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Old 07-07-2021, 05:06 AM
MarcopoloMint MarcopoloMint is offline
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Default How to create this shape in sheet metal

Hello all, my first post here so please be gentle!!

I've got this shape in aluminium I need to make. It's approx 500mm high, those bends are approx 30mm radius, Aluminium say 2-3mm think.
My local metal fabricators said "we can't bend to that shape".

Now in the final production item it will be an aluminium extrusion but for the proto I haven't got the budget to do a trail run extrusion just for this shape.
S0 it's not production that will be the problem; it's prototyping it.

What I'm wondering is why they can't bent to that shape? Is it because they specifically don't have a machine that will do it or is it not possible for any fabricator to make this shape?

Any help or idea on how I can create this would be much appreciated.


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Old 07-07-2021, 05:44 AM
billfunk29 billfunk29 is offline
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Default bending

No reason that shape can't be formed on a press brake, with the right tooling. I suspect they lack the tooling. If you are using hardened Aluminum, spring back will have to be accounted for.



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Old 07-07-2021, 10:00 AM
Reno Reno is offline
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The first thing I thought of is a Gene Winfield pipe anvil.
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Old 07-07-2021, 12:52 PM
mastuart mastuart is offline
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Marco Build a down and dirty version of one of these brakes in this link. You should be able to make something out of scrap laying around. https://www.mittlerbros.com/mittler-...us-brakes.html

I have a question for you? What does a mechanical design engineer do? I would of thought that a mechanical design engineer would be well versed in all of the machines and mechanics to build anything that you could think up to design. When I am building something I am always thinking about what i will build it out of and with what.
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Old 07-07-2021, 03:42 PM
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Most shops have a large press brake that cannot close in the part as you have designed it. If you are willing to have it made in two halves, they can probably do it. To make that part, you will have to bend it around a tube and have a way of opening the tool to remove the completed part. It should not be that difficult to put together something to do that. Your part can be built, it is just not something that is done with standard shop brakes. What are your dimensions? You might. E able to fit it into a roller.
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Old 07-07-2021, 03:56 PM
Bob Bob is offline
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Quote:
Originally Posted by mastuart View Post
Marco Build a down and dirty version of one of these brakes in this link. You should be able to make something out of scrap laying around. https://www.mittlerbros.com/mittler-...us-brakes.html.

I had a need to form a similar part some years ago, so I built a machine like Mark suggests. So I can attest to the thinking it can do it. Mine comes apart so getting the part out would be possible.

And too, figuring out the workings of the machine was a bit of fun. As was building it.

You'll have to pre determine the springback on the chosen material before choosing the die diameter. Ron Covell did a recent video on how to do that.
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Old 07-07-2021, 09:56 PM
skintkarter skintkarter is offline
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Is welding out of the question?
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Old 07-08-2021, 09:39 AM
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A magnetic brake will do the job.
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Old 07-08-2021, 11:31 PM
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A magnetic brake will do the job.
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Old 07-09-2021, 10:51 AM
mastuart mastuart is offline
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Hey Joe The part he needs has about a 20 inch long bend in 1/8 inch aluminum. Is the magnet strong enough to hold that tube down to bend that thick of aluminum? I have never played with that kind of brake. I assume if the clamp bar has enough mass and surface area the magnet could clamp with a lot of pressure. After looking at it again is there a flat plate with a tube attached to it ?
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Last edited by mastuart; 07-09-2021 at 11:00 AM.
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