Fareham-based Searle Manufacturing, a producer of heat-exchange products, has invested in two further Baykal press brakes with two-axis CNC backstop from Press and Shear Machinery.

This time they are equipped with an additional computer-controlled axis on the backstop that speeds set-up between batches, resulting in less machine idle time and higher output.

The latest models, both of 1500kN (150 tonf) capacity with a three-metre bending length, have synchronised control of the hydraulic cylinders, Y1 and Y2, plus a programmable X-axis (backgauge depth), R-axis (backgauge height) and Z-axis (sideways movement of backgauge fingers).

They also have automatic beam crowing, which compensates for machine deflection when processing long material.

All axes are controlled by the Delem DA66W CNC system.

In practice, the additional CNC Z-axis means that the operator no longer has to walk around to the back of the machine to physically move the position of two hinged backgauge fingers along the bending line.

They normally need to be adjusted to suit the size of material prior to each new production run.

With batch quantities at Searle frequently as short as five-, 10- and 20-off, and rarely more than 100-off, mainly from 1mm to 1.5mm gauge galvanised steel but also from stainless steel and aluminium up to 3mm thick, savings on machine set-up time are considerable.

Modifications to its standard APHS 3108×150 machine include the fitting of lockable front support arms, as the free moving type makes it difficult for one operator to present larger sheet to the tooling without the arms moving along the rail.

Another change to the standard specification was to provide a radius on the ends of the backstops, which also helps when handling large material and facilitates the production of tapered bends.

All programs for the Baykal press brakes at Fareham are written on the shop floor from drawings, rather than being downloaded from Searle’s CAD/CAM system.

This is because the majority of components require only simple folds and in any case, the varied throughput of standard products would tie up the CAD/CAM resource, which is devoted to more complex work and custom-built products.

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