Press brake tooling needs to be selected around the material, thickness, required bend, component geometry and press brake being used. The punch and die determine how the material is formed and can also affect the bending force required, inside radius and minimum flange dimensions.
There is no single punch and die combination suitable for every job. A tooling setup that works for general air bending may not suit a component with a short flange, deep return or restricted clearance around an existing bend.
Tooling should therefore be considered as part of the bending process rather than separately from the press brake and the component being produced.
Press Brake Punches & Dies
A typical press brake tooling setup consists of an upper punch and lower die. During the bending cycle, the punch forces the material into the die to produce the required bend.
Both are available in different profiles and sizes. The correct combination depends on the bending method, material thickness, required angle, bend radius and shape of the component.
The tooling also needs to be suitable for the load being applied. The capacity of the press brake does not mean that every punch and die fitted to it can withstand the machine’s full tonnage.
Choosing a Press Brake Punch
Punch selection is influenced by the bend being produced and the geometry of the component around it.
A straight punch may be suitable for straightforward bends where there is sufficient clearance around the tooling. Other profiles can be required where an existing flange or return would otherwise interfere with the punch or press brake during subsequent bends.
Punch angle, tip radius, height and profile therefore need to be considered against the complete bending sequence rather than looking at one bend in isolation.
Choosing a Press Brake Die
The lower die supports the material during bending and provides the opening into which the material is formed.
For air bending, V-dies are commonly used and the width of the V-opening is an important part of the tooling specification. It affects the force required to produce the bend as well as the resulting bend geometry and the minimum flange that can be formed.
The die must also have sufficient load capacity for the material, bend length and force being applied.
V-Die Opening & Material Thickness
The V-opening should be selected in relation to the material thickness and the bend being produced.
Increasing or decreasing the opening changes the bending conditions. A smaller V-opening generally increases the force required for air bending, while a larger opening reduces the required force but also changes other aspects of the bend.
This means the V-opening should not simply be made larger to reduce tonnage. Required inside radius, flange dimensions, material characteristics and component geometry all need to be considered.
Our guide to press brake tonnage looks in more detail at how tooling and die opening affect the bending force required.
Press Brake Tooling & Bend Radius
Tooling selection affects the radius produced during bending, but the relationship depends on the bending method being used.
With air bending, the material is not forced completely into the bottom of the die. The resulting inside radius is influenced by the material and die opening rather than being determined solely by the punch tip radius.
Where a particular inside radius is required, the material, tooling and bending method therefore need to be considered together.
Minimum Flange Length
The flange needs sufficient support on the die during the bending process.
Die opening therefore affects the minimum flange that can practically be produced. This can become an important limitation when components contain short flanges, particularly if a larger V-opening would otherwise be selected for thicker material or to reduce bending force.
Component dimensions should be checked against the proposed tooling before the machine setup is finalised.
Tooling Clearance & Component Geometry
Some components require several bends, and tooling that can produce the first bend may not provide sufficient clearance for later stages of the bending sequence.
Existing flanges, returns and deeper profiles can interfere with a straight punch or other parts of the tooling. Punch profile and height may therefore need to be selected around the complete finished component.
Reviewing the full bending sequence before production helps identify potential tooling collisions and clearance problems before the component reaches the machine.
Segmented Press Brake Tooling
Segmented tooling allows the working length of the punch or die to be assembled from individual sections rather than using one continuous tool.
This provides greater flexibility when different component lengths are being produced and can also help with components where clearance is required around boxes, returns or other formed sections.
The required segment arrangement depends on the component and tooling system being used.
Tooling Capacity
Press brake tooling has its own load limits and these need to be respected independently of the capacity of the machine.
A high-tonnage press brake can generate considerably more force than some tooling is capable of carrying. The permissible load of the punch, die and tooling system therefore needs to be checked against the force required for the bend.
This is particularly important where high force is concentrated over a relatively short bend length.
Tooling for Air Bending, Bottom Bending & Coining
The bending method affects both tooling selection and the force required.
Air bending forms the material without forcing it fully into the bottom of the die. Bottom bending brings the material further into contact with the tooling, while coining uses substantially greater force to form the material into the tooling profile.
Tooling and machine capacity therefore need to be suitable for the bending method being used. Tonnage figures based on air bending should not automatically be applied to bottom bending or coining.
Can Existing Press Brake Tooling Be Reused?
Existing tooling may be suitable for use when replacing a press brake, but compatibility should be checked before the new machine is specified.
The tooling system, clamping arrangement, tool dimensions, condition and load capacity all need to be considered. It is also worth checking whether the existing tooling still suits the components currently being produced rather than retaining it simply because it is already available.
If a business has a substantial tooling inventory, compatibility can be an important consideration when choosing a replacement press brake.
Tooling Condition & Maintenance
Press brake tooling should be kept clean and inspected regularly for wear or damage.
Damage to working surfaces can affect the component being produced, while damaged or overloaded tooling can also create a safety risk. Particular attention should be paid to punch tips, die shoulders and other contact surfaces.
Tooling should also be stored correctly when it is not in use to protect the working surfaces and make individual tools easier to identify.
Choosing Tooling for a New Press Brake
Tooling for a new press brake should be specified around the work the machine will actually produce.
Useful information includes material type and thickness, bend lengths, required angles and radii, flange dimensions and component drawings. Where several bends are required, the complete bending sequence also needs to be considered so that sufficient tooling clearance is available.
The required bending force should then be checked against both the machine capacity and the permissible load of the tooling.
Our press brake tooling range covers tooling for new and existing press brakes, while our CNC press brakes page covers the current machine range.
Frequently Asked Questions
How do I choose a V-die opening for press brake bending?
The V-opening needs to be selected around the material thickness, required bend, inside radius, flange dimensions and bending method. It also affects the bending force required, so tooling and machine tonnage need to be considered together.
Does press brake tooling affect the tonnage required?
Yes. During air bending, the V-die opening has a direct effect on the bending force required. A smaller opening generally requires more force for the same material thickness and bend length.
Does the punch tip radius determine the inside bend radius?
Not by itself. During air bending, the resulting inside radius is influenced by the material and V-die opening as well as the tooling. The relationship differs with other bending methods.
Can I use the same press brake tooling for different material thicknesses?
Sometimes, but the punch, die opening and tooling capacity need to be suitable for each material and thickness. One tooling combination should not automatically be assumed suitable for the complete material range.
What is segmented press brake tooling?
Segmented tooling consists of separate tool sections that can be combined to create the required working length. It provides flexibility for different component lengths and can help provide clearance when producing boxes, returns and other formed components.
Can I keep my existing tooling when buying a new press brake?
Potentially. The tooling system, clamping arrangement, dimensions, condition and load capacity need to be compatible with the replacement machine. It is also worth confirming that the existing tooling still suits the work being produced.
