low-Carbon Steel and Aluminum (Metric) | ||||||||||
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Bend Allowance (mm) for Bends with Inside Radius (r) of: | ||||||||||
Metal Thickness ( t ), mm (Inches) | 0.8 mm(1/32") | 1.6 mm(1/16") | 2.4 mm(3/32") | 3.2 mm(1/8") | 6.4 mm(1/4") | 12.7 mm(1/2") | ||||
Steel | Al | Steel | Al | Steel | Al | Steel | Al | Steel | Steel | |
0.8 (0.032") | 1.5 | 1.4 | 1.7 | 1.7 | 2 | 2.1 | 2.4 | 2.4 | 3.7 | 6.5 |
1.3 (0.050") | 2.2 | 2 | 2.6 | 2.3 | 2.9 | 2.7 | 3.3 | 3 | 4.3 | 7 |
1.6 (0.062") | 2.7 | 2.4 | 3 | 2.7 | 3.4 | 3 | 3.7 | 3.4 | 4.7 | 7.4 |
2.0 (0.078") | 3.3 | 2.9 | 3.6 | 3.3 | 3.9 | 3.7 | 4.3 | 4 | 5.1 | 7.9 |
2.3 (0.090") | 3.7 | 3.3 | 4.1 | 3.7 | 4.4 | 4 | 4.8 | 4.3 | 5.5 | 8.2 |
3.2 (0.125") | 5 | 4.4 | 5.4 | 4.8 | 5.7 | 5.2 | 6.2 | 5.5 | 6.6 | 9.3 |
4.8 (0.188") | 7.3 | 6.5 | 7.7 | 5.5 | 8 | 7.2 | 8.4 | 7.5 | 9.7 | 11.3 |
6.4 (0.250") | 9.7 | 8.6 | 10 | 8.9 | 10.4 | 9.3 | 10.8 | 9.6 | 12.1 | 13.2 |
8.0 (0.313") | 12 | – | 12.4 | – | 12.7 | – | 13.1 | – | 14.5 | 17.2 |
9.5 (0.375") | 14.4 | – | 14.7 | – | 15.1 | – | 15.4 | – | 16.8 | 19.5 |
11.1 (0.437") | 16.7 | – | 17.1 | – | 17.4 | – | 17.8 | – | 19.1 | 21.8 |
12.7 (0.500") | 19.1 | – | 19.4 | – | 19.7 | – | 20.1 | – | 21.5 | 24.2 |
![](http://mecon.com/wp-content/uploads/Press-brake-bend-allowance.jpg)
w = a + b + c + d + e –
(4 x bend allowance)
![](http://mecon.com/wp-content/uploads/Press-Brake-Tooling-Bend-Allowance-Quad-Bend.jpg)
w = a + b –
(single bend allowance)
![](http://mecon.com/wp-content/uploads/Press-Brake-Tooling-Bend-Allowance-Single-Bend.jpg)
w = a + b + c –
(2 x bend allowance)
![](http://mecon.com/wp-content/uploads/Press-Brake-Tooling-Bend-Allowance-Double-Bend.jpg)
w = a + b + c + d –
(3 x bend allowance)
![](http://mecon.com/wp-content/uploads/Press-Brake-Tooling-Bend-Allowance-Triple-Bend.jpg)
Note: w = developed width of blank, t = metal thickness, r = inside radius of bend
Notes of Interest
Offset Dies
![](http://mecon.com/wp-content/uploads/Press-brake-offset.jpg)
Tonnage requirements can be reduced by air bending rather than bottoming (compromising on accuracy), and also by using larger radii on the forming points.
Radius Dies
![](http://mecon.com/wp-content/uploads/Press-brake-radius-dies.jpg)
Fracturing
![](http://mecon.com/wp-content/uploads/Press-brake-fracturing.jpg)
Channel Dies
![](http://mecon.com/wp-content/uploads/Press-brake-channel-dies.jpg)
Press Brake Deflection
![](http://mecon.com/wp-content/uploads/Press-brake-deflection.jpg)
In some presses the bed and ram do not deflect in an even curve. The deflection can be mapped out for a press that is doing a particular job by taking accurate measurements along the length of test pieces. This deflection curve can then be reproduced by the machine.
- Shim the bottom (crowning) die manually by using a roll of adding machine paper. Start in the middle with a short piece, gradually increasing the length of the layers. The number of layers may be increased or decreased as required. Three layers of paper equals approximately 0.012-0.015 inches.
- If you are working within a small range of material thickness, the crown required may be reasonably consistent. Map out the deflection and machine it into the riser block.
- If you have dedicated tooling for a specific job, map out the deflection and have the tooling crowned.
- Purchase a “Mecon Deflection-Compensating Die Holder.”
![](http://mecon.com/wp-content/uploads/Press-Brake-Compensating-Riser.jpg)
Mecon Deflection-Compensating Die Holder.
- Multi point calibrating adjustment.
- Crown read-out indicators.
- Patent#1234039
Thinking Safety
![](http://mecon.com/wp-content/uploads/Press-Brake-Tooling-Safety.jpg)
Our dies are never intended to be used in equipment without a means provided to prevent hands or other body parts from entering or remaining in the die space at any time.
- Require that dies be set only by a qualified, safety-conscious die-setter.
- Insist that the die-setter be fully familiar with the press or machine’s manual.
- Provide all point-of-operation guards or devices necessary to avoid exposing any part of the operator’s body to the closing of the machine or press.
- Provide hand tools to insert, hold, and remove material, and to keep hands at a safe distance from the point of operation.
- Insist on safety practices and procedures and enforce them daily.
- Follow the instructions provided in the manual for the machine in which dies are being installed and operated.
- Ascertain that operators are trained in safety procedures, and arrange for periodic inspections to ensure that those procedures are being followed.
- Make available such safety-standard approved devices as pull-backs, fences, and infrared light curtain and controls for all press equipment. Two-button operation may also be necessary in some instances.