PRESS BRAKE

TECHNOLOGY
a guide to precision sheet metal bending

Steve D. Benson

Society of Manufacturing Engineers

Dearborn, Michigan

Copyright 1997 Society of Manufacturing Engineers

987654321
All rights reserved, including those of translation. This book, or parts
thereof, may not be reproduced in any form or by any means, including
photocopying, recording, or microfilming, or by an information storage
and retrieval system, without written permission from the copyright
owners.
No liability is assumed by the publishers with respect to the use of
information contained herein. While every precaution has been taken
in the preparation of this book, the publisher assumes no responsibility
for errors or omissions. Publication of any data in this book does not
constitute a recommendation or endorsement of any patent, proprietary
right, or product that may be involved.
No responsibility is assumed by the publisher for any injury and/or
damage to persons or property as a matter of product liability, due to
negligence or otherwise, or from any use or operation of any methods,
products, instructions, or ideas contained in the material herein.
Library of Congress Catalog Card Number: 96-070755
International Standard Book Number: 0-87263-483-3
Additional copies may be obtained by contacting:
Society of Manufacturing Engineers
Customer Service
One SME Drive
Dearborn, MI 48121
1-800-733-4763
SME staff who participated in producing this book:
Larry Binstock, Senior Editor
Rosemary Csizmadia, Operations Administrator
Frances Kania, Production Assistant
Judy Munro, Manager, Graphic Services
Dorothy Wylo, Production Assistant
Cover photo courtesy of The LVD Corporation

Printed in the United States of America

ABOUT
THE SOCIETY
OF MANUFACTURING
ENGINEERS
Founded in 1932, the Society of Manufacturing Engineers (SME) is a
nonprofit professional society dedicated to the advancement of scientific knowledge in the field of manufacturing engineering. By providing
direction for the evolution of manufacturing, SME has earned an international reputation for leadership in manufacturing technology.
Among its activities, SME produces and distributes a vast array of
literature focusing on state-of-the-art, as well as traditional manufacturing techniques. Press Brake Technology, a Guide to Precision Sheet
Metal Bending, is a product of this ambitious publishing effort, which
includes books, periodicals, videotapes, and an on-line data service.
For a catalog of SME publications, call 1-800-733-4763.

This book is dedicated to my wife, Patricia, for the countless hours

she spent proofreading this work, which would not have been possible
without her. Thank you!

vii

Contents
Preface .................................................................................................. xiii

Chapter 1The Machine ............................................................ 1

The History and the Machines ............................... 1

Chapter 2Types of Bends ..................................................... 11

Three Types ......................................................... 11

Chapter 3Tools of the Trade .................................................. 15

Precision Tools of Sheet Metal ............................ 15

Chapter 4The Controllers ..................................................... 25

The Modes .......................................................... 25
Terminology ......................................................... 33

Chapter 5Safety Tips ............................................................. 35

Machine Setup .................................................... 35
Operational Safety ............................................... 36
General Safety Tips ............................................. 38

Chapter 6General Mathematics ............................................ 41

Integers ............................................................... 41

Chapter 7Trigonometry (Right Angle) ................................. 45

Chapter 8Bend Functions..................................................... 53
Bend Charts ........................................................ 53
Terminology ......................................................... 54
Working with Sharp Bends .................................. 59
Working with ISTM .............................................. 65
Working Bend Deductions
for Bends Over 90 ......................................... 66

Chapter 9Flat Pattern Development .................................... 67

Chapter 10Reading Engineering Drawings ........................ 71
Elements ............................................................. 71

Chapter 11Notching .............................................................. 87

Four Types ........................................................... 87

Chapter 12Program Writing .................................................. 91

Saving Programs ................................................. 91

Chapter 13The Tooling .......................................................... 95

Springback .......................................................... 95
Factors Affecting Springback ............................... 96

Chapter 14The Punches ...................................................... 101

Types of Punches .............................................. 101

Chapter 15The Dies ............................................................. 109

Die Width Selection ........................................... 109
Profound Radius Bends .................................... 119

Chapter 16Special Purpose Tooling ................................... 129

Bottom Bending ................................................. 129
Coining .............................................................. 131

Chapter 17Acute Angle Bends ........................................... 133

Punch Radii ....................................................... 134

Chapter 18Hemming and Seaming .................................... 137

Chapter 19Offset Tooling ................................................... 141
Two Styles ......................................................... 141

Chapter 20Urethane Tooling ............................................... 151

Advantages and Disadvantages ........................ 151
Terms ................................................................ 152
Characteristics .................................................. 152
Working Parameters .......................................... 154

Chapter 21Machine Operations .......................................... 161

Machine Setups ................................................ 161
Tooling Installation ............................................. 163

Chapter 22Creative Solutions for Common Problems ..... 171

Window Punches .............................................. 171
Form Gussets .................................................... 176
Carrying a Bend or Creative Die Spacing .......... 177
Forming Wraps .................................................. 178
Squaring the Stops ............................................ 179

Chapter 23Gaging ................................................................ 181

Side Gaging ...................................................... 181

Chapter 24Pin Gaging ......................................................... 185

What is Pin Gaging? .......................................... 185

Chapter 25Deep Box Forming ............................................ 189

Chapter 26Related Equipment ........................................... 193
Slip Roller .......................................................... 193

Chapter 27The Leaf Brake .................................................. 205

Composition of the Leaf Brake .......................... 205
Index .................................................................................................... 209

xi

PREFACE
In the 20 odd years that I have been in the precision sheet metal
trade, I have never found any comprehensive information regarding press
brake operations.
Sure, there were sales brochures and an occasional magazine article,
but never could I find a complete text. That void gave me the motivation
to write this book.
Over the years I collected and saved every bit of information I found
on the subject of press brakes. That, coupled with 20 plus years of experience, gave me the knowledge I try to impart here. I truly hope this
work becomes the comprehensive text for press brake operators of the
future, as well as those who work in the field today.
Many different people and organizations over the last 100 years have
developed the information that I present in this text. To them I am
truly indebted. I also thank Larry Binstock and SME who took a chance
on me and published this work.
Thank you all.
Steve D. Benson
Salem, Oregon

xiii

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