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  #21  
Old 08-06-2021, 11:09 PM
crystallographic crystallographic is offline
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Originally Posted by xlr8tr View Post
Attachment 60779
Attachment 60780
Attachment 60781
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Attachment 60783

Following Kents advice I made my form and clamping blocks from MDF, drilled oversize holes in the Ali, annealed using the sharpie method and tried to work evenly and slowly - However as you can see the material tore.
So my question is should I anneal several times during the process? Is there some technique I'm missing that would help?

Hi Neil,
Hmm.
I think ... your "even" is not quite correctly interpreted.
You cannot focus your forming on the "deep spot" at first.
No, you must form the whole surface evenly, and then like draining water from a tub, the level must go down all together. When the shallows contact you stop hitting there and continue out in the deeps. This is the only way to success.

A "Do this, or fail" sort of thing?

NOTE: alloy is non-trivial - some anneal at 750F - and others anneal at 650F. Use the correct temp for the alloy.


As you were ....
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  #22  
Old 08-10-2021, 03:27 AM
xlr8tr xlr8tr is offline
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Many thanks for all the help and guidance, I managed to get it done in the end - still some final trimming of the flange to do in the picture.
It took a few attempts to get it right and I learnt a lot in the process, now just need to order some flow forming tools from Kent.

IMG_5336.JPG

IMG_5343.JPG
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  #23  
Old 08-10-2021, 03:47 AM
xlr8tr xlr8tr is offline
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Originally Posted by crystallographic View Post
No, you must form the whole surface evenly, and then like draining water from a tub, the level must go down all together. When the shallows contact you stop hitting there and continue out in the deeps. This is the only way to success.
I also wanted to say that this is a great analogy, it really helped me to understand the process.
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  #24  
Old 08-10-2021, 04:15 AM
Jaroslav Jaroslav is offline
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Neil great result and good tool. It looks similar to my hobby hammer but it's a different dimension to the punch. I have to buy too.

You managed to brake the plate correctly in the clamping. Great result. Good preparation.
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  #25  
Old 08-10-2021, 09:20 AM
dwmh dwmh is offline
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Excellent result. There are some great teachers on here. Well done
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  #26  
Old 08-10-2021, 01:00 PM
crystallographic crystallographic is offline
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Hi Neil,
Nice part.
finesse is a seasoning used in metalworking. Rote first. Quick grasps move quickly. (Also love challenge.)
Nice part.

........................ (memories: had one workshop here: Edwards AFB guys. Tigers.

Started throwing challenges, 1st day...... Slurrrp.
2nd day, harder..... Rackety-blap - what next?
Hm, okay, 3rd day stiffen up. Aha, kept occupied for 1.5 hours. Then: ..... what next? Good crew.
4thday - took the crew down the dark path deep into the "icky middle" 1-1.5hrs - and stopped, sighed, set tools down, took off gloves ..... left the shop for water-in/out.
I waited for 18 minutes, came back in - silence - then commotion. Money was wagered.

I waited, din subsided. Focus returned.

I quietly changed tool set and whacked the nasty wreckage into a nice WW1-era 1-piece radiatior shell. Cheers all around. Big chitchat flow.

Good practical lesson for young dynamic crew doing fulltime .mil/nasa and race planes on the side. ....
eh, memories......)

your "inside corner problem" disappeared when doing it more coherently?
Are you making a mating 2nd half for a tube section?
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Last edited by crystallographic; 08-10-2021 at 01:06 PM.
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  #27  
Old 08-22-2021, 10:15 PM
Coastflyer Coastflyer is offline
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Very interesting thread. I want to make similar parts out of aluminum. Kent says alloy is non trivial, and that seems like the biggest mystery to me at this point. How do you go about deciding what material to use? I assume it would be common to desire the strongest alloy that is going to be possible to form into a given part, so do I just experiment with different alloys until I figure it out, or is there reference material I can use as a starting point?
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  #28  
Old 08-23-2021, 09:38 AM
skintkarter skintkarter is offline
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Very nice result Neil! Some good learning there for a number of us.
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