Press brake programming is the cornerstone of successful sheet metal fabrication, especially when tackling complex bend sequences on Durma press brakes. Australian fabricators know that mastering these sequences isn’t just about avoiding costly errors on your sheet metal machine—it’s about transforming challenging projects into profitable opportunities. Whether you’re operating the latest AD-S Series with its advanced Delem controls or working with the reliable E Series machines, the right programming techniques make all the difference. ACRA Machinery has supported countless workshops across Australia in optimising their bending operations, and this guide distils that expertise into practical strategies for your shop floor.
Understanding Durma Controller Technology
The heart of effective press brake programming lies in understanding your machine’s control system. Durma press brakes offer various controller options, each with unique capabilities for handling complex bend sequences.
Durma Controller Varieties
Durma’s flagship AD-S Series comes equipped with the sophisticated Delem DA-66T controller, offering unparalleled precision for challenging bends. This premium option provides intuitive touchscreen interfaces and advanced sequence optimisation tools. The mid-range AD-R Series features Delem DA-58T or DA-69T controllers, balancing performance with accessibility for operators at all skill levels. For workshops with straightforward needs, the E Series offers reliable Cybelec controls that still handle most bending operations efficiently. The key differences between these systems impact how programmers approach multi-step bending strategies.
Simulation Capabilities
Modern Durma controllers excel in their 3D visualisation capabilities, allowing operators to identify potential collisions before executing a single bend. This virtual testing environment integrates seamlessly with the broader Durma CAD/CAM ecosystem, enabling full digital prototyping of even the most intricate parts.
Programming Methodology for Complex Parts
Successful press brake programming requires a methodical approach when tackling complex bend sequences. The right methodology prevents costly errors and maximises efficiency on your Durma press brake.
Sequence Planning Principles
Planning your bend sequence is critical before programming begins on any Durma controller. The most effective approach often follows inside-out programming for enclosed shapes, allowing internal features to be formed before external ones restrict accessibility. On Durma press brakes, collision avoidance must be considered at every step, particularly when working with tall flanges or complex geometries. Part rotation planning deserves special attention—strategically flipping the workpiece during the sequence can solve seemingly impossible bending challenges. Australian fabricators often develop standard procedures for common part families, reducing programming time across similar components.
Material Considerations
Sheet metal bending success depends heavily on understanding your material’s behaviour. Springback compensation requires careful attention on your Durma press brake, especially with high-strength materials. The controller allows fine-tuning of angles to account for this physical property. Material thickness variations, even within spec, can significantly impact final results, requiring programmers to build in tolerances. Grain direction affects bending performance, particularly with aluminium and stainless alloys common in Australian workshops. Temperature fluctuations throughout the production day can subtly alter bending characteristics, requiring occasional program adjustments.
Tooling Selection Strategy
The right tools dramatically simplify complex bend sequences. Durma’s Quick Tool Change system enables rapid transitions between bending configurations without sacrificing precision. For challenging geometries with tight internal radii, specialised tooling selections make the impossible possible. Radius tooling applications require specific programming techniques to ensure accurate results, including proper speed control during forming. The integrated Durma crowning system compensates for deflection under load, ensuring consistent angles across wide workpieces.
Advanced Programming Techniques
Mastering complex bend sequences on Durma press brakes requires going beyond basic programming. Advanced techniques enable fabricators to tackle challenging parts that competitors might decline.
Multi-Step Bending Strategies
Breaking down intricate components into manageable steps forms the foundation of advanced press brake programming. When facing geometries with multiple intersecting flanges, Durma controllers allow operators to program intermediate positioning states that temporarily hold material in transitional positions. This approach prevents tool collisions while ensuring precise final dimensions. Durma’s multi-axis backgauges enhance this capability by providing reference points beyond standard X and Y coordinates. Programming for these auxiliary axes requires understanding the full movement envelope of your specific Durma press brake model. Australian fabricators often develop custom gauging fixtures to complement these advanced programming strategies, particularly for repeat production runs of complex parts with unusual geometries.
