BENDING & CUTTING TECHNOLOGIESCollection 2013

3

BENDING & CUTTING TECHNOLOGIESCollection 2013

4 5

IndexCompany profile pag. 06

Bending processes pag. 08

X-PRESS ECO pag. 14

Shearing process pag. 38

X-CUT pag. 42

Plasma cutting process pag. 50 SPARK HEAVY pag. 54

Tailor made solutions pag. 62

6 7

GASPARINI INDUSTRIES:30 years of excellence in the folding and cuttingMore than 8.000 machines installed worldwide10,000 m2 of production - 2400 m2 of offices700 m2 showroomThree product platforms: press brakes, shears, plasma cutting

No other manufacturer introduces innovative technologies such as Gasparini Industries. We have carved a reputation as pioneers in the industry, often being the first to introduce innovative products in the market. The combination of innovation, quality and performance is unmatched in the industry. We invest a significant amount of time and resources to bring to market technologies of metal forming more efficient and precise to offer our customers the best solutions available.Performance, Quality and Service are the three pillars on which Gasparini Industries bases its strategy.

THE CUSTOMER: OUR “MAGNIFICENT OBSESSION»

All the staff at Gasparini Industries are dedicated to customer satisfaction; we highly value the opinion of our partners and end users, since our first aim is to improve our performance and to fulfill market expectations.

With this purpose, we have introduced in our organization the “Tech Center Division”, formed by a team of specialists, fully dedicated to analyzing the specific customer needs and to providing the best “tailor made” solution.

The Service Organization and related processes have also been significantly improved to guarantee excellent service levels, both as concerns spare parts availability and timely maintenance.

The product range

Gasparini offers three main product platforms: press brakes, shears and plasma cutting machines. All products are positioned at the high end of their specific market, providing a significant technological content, a robust design, together with an “easy to use” configuration and a wide range of options and accessories, to customize the machine according to your needs.

The press brakes range, now enriched with the introduction of the ECO version, includes machines with bending force from 25 to 1500 tons and bending length from 1250 to 10000 mm, available as single machine or in tandem solution, stand-alone or integrated in a robot cell.

Guillotine Shear range includes all of Gasparini 40 years’ experience in sheet-metal shearing. Top class machine, high performances and quality standards to produce highest precision cut blanks in large volumes, cost-

efficiently. The range includes cutting length from 2 to 6 m with cutting capacity up to 30 mm. We can also offer complete cutting lines equipped with feeding, stacking, conveying systems as well as other automation, on demand.

Plasma cutting machines can be supplied with width from 1.5 m to 4 m and length from 3 m to 27 m, able to cut up to 80 mm depending on generator power. Gasparini plasma machines, thanks to the precision, speed, flexibility and the wide range of options and accessories, are well recognized as some of the highest-performing plasma machines on the market.

9

e

m

8

V-BENDINGV-bending is the most used bending technique. There are three V-bending techniques: Air bending, Hemming (Flattening) and Coining (Bottoming). All work on the principle of a punch that presses the sheet metal into the bottom die.

Most of the processes sheet metal forming involve initial folding of the blank. Different bending processes are widely used in a wide range of products: automotive, furniture, doors, trains, construction, aeronautics, electronics, telephony, ships, etc.. We can say with good reason that the process of folding a sheet find a place in the vast majority of the products. Despite its apparent simplicity, the bending process is a highly complex manufacturing technique that must be understood, led and dominated.

A bend is the permanent deformation of sheet metal under the effect of an external force.

In the fabrication industry, one of the critical challenges is to maintain close geometric tolerances in finished products. The perfect bend is defined by three main factors:

• Accurate bending angle (ß theor vs ß real) • Constant bending angle to the entire bending length • Correct parallelism along the entire bending length

ep = plastic deformationee = springback

SPRINGBACK EFFECTThe problem in respecting angle tolerances is related to the springback effect in the sheet metal: this effect is the elastic recovery of the non uniformly distributed stresses in a deformed part after forming load is removed.

BENDING PROCESS

10 11

V Ri

B t

AIR BENDINGAmong the V-bending processes, air bending is the simplest one and it is commonly used in a wide range of productions.The Air Bending process involves the punch pressing the sheet metal down into a V-shaped die. This way sheet metal flanges are folded up, creating the angle at the contact point between punch and sheet metal. The sheet metal has 3 contact points with tool and die.The bending angle is determined by how deep the tool pushes the sheet metal into the die.The spring-back is compensated by a longer stroke, allowing the plate to return to the required bending angle (over-bending).The advantages of air bending are: low bending force, possibility to bend very thick sheets and possibility to obtain different angles with the same tools. These make it less expensive and more flexible.Air bending is characterized by an initial difficulty in finding the correct bending angle due to sheet springback, and the need to dispose of a high tech press brake to guarantee excellent bending precision.

COINING (bottom bending)In coining, the punch presses the sheet metal completely into the die, so that the punch, the sheet metal, and the die are coupled together. For bottom bending, the punch and die have to fit together exactly. Bottom bending is mainly used for producing 90-degree angles on thin sheet metal parts where small bend radius is required.The bend is obtained by forcing the part completely into the die, so that the sheet metal follows exactly the die profile/angle.The sheet metal is permanently deformed and spring-back is minimized.Its advantages are a high angle precision, no springback, the possibility to obtain smaller bending radius.Its main disadvantages are the need a different tool set for each angle and shape, and the need to use high tonnage (5 times compared with air bending).

HEMMINGIt is normally applied to obtain rigidity, edge protection and avoid sharp edges. It is a 2-step process: first a 26°-35° pre-bend (by air bending process), then the bended part is completely or a partially flattened, depending on the applied force.

