Finallygotit
ALLIANCE MEMBER
Awesome!! 
Above 1200 Sq/FT Eastern Washington Workshop
- Thread starter slodat
- Start date
Wokspaces above 1200 squarefeet.
Just found out my neighbor has that same plasma table. He made me some base plates for a rack I am building. His shop is his retirement play place, he mostly builds signs and small pieces , he wants to take on small projects that bigger production places wont touch. Awesome to see how your stuff turns out. My sheet metal experience is making a small tray/box in high school. I enjoyed the project but nowhere near the complexity of what you are up against.
My first (and only) previous exposure to sheet metal was in shop class in junior high. One year we made a tool tray. The next year a toolbox the tray went in. I still have them. Truly prized possessions at this point. I've played with cars over the years, but nothing serious on the sheet metal side of things.
What I'm doing now is an extension of lifelong career in various aspects of the electrical, and power generation industries. The context is what I'm leveraging. I truly am happiest when I'm making something. It completely kicks my ***, and I don't always love that while it's happening. When I'm done, I'm in that happy spot.
Plasma ***** compared to laser. It just does. With that said, the price delta between plasma and the "cheap" laser I'm eyeballing is what I paid for my house. For now, and a while, we will continue to use plasma. A lot can be gained by taking the time to dial in THC voltage and feedrate. This is how you at least attempt to minimize low and high-speed dross, edge angularity, etc. It's a pain in the *** and I have seen it change significantly with the same size steel from a different supplier or batch. A laser will behave in a similar fashion, I am sure. When it comes to making parts for others with plasma, you have to make sure the cut quality is acceptable to the client. That's where laser and waterjet shine. The edge quality is so much better than plasma. Especially on sheet metal.
We've got their 10HP VFD model at work. looks like the same head. definitely an improvement over previous iterations, but their support is solid. we've got over 2000 hours on it this year and it's been great so far.
I love when it's running at 35-40Hz and is just a quiet thump thump thump in the background.
btw the VFD model is a 15HP vfd so you can feed it 3ø or 1ø.
I love when it's running at 35-40Hz and is just a quiet thump thump thump in the background.
btw the VFD model is a 15HP vfd so you can feed it 3ø or 1ø.
This compressor looks really good. Pressure lubrication, with a spin on filter. Another 10hp single phase motor. Hopefully the last. The need for new three phase service at both buildings is quite evident.
I’m kinda bummed about the compressor. I thought sure I ordered the model with the aftercooler. I didn’t see the VFD options when I bought it. I would have went that route. A cycling single phase 10hp motor is a big load. The compressor has an unloader. It won’t be bad. But a soft start would be nice. It will live in the basement. The idea with the intake silencer is we won’t hear it at all. I will install a big pressure gauge on the header upstairs so we can see air pressure.
4 FN 27
ALLIANCE MEMBER
Steven I am here to help!!! I don't make that offer too often simply our competitors would love the knowledge and experience. Based on your tenacity and self motivation/teaching I don't mind at all helping you shorten the learning curve.
Solidworks is a tool...and a powerful one at that. On the Sheet Metal side, they have some great features but like most software, Sheet Metal takes a second seat and most writing the software don't understand it. Yes it can get it done but there are things it does not offer mostly related to corner reliefs and setback to keep from bottom out in the bottom die...we will get to that...
Once you get your Bend Deductions by Material, ISBR and Bottom opening you will be driving the parts. Forced Bend Deduction at 90° is the only way to go. For all other bends use a .031 R and .44 K-Factor and you will be +/-.005 on your Flange Lengths first hit. As you add a wider variety of Bottom Dies you will need to update your Bend Deductions...maintain a good database and it will just turn into plug and play.
Today I formed up a whole bunch of .100 5052-H32 Aluminum...no set up parts. Used a force Bend Deduction of .154 punched in the numbers in the control and started forming. All parts within +/-.005. Design in SW using .031 Radius. .008 (.2mm) Punch and a 12mm Bottom Die.
The Entry side of the Rivet hole is .135 and the clinch side is .130. Assembling 3 parts together I didn't have to reem a single hole. A Panel and 2 End Caps make up a subassembly and that gets riveted to a main panel...involving all the parts in sets.
Check out the hole alignment and how flush the 2 surfaces come together.
After riveting...yes that 1/64 gap was designed in the model.
You got this!!! I know it!!!
If I can hold these tolerances using junk tool our shop was throwing out and a 2 Axis 27 year old Press Brake I know you can do it!!!
EDIT: you have my number and my email...anytime!
EDIT 2: I had the guys at the Shop Laser these...they had an 50 extra sheets of material and I would have had to cut it in half to get it in the Water Jet...saved me the headache.
Pat- THANK YOU! I had planned to reach out once I had a question formulated. I’m with you on SW (and any CAD program) being a tool. I’ve got some learning curve to get over so I can work in SolidWorks. I’ve already applied some of what we talked about and I’m seeing results. I guess my mindset was I’d save the silver bullets for when I have more of a question . I can’t thank you enough. I will definitely continue to take you up on your very generous offer!
4 FN 27
ALLIANCE MEMBER
You are welcome...all I ask in return is pay it forward to those wanting to learn the skillsets you develop.
I'll set-up a Sheet Metal Template part for you and email it. I have a few updates I need to make on my template before I send. It will save you the headache.
the intake silencer does WORK. the aftercooler is tiny but I can hold my hand on the pipe that feeds into the tank, so I can't fuss.
you might be able to add it on after the fact. they'll probably sell it to you.
