In the demanding processes of the metal-working industry, and in particular the specialization of sheet metal processing, production efficiency, productivity and quality are decisive factors for competitiveness
Each component incorporated in sheet metal working machines has been specifically designed to perform its function efficiently. Since the first developments of this type of machine, we have tried to solve the problem of how to support the sheets and how to make the machine work on them safely, so that they do not move, do not burn, are easy to empty and have a long life even when the machine is working intensively.
In general, sheet metal is supported on metal parts, whether flat or triangular in shape, to minimise contact points, and these designs are useful for most cutting methods, such as oxyfuel, plasma, laser or water cutting.
Since the early development of stamping machines, technical brushes in the form of large flat plates have been used as sheet support material, providing a soft and comfortable support that does not leave marks on the parts.
What are brushes for punch press support tables and why are they important?
The plate-shaped technical brushes used as a support on the tables of metal-cutting machines are devices composed of filaments or bristles, usually made of synthetic material.
Although in some cases, metal wires are used, which are fixed to a plastic base plate, usually rectangular.
These brushes are installed on the worktables of the punching machines, combining brush modules together to completely cover the areas where contact between the workpiece/sheet and the machine occurs.
Its main function is:
- Allow the punch to be released: When violently crossing the punch the sheet, it is necessary to allow a release of the punch by the output of the same on the opposite side of the sheet
- Allow the material from which the punch is pulled out to be evacuated, that is, the waste and excess with the forms of the punches.
- Protect the table surface: Acting as a protective barrier, the brushes prevent impacts, scratches and premature wear of the worktable, prolonging its service life.
- Facilitate the transport of parts: The smooth and uniform surface generated by the multitude of filaments of the brushes facilitates the movement of parts, improving accuracy and reducing the risk of damage.
- Reduce noise and vibration: By absorbing some of the energy generated during the punching process, the brushes help to create a quieter and safer working environment.
Geometry of the punching table brushes
The choice of brush sizes depends on the geometry of the surface of the punching machine to be covered.
The surfaces to be covered are generally several square metres, making it impractical to produce single-piece plate brushes because of their high cost and difficult manageability, so they are manufactured in smaller modules, which are tried to be equal, to facilitate manufacture, transport, handling and transport.
These plate-shaped brushes are designed in a rectangular shape, with customized measures so that by combining a multiple of them, the surface of the support table of the punching machine is perfectly covered.
A curly pattern is designed, with a sufficient and adequate pitch so that the transition between one plate and another is not noticeable.
Small holes are also provided for attachment to the machines.
The filaments of the brushes are usually between 10 and 25 mm long, and have a cross-section generally between 0.1 and 0.5 mm, but these aspects are defined according to the pressure exerted by the weight of the plates on the brushes, and whether the brushes are intended to be softer or harder.
Benefits of punch press table brushes
There are a number of significant benefits to be gained by incorporating punch table brushes into your production process:
- Improved part quality: By facilitating scrap removal and protecting the table surface, parts are produced with a cleaner and more accurate finish, as the sheets rest on the brush filaments like a carpet.
- Longer machine life: By protecting the table surface and making it easier to unload the punches, the life of the punching machine is extended, minimising maintenance and replacement costs.
Factors to consider when choosing brushes for punching tables
When selecting a brush for punching tables, the following factors must be taken into account:
- Compatibility with the machine: you must ensure that the measurements and design of the technical brush are suitable for the surface of the punching machine table, measuring correctly and checking that there is no interference or element that should not be covered with the brushes.
- Material durability: opt for brushes made with high-quality filaments, such as PA6, that are resistant to wear and do not use polypropylene, polyethylene or PVC filaments. On the other hand, it is not necessary to use bases made of very technical materials; 10 or 15 mm thick polyethylene plates are sufficient.
- Ease of installation and replacement: Brushes must be easy to install and replace to minimise machine downtime. To achieve this, the position and shape of the attachment on the punching machine table must be well defined.
- Paints that do not smear. The metalworking industry creates a dirty, dusty and polluted environment, so it is preferable to use black brush filaments, which look good for much longer, rather than light colours that are more prone to soiling, such as white.
Innovation and sustainability in brushes for punching machine tables.
Sacema‘s industrial brush factory in Gijón is equipped with modern machinery, the latest CAD3d tools, numerical control and robotic manufacturing processes, which allow us to work with passion and commitment to meet the needs of the sheet metal working industry.
We are committed to innovation in the search for more personalised products and sustainability. Our table or panel brushes are manufactured with high quality materials that guarantee exceptional performance and lower environmental impact, and are the right replacement for punching machines.