A press brake is basically defined by its bending length (L) and its bending force (F=FY1+FY2).The maximum bending force (F max) applicable to the sheet metal, as a percentage of the total nominal machine force (F tot), depends on the length of the part (vs. machine length) and the bending position (centered or not).F max is further reduced when coining, due to the heavy process.Also the utilization rate (time) at full capacity is a factor to be considered when dimensioning correctly the press brake. It is always recommendable to over-dimension the machine by about 20-30%.

The following formula allows to calculate the required bending force and consequently to correctly size the press brake.

F = k (L * t2 * am) / VL = bending lengtham = tensile strengthk = correction factor

V/t reccomended:

V/t ≥ 8 (if t < 8 mm)V/t ≥ 10 (if t ≥ 8 mm)

V/t = up to 20!

SS, MS

HSS (see HSS bending)

BENDING FORCE

12 13

100-

70-

4371

3132

2338

1627

1221

1610,5

2

20132,5

2516,53,2

322144

40265

1830

1221

915

712

58

64

0,8

85,51

106,51,3

128

1,5

1610,5

2

5080

1730

3

1,2100

-

70-

4371

3132

2338

1627

1221

1610,5

2

20132,5

2516,53,2

322144

40265

1830

1221

915

712

58

64

0,8

85,51

106,51,3

128

1,5

1610,5

2

5080

1730

3

1,2

BENDING PROCESS FOR HSS

The following table shows the minimum recommended punch radius (R) and V-opening die (W), ratio to part thickness (t) for different HSS types for plate bent at 90° along rolling direction or at a right angle.

RULER USE EXAMPLEExample:

Plate of mild steel, thickness = 1.2 mm

Length of bend 2.5 m

I choose a V of 10 mm (because 1.2 x 8 = 9.6)

The square in the grid where the vertical column is thickness, and the

horizontal line is the Wp, indicates 9 (meaning tonnes per metre)

Calculation of total force: 9 x 2.5 = 22.5

This choice determines the inner radius of bend at 1.3 mm and a

minimum inner edge of 6.5 mm

Thicknessmm

At rightangles R/t

AlongR/t

At rightangles W/t

AlongW/t

Springback[*]

S355 - EN 10025 2,5 3,0 8,0* 8,0* 3-5

WELDOX 700t < 8

8 ≥ t < 20t ≥ 20

1,52,03,0

2,03,04,0

7,07,08,5

8,58,5

10,06-10

WELDOX 900/960t < 8

8 ≥ t < 20t ≥ 20

2,53,04,0

3,04,05,0

8,58,510,0

10,010,012,0

8-12

WELDOX 1300t < 8

8 ≥ t < 20t ≥ 20

3,03,54,5

3,54,55,5

9,09,011,0

10,011,013,0

10-32

WELDOX 1100t < 8

8 ≥ t < 20t ≥ 20

3,54,05,0

4,05,06,0

10,010,012,0

10,012,014,0

11-18

WELDOX 1300 t < 66 ≥ t < 10

3,55,0

4,05,0

10,012,0

12,014,0

12-45

HARDOX 400t < 8

8 ≥ t < 20t ≥ 20

2,53,04,5

3,04,05,0

8,510,012,0

10,010,012,0

9-13

HARDOX 450t < 8

8 ≥ t < 20t ≥ 20

3,54,05,0

4,05,06,0

10,010,012,0

10,012,014,0

11-18

HARDOX 500t < 8

8 ≥ t < 20t ≥ 20

4,05,07,0

5,06,08,0

10,012,016,0

12,014,018,0

12-20

* Dipending on thickness

BENDING FORCE RULER

The bending force ruler is an easy tool to define the required bending force per meter (t/m), given the thickness (s), and the die opening V.The value given refers to air bending process, mild steel and a 90° angle. However, the tool includes the correction factor to be applied, depending on angle, material and bending process.

BENDING FORCE

14 151514

Heavy frame built with bolted elements for maximum structural rigidity and accuracy

Patented Reflex proportional frame deflection compensation system.

Wide range of back gauges for all production situations

New standardized hydraulic system developed by Gasparini

Active Crowning System ACSG1 and ACSG2 (PATENTED)

Wide range of front supports and sheet followers for all production needs

Tandem, Tridem, Quadrem, configuration of all models for maximum flexbility

New design: unique, technological, Italian. One look and feel for all

product families

LED lightning of the working area: maximum ergonomics and safety

Wide range of upper tool clamping systems and technologies with possibility to install all

tools on the market

Wide range of die clamping systems and

technologies with possibility to install all

dies on the market

CNC touch Gasparini PHOENI-X or Delem

DA66T

The DSP-AP laser safety system, compared to the DSP laser

safety syem, lowers the mute point. As a consequence, the

cycle time will be reduced.

Angle control system GPS4

Hemming bench optionRobotic cell option

1716

THE POWER WHEN YOU NEED IT

SAME JOB, 50% LESS ENERGY

LESS WASTE, LESS MAINTENANCE

-7 DBA

200 mm/s

In line with our strategy based on the continuous innovation, we are proud to introduce the Eco Concept: a package of innovative and customer oriented solutions aimed at reducing machines’ consumptions.

In this period of critical economic situation the energy saving assumes a double value: eco-nomy to optimize company resources utilization eco-logy to take care of the environment for a better future.The first application of the Eco Concept is the brand new X-PRESS eco series. Environmental friendly, energy saving, speed, noiselessness, limited maintenance, less waste, extreme precision and repeatability are the trademarks of the new X-PRESS eco. The eco configuration of the X-PRESS series is just the first step of an innovation plan that will distinguish the products Gasparini Industries will develop from now on.

