Architectural Flashing Supply
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Tier 2 · Fabrication Technician

Press brake tooling and sequencing

How a press brake bends, how it differs from the folder AFS forms on, and how thickness and metal set the die, radius, flange, tonnage and springback. A worked set-up and bend sequence for 24 ga galvanized, and how to diagnose bending defects from their symptoms.

4 lessons · about 39 min · 11 diagrams · 5 videos

Version 1.1.0

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Lessons

0 of 4 complete

  1. Lesson 1 · 10 min · 11 slides · 7 questions

    Press brake tooling and sequencing: principles and terminology

    What a press brake is, its punch, die and backgauge, the three ways it bends, how a folding machine differs, why AFS forms on a folder, and the OSHA rules for press brakes.

    You will be able to: Name the parts and tooling of a press brake, define air bending, bottoming, coining, springback and crowning, tell a press brake from a folder, and state the safety rules that apply.

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  2. Lesson 2 · 11 min · 9 slides · 10 questions

    Press brake tooling and sequencing: materials, standards and design constraints

    How thickness picks the die, how the metal changes the radius and springback, what force a bend takes, how grain, temper and paint limit a bend, and the limits that govern AFS orders.

    You will be able to: Choose a starting die from the thickness, predict the radius, minimum flange, tonnage and springback for the metal in hand, and tell published press-brake values from AFS's own limits.

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  3. Lesson 3 · 9 min · 10 slides · 6 questions

    Press brake tooling and sequencing: methods and worked application

    The press-brake set-up method step by step, a worked estimate of die, radius, flange and tonnage for 24 ga galvanized with its assumptions, bend order, collision checks and what to inspect.

    You will be able to: Apply a documented set-up method to a 24 ga galvanized bend, recording every input, assumption and unit, plan a bend sequence that avoids collisions, and name the inspection points.

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  4. Lesson 4 · 9 min · 11 slides · 6 questions

    Press brake tooling and sequencing: defects, verification and case study

    Reading bad bends: open angles, short flanges, creases, collisions, scratches and cracks; why hemming overloads a brake; why bad parts are remade; a case worked through and the evidence record.

    You will be able to: Diagnose a press-brake bending defect from its symptom, choose the published correction, and document the evidence and the checks for review.

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Practical task

Build a press brake tooling and sequencing job packet for a two-bend Z flashing in 24 ga galvanized steel: choose and justify the die, estimate the radius, minimum flange and tonnage, plan the bend order, set out the checks, and show how the same profile goes to AFS's folder instead.

Hand in

  • A decision rationale: the die opening chosen and why, with the thickness taken from the AFS material register and every rule named with its source
  • A sketch or marked-up detail of the Z flashing: legs to the mold line, bend lines, bend order, and where the part is turned over on a press brake
  • An assumptions sheet with units: material factor, radius percentage, minimum flange and tonnage per inch and in total, each labelled typical, manufacturer or AFS
  • A check of the profile against AFS's own limits: end flange, leg between bends, girth and piece length
  • A quality checklist: angles at both ends and the center, legs, hems, scratches and cracks
  • A defect analysis for one plausible defect: symptom, cause, correction and the evidence a reviewer would need

Rubric

CriterionMeets the standard when
SourcesEvery number names where it came from: the register, a named published rule, a manufacturer, or AFS's limits.
CalculationDie, radius, minimum flange and tonnage are worked correctly, with units and the assumptions stated.
SequenceThe bend order keeps the part gaugeable and collision-free at every stage (Benson starts inside out on his example), shows every turn-over, and notes any collision risk.
AFS limitsThe profile is checked against AFS's limits, kept apart from the press-brake rules of thumb.
VerificationThe checklist records angles at both ends and the center and covers legs, hems and the finish.
DiagnosisThe defect analysis ties a symptom to a published cause and correction, and lists the evidence for review.

Module quiz

10 questions drawn from a bank of 29; a new set each attempt. Pass mark 80%.

1. What machine forms AFS's production profiles?
2. Who do two-hand controls protect, in Minnesota OSHA's guidance?
3. What hazard does OSHA tie especially to foot pedals on press brakes?
4. What happens to springback when a wider die gives a larger radius?
5. On a folding machine, what clamps the blank?
6. A flange slips into the die instead of bending. What is it shorter than?
7. What is the real danger in hemming on a press brake?
8. What does folding do to scratches on the material surface, according to The Fabricator?
9. What gap does AFS give a smashed hem?
10. What is Steve Benson's advice, in The Fabricator, for a part that was bent wrong?