Optimisation Methods
Efficiency in bending operations comes from continual refinement of your programming approach. On older Durma controllers, memory management becomes crucial when programming extensive bend sequences. Structuring programs to reuse subroutines can dramatically reduce file sizes while improving readability. Speed optimisation for servo-driven axes involves carefully balancing velocity with precision requirements—faster isn’t always better when working with tight tolerances. The ability to transfer programs between different Durma machines enhances workshop flexibility, though care must be taken to account for controller-specific parameters. When working with newer Delem interfaces, utilising the graphical bend sequence visualisation tools helps identify opportunities to reduce cycle times through reordering operations without compromising quality.
Conclusion and Industry 4.0 Integration
The journey to mastering complex bend sequences continues as technology evolves. Durma press brakes are increasingly embracing digital transformation to enhance programming capabilities.
Future Programming Trends
Press brake programming is advancing rapidly with cloud-based solutions becoming increasingly accessible for Australian fabricators. These systems enable storing and retrieving bend sequence libraries from anywhere, facilitating collaboration across multiple workshop locations. Remote diagnostics capabilities now allow ACRA technicians to troubleshoot programming issues without travelling to your site, reducing downtime significantly. Integration with ERP systems streamlines workflow from design to production, with Durma controllers communicating seamlessly with business management software.
ACRA Support and Training
Australian workshops benefit from comprehensive support for their Durma press brake operations. ACRA Machinery offers specialised programming assistance for particularly challenging components, drawing on decades of sheet metal fabrication expertise. Structured training programs help operators transition from basic to advanced programming skills, with courses tailored to specific Durma controller models. Technical support resources include 24/7 hotline access and extensive documentation covering common challenges in complex bend sequences.
Need More Advice on Durma Press Brakes?
If you need more information on our services and products or advice on how we can help to meet your needs, simply fill out the contact form or call us on 03 9794 6674. With 42 years of experience in the sheet metal industry, we offer comprehensive support for machinery sales, repair, and maintenance.
Frequently Asked Questions
Q1: What controller options are available on current Durma press brakes?
A: Current Durma press brakes offer several controller options across their range. The high-end AD-S Series features Delem DA-66T controllers with advanced touchscreen interfaces and 3D simulation. Mid-range AD-R Series machines come with either Delem DA-58T or DA-69T controllers, while the E Series typically offers Cybelec control systems. Each controller has different capabilities for handling complex bend sequences, with varying levels of graphical interface sophistication.
Q2: How does Durma’s 3D simulation help with complex bend sequences?
A: Durma’s 3D simulation technology allows operators to virtually test bend sequences before cutting any material. This capability identifies potential collisions between the workpiece, tooling, and machine components during the bending process. For complex parts with multiple flanges, the simulation shows exactly how the material will behave during each bend, enabling programmers to optimise sequences, detect interferences, and resolve issues in the digital environment rather than discovering problems during production.
Q3: What training resources does ACRA provide for Durma press brake programmers?
A: ACRA Machinery offers comprehensive training resources for Durma press brake operators at all skill levels. These include hands-on workshops at customer facilities, detailed controller-specific training manuals, video tutorials covering advanced programming techniques, and one-on-one coaching for complex applications. ACRA also provides access to an online knowledge base with programming examples and troubleshooting guides specifically for Australian fabrication shops.
Q4: How can I optimise bend sequences for parts with multiple flanges on my Durma press brake?
A: Optimising complex parts with multiple flanges requires strategic planning. First, analyze the part to determine which bends might cause interference if performed in the wrong order. Generally, start with the most internal bends and work outward. Utilise Durma’s 3D simulation to test your sequence before production. Consider using stage bending for challenging geometries—making partial bends that are completed in later steps. Take advantage of Durma’s multi-axis backgauges for precise positioning between bends, and explore specialised tooling options for particularly difficult flanges.
Q5: What are the key differences between programming on older vs. newer Durma controller systems?
A: Newer Durma controller systems offer significant advantages over older generations, including touchscreen interfaces, 3D visualisation, automatic collision detection, and cloud connectivity. Older systems typically rely more heavily on operator experience and may require manual calculation of bend allowances. While newer systems automate many aspects of complex bend sequence planning, older controllers can still produce excellent results but require more manual intervention and expertise. When upgrading, programs can often be transferred between systems, though some parameter adjustments may be necessary to account for differences in controller functionality.