On X-PRESS eco, thanks to a new configuration of the hydraulic pump, we monitor the flow rate in the hydraulic circuit depending on the bending process.The motor is controlled by an inverter and it is activated only when the machine has to operate, always delivering only the power requested by the bending process.The right pressure on the circuit is granted also during the stand-by phases without any flow, and therefore any energy waste.

Thanks to eco system on X-PRESS eco the consumption management of an electric press brake, without the limits of the electric technology, is perfectly combined with the bending force that only an hydraulic machine can assure.The saving is up to 50% on the eco version, compared to the standard one.

On the X-PRESS eco we achieve a huge reduction of maximum oil temperature, thanks to the control of the flow rate.• limitation of oil thermic stress• performances steadiness• lower heat and energy waste• longer oil life: less waste• longer pump and system life: less maintenance

The X-PRESS eco is a noiseless machine. The pump, which represents the principal cause of the noise, produces significantly less noise in respect to conventional press brakes. Tests show that noise level on the operator side never exceeds 63* dBa, even at full power!

The new X-PRESS eco reaches a top of the market approaching and return speed of 200mm/s.

ECO CONCEPT e X-PRESS ECO

18 19

90°90°

90°

90°< 90°

90°

90°> 90°

90°

Maximum accuracy and absolute repeatability are the trademark of X-PRESS eco series thanks to the systems ACSG, reflex and GPS4.

The X-PRESS eco is equipped with the active crowning system family ACSG, simply one of the best crowning system on the market.No matter how you act your crowning system (mechanically with wedges, hydraulically with pistons, etc.) the key is how you manage your crowning system.ACSG simply does the job: ACSG bends the lower beam following in real time the bending of the ram no matter what, where and how you bend.ACSG guarantees a constant bending angle, all over the length of the bending line, without any alignment or correction by the operator.

All common crowning systems works bending the lower beam according to either calculation about the expected ram deformation or to assumptions of probable ram deformation: there is no control. Material variations, holes, different bending positions, can modify unexpectedly the ram deformation, making prevision, assumptions and calculations no more valid.

The result is simply a bad job: the angle is not what you need, what you expect.The heart of the ACSG are the crowning pistons driven by the real time information about the deformation of the ram.

The hydraulic pressure in crowning pistons is driven by the data coming from two potentiometers that measure in real time the deformation of the ram and of the lower beam in a retroaction loop.

ACSG2 is the improved version of ACSG1, improving the best.

In the ACSG2, a pressure accumulator and a proportional directional valve, releases to the crowning pistons, during the bending phase, the requested hydraulic pressure previously stored during the passive bending cycle.The crowning starts simultaneously during the bending phase.

The result is maximum precision, absolute repeatability and increased speed as the bending cycle is reduced up to one second and a half compared to ACSG1.

REFLEX

The new X-PRESS eco is equipped with the patented Reflex proportional frame deflection compensation system.

The Reflex system ensures each bend is executed with a constant angle (bending depth), regardless of the specific characteristics of the piece to be bent and bending conditions.

Side frames yawning phenomenon makes the ram position reading false if the sensor is just fixed on the side frames.With Reflex, the position of the upper beam is measured by two linear encoders installed on looms shaped “C” that does not undergo the deformation of the frame during the bending, and are connected by means of a lever system with the upper beam. In this way, reading errors of the encoder (for the yawning of the side frames) is canceled by moving the encoder mechanically itself (according to the deformation for the yawning) to allow the correct reading of the position of the upper beam.

No matter which deformations may occur due to load, thickness, length, part positioning and steel plate characteristics variations, on the X-PRESS eco the ram position is always under control to guarantee constant bending angle.

Standard, non active system

ACTIVE CROWNING SYSTEM ACSG REFLEX PROPORTIONAL FRAME DEFLECTION

COMPENSATION SYSTEM

RAM POSITIONCONTROL:linear encoder

C SHAPED IDLE FRAMES

YAWNING EFFECT

LEVER SYSTEM

LINEAR ENCODER

C SHAPED IDLE FRAME

3M LONG PIECES

SMALL PIECELower beam deformation data

Ram deformation data

Cyl

inde

rpr

essu

re d

ata

Only the Active Crowning System can ensure the perfect bend

Only the Reflex System can ensure the correctness of the angle along the whole profile length.

20 21

The new X-PRESS eco can be equipped with the patented angle and control system GPS4, simply one of the best angle control system on the market.

GPS4 constantly controls and adjusts the bend angle throughout the bending process via the CNC.GPS4 ensures angular accuracy regardless of material variations and forming conditions as it eliminates the influence of bend length, press force and off center loads.The result is maximum precision, absolute repeatability.No material setting, no sheet length setting, no bending force setting, no sampling test, no manual correction: you just set the desired angle and you get it, no matter which material, dimension bending force.

The heart of GPS4 is the double fork shaped tracer that detects (in contact with metal sheet) the bend angle of both sides of the sheet in four different points and tells the CNC how to perform the bend.

Features:

• No bending test required: (typical for an only/a few piece/s production)• Free space around the tools• Easy to program (thickness, length, type of material and bending force do not need to be set)• It measures from both sides of the metal sheet• It is in physical contact with the metal sheet (no optical)• It performs a real measure, it is not a theoretical measurement• You can use up to four working stations

STANDARD CESheet support standard CE, vertically adjustable.Supplied when no other system is requested.

FSA-AFront support arms, realized in aluminium profiles. A quick coupling system to the press brake, allows positioning along its entire length. They are also vertically adjustable to suit the eight of the bottom tool. The support has a particular aluminium profile allowing:

• disappearig stops• graded rule• ball transfers (steel)

A series of accessories can be installed on request, including the brushes for the support of materials with delicate surface, micrometric gauges and goniometer.

