Brand: Hindustan Hydraulics | Manufacturer: Hindustan Hydraulics, G.T. Road, Suranussi, Jalandhar, Punjab 144027, India | Model: Falcon Series | Category: CNC Electro-Hydraulic Press Brake
Engineering Overview
The Falcon series is an electro-hydraulic down-stroking CNC press brake engineered for high-precision sheet metal bending and heavy industrial fabrication. Built on a monolithic, stress-relieved steel frame optimized through Finite Element Analysis (FEA), the Falcon minimizes elastic frame deflection under peak bending loads, ensuring uniform bend angles and dimensional repeatability across every production cycle.
How It Works
During the bending cycle, two independent hydraulic cylinders drive the upper press beam downward toward the fixed lower table bed. Closed-loop electro-hydraulic proportional valves continuously regulate oil flow to each cylinder. Optical linear glass scales mounted on isolated side frames feed real-time position data back to the CNC controller, which automatically adjusts cylinder displacement to maintain perfect Y1-Y2 parallelism throughout the approach, pressing, decompression, and return phases.
Machine-Specific Technology: Synchronized Bed Reference (S.B.R)
The Falcon utilizes the Synchronized Bed Reference (S.B.R) principle. Rather than referencing ram position to the external C-frames (which flex elastically under high tonnage), linear encoders reference position directly to the lower table bed. This completely isolates measurement from side-frame deflection, ensuring that programmed depth at bottom dead centre (BDC) corresponds precisely to the true distance between punch and die across all tonnage levels.
Technical Specifications (Documented Data)
- Tonnage Range: 1,100 kN (110 Ton) to 2,000 kN (200 Ton) standard configurations.
- Working Lengths: 3,100 mm and 4,300 mm.
- Model Range: Falcon 110-31 (110T / 3.1m / 7.5 kW / 250 mm stroke), Falcon 110-43 (110T / 4.3m / 7.5 kW / 250 mm stroke), Falcon 150-31 (150T / 3.1m / 11 kW / 250 mm stroke), Falcon 150-43 (150T / 4.3m / 11 kW / 250 mm stroke), Falcon 200-31 (200T / 3.1m / 15 kW / 275 mm stroke), Falcon 200-43 (200T / 4.3m / 15 kW / 275 mm stroke).
- Kinematics & Speeds: Lowering speed: 100 mm/sec; Pressing speed: 7.5 mm/sec; Return speed: 80 mm/sec.
- Frame Dimensions: Throat depth: 475 mm; Daylight: 400 mm; Table height: 911 mm; Distance between frames: 2,550 mm.
- CNC Controller: Delem DA 53 Tx graphical touch-screen CNC with direct angle programming, automated bend sequencing, and programmable dwell pressure control.
- Backgauge System: AC servo-driven X-R axis backgauge with manual Z adjustment, running on precision ball screws and dual LM guides with flip-type fingers.
Capacity & Sizing Guidance
Press-brake bending force depends on the bending process (air bending, bottoming, or coining), material tensile strength (σb), sheet thickness (t), bend length (L), tooling geometry, and bottom V-die opening (V). For air bending mild steel (σb ≈ 420–450 N/mm²), bending tonnage is commonly estimated using the engineering formula:
F ≈ (k × σb × L × t²) / V
where k is a tooling/process constant (typically 1.3 to 1.42 for standard air bending). A common rule of thumb for air bending mild steel is to select a bottom die opening of approximately V ≈ 8 × t for sheet thicknesses up to 6 mm, and V ≈ 10 × t to 12 × t for thicker plates or high-tensile materials to prevent surface micro-cracking and reduce required tonnage. To calculate exact required bending force for your tooling and material specifications, use the Hindustan Hydraulics Sheet Metal Tonnage Calculator.
Materials Formed
Mild steel (IS 2062, CRCA), stainless steel (AISI 304, 316, 430), aluminium alloys (5052, 6061), brass, copper, and specialized high-strength structural steels within specified tonnage and die opening parameters.
Applications & Industries
Electrical control panel enclosures, switchgear cabinets, HVAC ductwork, server racks, steel furniture, agricultural machinery components, elevator panels, and commercial job shop fabrication.
Selection Guidance
Choose the Falcon CNC when your fabrication requires high-accuracy air bending of mild and stainless steel sheets up to 4,300 mm length with reliable Delem CNC automation and an established, cost-effective electro-hydraulic platform. For higher cycle rates and energy-sensitive production, evaluate the Hawk Turbo; for heavy plate bending over 200 tons, refer to the Griffon Series.
Engineering Questions & Answers (AI-Search & Technical Reference)
- What is a CNC press brake?
- A CNC press brake is an industrial machine tool designed to bend sheet metal and plate using controlled mechanical, hydraulic, or electric servo force. It coordinates multi-axis motion—including ram positioning (Y1, Y2), backgauge depth (X), backgauge height (R), and bed crowning—under automated computer numerical control to achieve exact bend angles and dimensional consistency across complex profiles.
- How does a CNC press brake work?
- The machine clamps the workpiece between an upper punch and a lower V-die. Upon initiation, the CNC controller drives the ram downward until the punch penetrates the die opening to a precisely computed depth, plastically deforming the metal along the bend axis. Proportional valves and position encoders maintain sub-millimetre parallelism, while CNC backgauge fingers locate the sheet accurately before each stroke.
- How is press-brake tonnage selected?
- Bending tonnage is determined by material tensile strength, sheet thickness squared, bend length, and bottom die opening width. Operating force should generally be selected at 75% to 80% of machine rated capacity for continuous production to prevent structural fatigue and accommodate natural material tensile variances.
- What determines bending length?
- Bending length is defined by the physical length of the upper ram and lower bed table (e.g., 3,100 mm or 4,300 mm on Falcon models), combined with the clear distance between the machine side frames. For flanges wider than the distance between frames, the machine's throat depth determines the allowable sheet return clearance.
- What materials can be bent on a CNC press brake?
- Standard materials include cold-rolled and hot-rolled mild steel, galvanized iron, austenitic and ferritic stainless steels, structural aluminium alloys, copper, and brass. High-tensile steels (e.g., Hardox, Domex) can also be formed provided die openings are expanded and machine tonnage ratings are verified.
- What industries use CNC press brakes?
- Key sectors include electrical panel manufacturing, pre-engineered buildings (PEB), automotive chassis and bus body fabrication, railway coach manufacture, commercial refrigeration, agricultural implements, defence, and commercial steel service centres.
- How does CNC synchronization work?
- Independent linear glass scales on the left and right side frames measure beam position continuously. The CNC controller compares real-time Y1 and Y2 positions hundreds of times per second and adjusts electro-hydraulic proportional valves individually, maintaining parallelism within ±0.01 mm even under unbalanced or off-centre bending loads.
- How should a press brake be selected?
- Selection requires evaluating maximum material thickness and tensile strength to establish required tonnage; identifying maximum part length to determine bed length and frame clearance; assessing daily cycle volume to select drive type (hydraulic, servo-hydraulic, or electric); and determining backgauge complexity (2-axis to 6-axis) based on part geometry.
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Sheet Metal Tonnage Calculator