FSA-BThis type of sliding front support has been designed to facilitate the job of the operator. They are attached to the press brake by means of a linear guide with precision ball screws which allows positioning along the entire length of the machine; they are also vertically adjustable to suit the height of the bottom tool.The linear guides extend beyond the table where the supports can be stored when not in use.The support has a particular aluminum profile with T-slot, allowing:

• disappearing stops• graded rule• ball transfers (steel)

A series of accessories can be installed on request, including the brushes for the support of materials with delicate surface, micrometric gauges and goniometer.

FUNCTIONING PRINCIPLE

During the bending the 2 fork shaped tracers (red and blue in the picture) are pushed up to touch the sheet metal, the C height difference between the tracers gives the bending angle.

Available for Manual, Pneumatic or Hydraulic clampings.

EUROPEAN (PROMECAM)

WILA-LVD-BEYELERWITH SPACERS

OR FIXED

ANGLE CONTROL SYSTEM GPS4 FRONT SUPPORTS

• ALUMINIUM• MILD STEEL• STAINLESS STEEL

23

25t

50t

100t

150t

200t

330t

420t

1500t

RPL-

3

RPG-

3RP

G-2

RPG-

1

RPS-

2RP

S-1

RPS-

0

SERIERPG

SERIERPL

SERIERPS

22

7 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5

X-PRESS presses can be equipped with a wide range of back gauges to meet the most varied production needs.The series RPS, RPL and RPG are characterized by robustness, accuracy and repeatability.

All back gauges*, also in the basic 4 axes configuration, can be moved and repositioned without having to access the rear of the machine with a considerable saving of time and a benefit in security. Selecting the Easy-Z function the operator pneumatically unlocks and moves the turrets toward himself without the use of keys or tools: now he can reposition the back gauges according to the new needs remaining in its working position.

Thanks to the Anti-Shock System the back gauge punch is disengaged in the event of shocks that could harm it or even make it lose its position. In this case the operator must simply put the punch back in its seat with a slight pressure of the hand.

Thanks to Thin-Support System (optional retractable rear supports) even thinner sheets are always correctly positioned and guided by the back gauge.

The series RPS and RPL with the different versions cover all combinations from 4 to 8 axes. The RPG system is based on completely independent turrets and integrates the maximum number of axes.

*Not available on RPS-0

FRONT SUPPORTS BACK GAUGES: THE RANGE

FSA-CThis type of front support has a pneumatic height adjustment (dual positioning), controlled by the CNC.This function is useful both when working with hemming bottom tools, which require positioning the plate at a different height as needed.

FSA-DThis type of front support has a motorized height adjustment completely controlled by CNC.This function is useful both when working with fold-and crush bottom tools and for particular profiles with counter-bends facing down, which require positioning the plate on surfaces at different heights.

FRONT SHEET FOLLOWERSThe sheet follower is an effective accessory for press brakes. It basically consists of a pair of sheet supports placed on the front of the machine at the height of the bending line (bottom tool). Each support is controlled byCNC and is synchronized with the bending process, moving together and supporting the metal sheet.

4 axes: Y1 - Y2 - X - R

4 axes: Y1 - Y2 - X - R

8 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5 - X6

8 axes: fully indipendent

24 25

RPS

RPL-3

The back gauge RPS consists of a one-piece structure, driven by rack & pinion travelling on recirculation balls linear guides. It includes an X and R axes (depth and height) in the standard configuration and is fitted with two or more reference back fingers (depending on the machine length) , mounted on linear guides. The guide profile is made of an aluminum extruded part which design grant a high rigidity and thus precision. All axes of the back gauge are programmed for maximum speed for all movements and for deceleration when approaching requested distances.

The back gauge has an integrated safety device so that it cannot hit the tools and which varies according to the size of the lower tool. The system can be upgraded (optional) up to 6 axes (X-R-Z1-Z2-X5-X6) and additional back gauge fingers may be fitted on request.

The back gauge rps is characterized by:

• High speed• High accuracy and reliability• AC brushless motors• The movements of the X and Z axes are made with helical gears with modular pitch• The movements of the axes X and R have transmission parts hardened and ground• Z movement is made with transmission spur, with cutrack modular pitch accuracy• Up to 75 degrees of curvature conical• All this leads to less noise, greater durability and greater precision

The back gauge RPL consists of a solid structure led by screws which run on rails rack and pinion and linear guides.

Provides an X axis and an axis R (height and depth) and is provided with two (or more) turrets reference (depending on the machine length) mounted on linear guides that can be moved from the front of the machine.On request, you can mount additional towers.

X-Press Eco From 420T To 1500T Can Be Equipped with The System Rpl-3 Characterized By:

• Robustness• High accuracy and reliability• AC brushless motors• The movement of the X and R axes are made with recirculating ball transmissions• Z movement is made with transmission spur, with cutrack modular pitch accuracy• Up to 75 degrees of curvature conical• All this leads to less noise, greater durability and greater precision

BACK GAUGE: SERIE RPS BACK GAUGES: SERIE RPL-3

7 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5

7 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5

4 axes: Y1 - Y2 - X - R

4 axes: Y1 - Y2 - X - R

6 axes: Y1 - Y2 - X - R - Z1 - Z2

6 axes: Y1 - Y2 - X - R - Z1 - Z2

8 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5 - X6

8 axes: Y1 - Y2 - X - R - Z1 - Z2 - X5 - X6

MODEL/FEATURE RPS-0 RPS-1 RPS-2

X Standard Strokes (mm) 300 600 800

X Speed (mm/s) 500 500 300

X Accuracy (mm) ± 0,05 ± 0,05 ± 0,05

X Repeatability (mm) ± 0,02 ± 0,02 ± 0,02

R Standard Strokes (mm) 150 200 250

R Speed (mm/s) 125 250 160

R Accuracy (mm) ± 0,01 ± 0,01 ± 0,01

R Repeatability (mm) ± 0,05 ± 0,05 ± 0,05

Z Speed (mm/s) - 1600 1000

Z Accuracy (mm) - ± 0,01 ± 0,01

Z Repeatability (mm) - ± 0,05 ± 0,05

X5-X6 Stroke (mm) - ± 150 ± 150

X5-X6 Speed (mm/s) - 125 125

X5-X6 Accuracy (mm) - ± 0,05 ± 0,05

X5-X6 Repeatability (mm) - ± 0,05 ± 0,05

X6 Max angle* (°) - 60 60

X5-X6 Max angle* (°) - 75 75

MODEL/FEATURE RPL-3

X Standard Strokes (mm) 800

X Speed (mm/s) 250

X Accuracy (mm) ± 0,1

X Repeatability (mm) ± 0,05

R Standard Strokes (mm) 250

R Speed (mm/s) 24

R Accuracy (mm) ± 0,2

R Repeatability (mm) ± 0,1

Z Speed (mm/s) 600

Z Accuracy (mm) ± 0,25

Z Repeatability (mm) ± 0,15

X5-X6 Stroke (mm) ± 200

X5-X6 Speed (mm/s) 125

X5-X6 Accuracy (mm) ± 0,05

X5-X6 Repeatability (mm) ± 0,05

X6 Max angle* (°) 60

X5-X6 Max angle* (°) 75

26 27

1500t

420t

330t

200t

150t

100t

50t

25t

The back gauge type RPG is extremely sturdy and precise, suitable to making heavy work and any type of bending. In order to assure this level of performance the back gauges are designed and manufactured with high technology, sophisticated and reliable components, providing a wide handling range, an easy oblique positioning, a very high precision and the possibility to integrate back sheet followers.

The back gauge type RPG consists of two trolleys, each equipped with 3 axes X-R-Z which are moved by guides, ball screws and AC motors. This configuration with independent trolleys and axes allows making any kind of positioning, does not limit any kind of inclination or misaligned stops, furthermore it allows the operator to make a big variety of movements within the machine itself.

The back gauge RPG is characterized by:

• High flexibility• X1-X2-R1-R2-Z1-Z2• Optional sheet followers• X axis stroke increased

CLAMPING SYSTEMSTo meet to the widest range of production needs, Gasparini offers a wide ranges of clamping systems and intermediate elements to fit almost all tools available. Combining Pneumatic, Hydraulic and Manual clamping technologies, with a wide range of intermediates Gasparini press brakes reach the best production needs coverage.Gasparini press brakes can equally use long type tools (i.e. Wila, Colgar, Beyeler, LVD, Gasparini, etc.) fitted straight on the ram and short type tools (i.e. Promecam, etc.) fitted on the intermediate.

PNEUMATIC CLAMPING: AIC SystemThe AIC upper self-aligning pneumatic tools clamping with intermediate, is suitable for European type tools. AIC clamp allows the tools to be inserted and removed safely from the front of the machine in a vertical manner. Tools are automatically aligned, seated and clamped, reducing changing time and significantly increasing productivity.The AIC clamping system also allows the fitting of reversed top tools, using a rear plate which can be activated from the front of the machine.Pneumatic clamping cannot be used for tonnage above 330t.

HYDRAULIC CLAMPING The hydraulic clamping system is used in large size machines and high bending forces, or with long tools that do not need intermediate tool holders.The system achieves elevated locking strengths that, acting over large surfaces, needs low pressure and thereby guarantees a longer life for the system.The clamps allow the rapid and precise locking of the tool guaranteeing perfect alignment even in the case of fractional tools.

MANUAL CLAMPINGWhen production condition does not call a frequent changeover, the manual clamping systems is a good choice. The manual clamping system is very robust: it does not have tonnage limit thus can be used even for the highest tonnage.Tools are extracted from the side in total safety condition since tools stay in place even when the clamping is open.

1500t

420t

330t

200t

150t

100t

50t

25t

MAN

UAL

CLAM

PING

PNEU

MAT

IC C

LAM

PING

HYDR

AULI

C CL

AMPI

NG

EUROPEAN(PROMECAM)

PNEUMATICCLAMPING

HYDRAULICCLAMPING

MANUALCLAMPING

WILA GASPARINI COLGAR-LVDBEYELER

Only withintermediates

Not available

Alone and withintermediates

Not available

Alone

Alone

Not available

Alone

Alone and withintermediates

Not available

Alone and withintermediates

Alone and withintermediates

BACK GAUGE: SERIE RPG UPPER TOOLS

* Work area not recommended for European (Promecam) tools

8 axes fully indipendent

MODEL/FEATURE RPG-1 RPG-2 RPG-3

X Standard Strokes (mm) 800 1000 1000

X Speed (mm/s) 400 400 400

X Accuracy (mm) ± 0,1 ± 0,1 ± 0,1

X Repeatability (mm) ± 0,05 ± 0,05 ± 0,05

R Standard Strokes (mm) 250 250 300

R Speed (mm/s) 250 250 250

R Accuracy (mm) ± 0,01 ± 0,01 ± 0,02

R Repeatability (mm) ± 0,05 ± 0,05 ± 0,01

Z Speed (mm/s) 500 500 500

Z Accuracy (mm) ± 0,02 ± 0,02 ± 0,02

Z Repeatability (mm) ± 0,01 ± 0,01 ± 0,01

28 29

Intermediate elements can be mounted to the ram with Hydraulic or Manual clamping systems.The range includes four single tool intermediates (one tool position) and six double tool intermediates (front and back tool positions) with various combinations of clamping systems.Tools can be mounted on the intermediate elements both Manually or Pneumatically (only European Type).The range of intermediate elements includes version suitable to be mounted on almost all rams: this allows the press brake to equally use long type tools (i.e. Wila, Colgar, Beyeler, LVD, Gasparini, etc.) fitted straight on the ram and short type tools (i.e. Promecam, etc.) fitted on the intermediate.

Thanks to the wide range of clamping systems almost all lower tools (i.e. European-Promecam, Wila, Colgar, Beyeler, LVD, Gasparini, etc.) can be fitted on X-PRESS ECO and Standard series with Pneumatic, Hydraulic or Manual clamping technologies.

SIM

PLE

(UP,

DOW

N)DO

UBLE

(UP,

DOW

N FR

ONT,

DOW

N BA

CK)

SUIT

ABLE

TOO

L PR

OFIL

ES

MANUALCLAMPING

PNEUMATICCLAMPING

HYDRAULICCLAMPING

WILA FIXEDWILA-LVD-BEYELERWITH SPACERS

CLAMPING SYSTEMS FOR INTERMEDIATE ELEMENTS LOWER TOOL CLAMPING SYSTEMS

EUROPEAN (PROMECAM)

ManualManual

ManualManual-Manual

HydrulicManual

HydrulicManual-Manual

ManualPneumatic

ManualPneumatic-Manual

ManualPneumatic-Pneumatic

HydraulicPneumatic

HydraulicPneumatic-manual

HydraulicPneumatic-Pneumatic

EUROPEAN(PROMECAM)

WILA

GASPARINI

COLGARLVDBEYELER

EUROPEAN(PROMECAM)

WILA

GASPARINI

COLGARLVDBEYELER

EUROPEAN(PROMECAM)

EUROPEAN(PROMECAM)

30 31

The continuous innovation of bending systems and their increasingly sophisticated functionalities have pushed Gasparini Industries to develop a new generation of controls.

For this project Gasparini Industries has chosen VisiTouch 19, the latest numerical control by Cybelec, for its high performances and its new expandability features.

The new control PHOENI-X, developed by Gasparini Industries on Cybelec platform, represents the best solution for the control and the integrated management of all machine parameters and functionalities.This allows perfect bending process, high precision, reduced energy consumption, noiseless and fast execution.

The communication between the PHOENI-X control, the actuators and the servo-drives is done by means of a digital BUS which grants a single channel of communication between all components of the system, with a better electronic noise rejection, the improvement of diagnostic and consequently of the control itself.

PHOENI-X panel combines full touch screen functionality with a state of the art look, modern and elegant. Its capability includes:

• On-screen finger profile drawing

• Importing DXFs with folding information and 3D models (MetaCAM, SolidWorks, SolidEdge, ParaSolid, IGES, STEP)

• Exporting of unfolded DXFs for cutting purpose

• Multiple viewpoints of the operations

• Windows XP Pro Compact for multitasking

TIP-TAPMulti – station bending processes are not normally easy to manage for the operator and productivity is typically low, since while stepping over to the next work position with the bent part, the operator must also manage to move the foot pedal box. The Multi Pedal Option (TIP TAP) is a concrete help in such kind of production, since each work position is equipped with a pedal.

TIP-TAP HIGHLIGHTS

• programmable pedals’ activation sequence according with bending sequence• pedals can be positioned all along the bending line or parking position• one-movement placement & quick fastening• transparent safety guard upon the sliding rail of pedals• active pedal marked by blinking led• possibility to install up to 6 pedals• productivity improvement

TELE-LINK SYSTEM The new Gasparini Tele-link system, available as standard on all X-Press machines, is a software suite that allows Gasparini Service Engineers to connect to the customer’s Machine CNC through a Bridge PC. Internet for remote help, reducing machine down times.

• Rapid failure analysis and reduction of machine down times• Possibility to fix software and CNC issue remotely• Reduction of the time spent on telephone assistance • Easy to use• Safe

TELE-LINK SYSTEM / TIP TAP / A-MDG-1 CNC: PHOENI-X

A-MDG-1 The A-MDG-1, or Angle Measurement Device Gasparini, provides the possibility to connect a digital protractor to the CNC USB port or wireless. The operator measures the angle with the digital protractor to measure the angle and send the value to the CNC, simply with a push button. The angle correction will be automatically calculated and corrected into the CNC control.

32 33

PHOENI-X full 3D multi-simulation capability includes:

• Machine components can be individually made invisible for better job examination

• Optimization of bending sequences, back-gauge placement and part manipulation

• Real-time collision detection for tool selection appropriateness check

• Automatic or interactive tooling and gauging placement

• Browse through tool mounts and tooling, edit them interactively

• Modify bend tooling directly on the control

• All the above actions can be performed automatically or interactively according to the user’s needs

PHOENI-X expandability allows to easily add new features:

• Associate a machine parameter page or a manual movement to new features

• Program new features in a specific sequence/part- program and correct and

• Modify them while running

• Adapt machine cycle and calculations to the new features

• Add messages and specific diagnostics for the new features

The new X-PRESS eco is equipped with the new DA-66T by Delem.

Ease of use combined with state-of-the-art technology go hand in hand, improving productivity.The touch screen gives access to the proven Delem user-interface and enables direct navigation between programming and production. Functions are directly located where you need them, offering optimized ergonomics throughout the application.

The DA-66T offers 2D programming that includes automatic bend sequence calculation and collision detection.

Full 3D machine set-up with multiple tool stations giving true feedback on the product feasibility and handling.Highly effective control algorithms optimize the machine cycle and minimize set-up time. This makes using press brakes easier, more efficient and more versatile then ever.

• 2D graphical touch screen programming mode

• 3D visualization in simulation

• Production

• 17” high resolution color TFT

• Full Windows application suite

• Delem Modusys compatibility (module scalability and adaptability)

• USB, peripheral interfacing

• Open system architecture

• Sensor bending & correction

CNC: PHOENI-X CNC: DA66T DELEM

34 35

16000 ••15000 •••12000 ••••• •• •• ••• •• •• ••10000 •• •• ••• • •• •9000 ••• ••• •••8000 •• •• •• •• •• •• •• • •• ••• • •• •7000 •6000 ••• • • •• • •• • ••• • • • •5000 • ••• • • • • • •4000 • • • • • • • •3000 • • • • •2500 •2000 •1600 •1250 •

25 50 100 150 200 250 300 330 400 420 500 600 640 660 800 840 900 1000 1250 1280 1500

Macchina singola • • • • • • • • • • • • • •tandem •• •• •• •• •• •• •• •• •• ••tridem ••• ••• ••• •••

••• •••

•••

The X-PRESS is available in a wide range of models and powers, with a tonnage that vary between 25 and 1500 tons, a length between 1250 and 16000mm.

With stand alone, tandem and tridem configurations, with a wide range of accessories (back gauges, front supports, clamping systems, sheet followers, controls, etc.), with tailor made approach, we always guarantee the best solution for every production need and every set of technical and economical constraints.

RANGE

See example below

Lenght [mm] / tonn

NOTEFor a required force we can provide:

One stand-alone machine Two machines in tandem configuration Three machines in tridem configuration

EXAMPLEIf you need 6000 mm bending length and 500 ton, we can provide

One stand-alone machine of 500 ton Two machines of 250 ton each in tandem configuration

IF YOU DO NOTFIND IN THECATALOGS,

ASK

36 37

TECHNICAL FEATURES

mm kN mm mm mm mm mm mm mm mm/s mm/s mm/s kWall all all all all std I C std I C std I C all all std I C all all std I C all all all all

X-Pr

ess

25

1250 250 1250 1200 0 150 - - 340 - - - - - 905 2000 2000 - - 1100

non

richi

esta

1,94 - - 200 200 (170) 0÷10 3

1600 1670 1300 - - - - - - 2735 2550 (2475) - - 1675 3,75 - -

2000 2100 1600 200 300 600 500 300 100 3030 2550 (2475) 2750 (2675) 2750 (2675) 1675 4,2 4,5 4,5

2500 2600 2100 3575 3030 (2830) 3330 (3130) 3330 (3130) 8,5 8,7 8,7 200 (170)

3000 3100 2600 4100 3030 (2830) 3330 (3130) 3330(3130) 10 10,2 10,2 200 (170)

4000 4100 3600 5100 3030 (2830) 3330 (3130) 3330(3130) 12,3 12,5 12,5 145 (120)

3000 3100 2600 4090 3140 (2970) 3440 (3270) 3440 (3270) 12,1 12,8 12,8 170 (140)

4000 4100 3600 5090 3140 (2970) 3440 (3270) 3440 (3270) 15 15,8 15,8 170 (140)

5000 5100 4600 6090 3450 (3280) 3750 (3580) 3750 (3580) 18,7 19,2 19,2 180 120 (100)

3000 3100 2600 500 965 4110 3380 (3260) 3680 (3560) 3680 (3560) 2080 15,6 18 18 175 (145)

4000 4100 3600 500 965 5110 3380 (3260) 3680 (3560) 3680 (3560) 2080 19,6 20,7 20,7 175 (145)

5000 5100 4600 500 985 6110 3600 (3350) 3900 (3650) 3900 (3650) 2080 25 26 26 170 (140)

3000 3100 2600 500 965 4110 3380 (3260) 3680 (3580) 3680 (3580) 2195 16,1 17,2 17,2 200 175 (145)

4000 4100 3600 500 965 5110 3380 (3260) 3680 (3580) 3680 (3580) 2195 20 21 21 200 175 (145)

5000 5100 4600 500 985 6110 3670 (3240) 3970 (3670) 3970 (3670) 2195 27 28 28 150 115 (95)

6000 6100 5600 500 1075 7110 3670 (3370) 3970 (3670) 3970 (3670) 2195 33 34 34 150 115 (95)

3000 3100 2600 500 965 4110 3555 (3430) 3855 (3730) 3855 (3730) 2220 18,5 19,7 19,7 200 150 (125)

4000 4100 3600 500 965 5110 3555 (3430) 3855 (3730) 3855 (3730) 2220 22 23,2 23,2 200 150 (125)

5000 5100 4600 500 985 6110 3755 (3480) 4055 (3780) 4055 (3780) 2220 28,7 29,7 29,7 180 145 (120)

6000 6100 5600 500 965 7110 3950 (3600) 4250 (3900) 4250 (3900) 2220 700 35 36 36 150 100 (85)

4000 4300 3600 500 400 600 5375 4000 2500 1250 41 120 (100)

6000 6300 5600 500 400 600 7375 4300 2500 1500 51 85 (70)

4000 4300 3600 500 400 600 5400 3910 2500 1350 42 100 120 (100)

5000 5300 4600 500 400 600 6375 4180 2500 1600 48 120 120 (100)

4000 4300 3600 500 400 600 5420 4200 2600 1500 55 120 (100)

5000 5300 4600 500 400 600 6420 4180 2600 1285 62 120 (100)

6000 6300 5600 500 400 600 7420 4330 2600 1575 70 110 (90)

5000 5100 4100 500 450 650 5900 4500 2840 1285 61,5 110 (90)

6000 6100 5100 500 450 650 7025 4735 2840 1575 78 110 (90)

6000 6100 5100 500 600 850 7100 5800 2970 1900 90 110 (90)

8000 8100 7100 500 600 850 9100 6050 2970 2750 160 80 (65)

9000 9100 8100 9900 6670 4155 3400 180 110

10000 10100 8100 11100 7415 4300 3755 207 110

X-Pr

ess

1500 8000 12500 8100 7100 500 600 850 820 9115 6700 4100 3500 200 60 70 (60) 0÷6 110

500 600 850

non

richi

esta

non

richi

esta

non

richi

esta

non

richi

esta

930

920

920

920

850

820

100

300 500 400 500 800 600

300 500 300 500 800 600 400

100 400 100

100

200

100 400 100

100

200 200 (170)

300 300 400 500 800 600

800 600

0÷670 (60)60

80

80

100 0÷8,5 55

0÷7.5 75

0÷7.5 90

0÷10 5,5

0÷8,5 37

0÷8,5 45

11

0÷10 22

0÷10 30

0÷8,5 30

100 400 100 950

200 400 100 950300

400 300 300 400 500

950 2110

non

richi

esta

0÷10 18,5

2000

non

richi

esta

200

200

0÷10

100 400 100300500 300 400 500 800 600

10000

12500

6400

8000

4200

5000

Alte

zza

Inte

rmed

i se

mpl

ici m

anua

li (IN

T)

mm mm

DIMENSIONI E PESI

X-Pr

ess

50X-

Pres

s 10

0

X-Pr

ess

50 I

X-Pr

ess

50 C

X-Pr

ess

100

I

X-Pr

ess

100

C

mm

2000

tonn

Alte

zza

Mas

sim

a H

max

(A

ltezz

a m

inim

a H

min

B

DC

per

tras

port

o)(H

min

BD

C fo

r tra

nspo

rt)

VER

SIO

NE

STA

ND

AR

D

VER

SIO

NE

CO

N C

OR

SA

MA

GG

IOR

ATA

VER

SIO

NE

CO

N L

UC

E M

AG

GIO

RA

TA

X-Pr

ess

150

1500

X-Pr

ess

150

I

PRESSE PIEGATRICI

Lung

hezz

a no

min

ale

Forz

a di

peg

atur

a

Lung

hezz

a m

assi

ma

real

e

X-PR

ESS

200

X-PR

ESS

200

I

X-PR

ESS

200

CX-

Pres

s 15

0 C

500

1000

Prof

ondi

tà (B

)

Prof

ondi

tà p

ozze

tto

2500

X-Pr

ess

250

X-Pr

ess

250

I

X-Pr

ess

250

C

Dis

tanz

a m

assi

ma

tra

le

spal

le la

tera

li

Luce

: dis

tanz

a tr

a ba

nco

e tr

aver

sa (D

L)

mm

Cor

sa m

assi

ma

trav

ersa

(Y

Str

oke)

SPECIFICHE TECNICHE

Velo

cità

di r

itorn

o ve

rsio

ne E

CO

(ver

sion

e st

anda

rd)

Velo

cità

di l

avor

o

Pote

nza

50 H

z - 4

00 V

X-Pr

ess

330

X-Pr

ess

330

I

Velo

cità

di

avvc

inam

ento

Peso

app

ross

imat

ivo

AREA DI LAVORO

Lung

hezz

a (A

)

X-Pr

ess

1250

X-Pr

ess

800

X-Pr

ess

1000

Alte

zza

banc

o di

lavo

ro

(BH

)

Inca

vo (T

H)

X-Pr

ess

640

X-Pr

ess

500

X-Pr

ess

330

C

3300

X-Pr

ess

420

62 63

TAILOR MADE SOLUTIONS 1

GASPARINI INDUSTRIES is an Industrial Company, with the ambition to be recognized as the Leader in the development of bending and cutting technology. We develop ideas, design solutions and realize products, for Customers looking for the best Partner, as for skill, commitment, safety and service.

Our Team is capable to understand and even anticipate, the most sophisticated customer’s needs, providing outstanding “tailor made” solutions, supported by our differentiation factors: co-design attitude, adaptability, ecological approach.

The following examples are just some of the Projects developed recently.

PROJECT: PRESS BRAKES “TANDEM” 2X 200T-3M

Destination: RussiaCustomer Industry: Trucks equipment & road construction machinery

PROJECT: PLASMA ROBOTIC CELL

Destination: ItalyCustomer Industry: Pressure vessels

6564

PROJECT: SHEAR LINE 6 m - 10 mm, WITH SEMI-AUTOMATIC DOWN LOADING DEVICE

Destination: SwitzerlandCustomer Industry: Metal parts production.

PROJECT: SHEAR LINE 4m - 6 mm, WITH SEMIAUTOMATIC LOADING, DOWN LOADING AND STAKING DEVICES

Destination: SwitzerlandCustomer Industry: Multi-metal service centermachinery

TAILOR MADE SOLUTIONS 2

66

Gasparini Industries Srl COLLECTION 2013This edition was printed in October 2012

All rights reserved and protected by industrial design rights. Gasparini Industries srl reserves the right to change or technically improve the products featured in this catalogue.

GASPARINI INDUSTRIES SRLvia F. Filzi 33 - 31036 Istrana - (TV) Italy

Ph: +39 0422 8355 - Fax: +39 0422 835 600info@gasparini.it - www.gasparini.it