I have already planned to add an after cooler. Figured I’d reach out to Emax and see if they will sell me theirs. If not, a belt guard setup wouldn’t be difficult to sort out. It looks like a good compressor. Getting it in the basement isn’t going to be easy though at nearly 800 pounds. We think we have a plan.
GeddyT
ALLIANCE MEMBER
10 hp single phase is a beast of a motor for just a magnetic starter. I have a 5 hp on the Quincy, and I'm thinking about changing the starter out for a VFD as well. It lumps along pretty innocuously when it's running, but the startup will make you jump and maybe poop a little if you're not expecting it. It cycles on and off about every two or three minutes while the VMC is running.
That compressor starting is 100 times scarier than the 40hp RPC kicking on (although the neighbors might disagree...).
That compressor starting is 100 times scarier than the 40hp RPC kicking on (although the neighbors might disagree...).
I’m thinking/hoping the fact the compressor has an u loader should have a significant impact on starting. It’s still a momentary bolted fault when a (any) motor starts across the line. It’s being fed with 4ga THHN. It’s all rated for it.. I’ll know soon enough. The VFD isn’t an option anymore without significant expense.
GeddyT
ALLIANCE MEMBER
Yeah, VFDs get a lot more expensive when the horsepower climbs. I believe my compressor has an unloader too. It's still quite the violent start. In fact, it's probably the venting of the unloader valve itself that makes the startup so loud!
In other news, it's awesome reading about the growth of your business! It's amazing what you've been able to put together in such a short time. Really cool that we've all been able to follow from back when it was just a hobby/upholstery shop to what it's become.
In other news, it's awesome reading about the growth of your business! It's amazing what you've been able to put together in such a short time. Really cool that we've all been able to follow from back when it was just a hobby/upholstery shop to what it's become.
the other compressor at work is a 25HP quincy. DOL mag starter. it was doing loaded starts for who knows how long until I had the carbon cleaned out of it. that'll make you jump.
unloader takes it to just inertia (typically). I think *most* unloaders use tank pressure to hold the valves open, so the first start on an empty tank won't be unloaded, but it doesn't really matter then, right?
Busy week in the shop. I suppose they all are though. The wide belt sander is in place, and temporarily powered up with SO cord.
I'm not thrilled with their ducting. They sent some components that were the wrong parts. The replacement parts change the overall length of the shorter section, creating a nice down angle. It works, so I'm moving on. This is the first parts ran through the sander:
The drum oscillates. The wavy lines are there by design.
I got it dialed in and I'm really happy with how it is working. The manufacturer included a nice assortment of 3M aluminum oxide belts. This is the 120 grit from 3M. I ordered ceramic 120 grit belts from Combat Abrasives.
Speaking of metal finishing and sanding. I've used the same Rigid 5" RO sander for every sheet metal part that has come through here. Until today..
The backing pad is completely smooth now. It doesn't have any of the velco like backing any more. It's all worn off.
It has been peacefully laid to rest. The small oven arrived yesterday:
They did a great job on the oven, crating, packaging, etc. Manufacturer said it weighs about 750lb. It was easy enough for us to slide on to a pallet jack, and then slide into position. We rearranged the wood working room to make a spot for the oven. The forklift sure is nice for moving heavy things.
The 20" disc sander has been repurposed for metal fabrication at Bldg 2. Back in the wood working room, this is where the oven sits.
I still use the table saw, bandsaw, routers and some of the Festools for customer work (and work around the shop). There's more to clean out and sell in here when I have some time. The oven door faces the finishing room door.
Overall, I am really happy with the oven, the build quality, and all that. I'll get it wired up and see how it works over the next day or so. I have several colors of powder I need to make test coupons of to see if I have a good color match.
I'm not thrilled with their ducting. They sent some components that were the wrong parts. The replacement parts change the overall length of the shorter section, creating a nice down angle. It works, so I'm moving on. This is the first parts ran through the sander:
The drum oscillates. The wavy lines are there by design.
I got it dialed in and I'm really happy with how it is working. The manufacturer included a nice assortment of 3M aluminum oxide belts. This is the 120 grit from 3M. I ordered ceramic 120 grit belts from Combat Abrasives.
Speaking of metal finishing and sanding. I've used the same Rigid 5" RO sander for every sheet metal part that has come through here. Until today..
The backing pad is completely smooth now. It doesn't have any of the velco like backing any more. It's all worn off.
It has been peacefully laid to rest. The small oven arrived yesterday:
They did a great job on the oven, crating, packaging, etc. Manufacturer said it weighs about 750lb. It was easy enough for us to slide on to a pallet jack, and then slide into position. We rearranged the wood working room to make a spot for the oven. The forklift sure is nice for moving heavy things.
The 20" disc sander has been repurposed for metal fabrication at Bldg 2. Back in the wood working room, this is where the oven sits.
I still use the table saw, bandsaw, routers and some of the Festools for customer work (and work around the shop). There's more to clean out and sell in here when I have some time. The oven door faces the finishing room door.
Overall, I am really happy with the oven, the build quality, and all that. I'll get it wired up and see how it works over the next day or so. I have several colors of powder I need to make test coupons of to see if I have a good color match.
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GeddyT
ALLIANCE MEMBER
In consecutive sentences, you said that you laid the old Rigid RO sander to rest, then the small oven arrived. The first place my brain went was, "Did he cremate his sander!?"
Only took a couple of sentences more to realize it was a change of subject...
Only took a couple of sentences more to realize it was a change of subject...
Oh man! That's hilarious. I try to proofread my posts. That one definitely slipped through. Mostly because I know what my thought process was. Ha!
No.. it just went in the trash can. It was starting to growl. The bearings are shot. It provided a long life of service sanding metal when it is definitely a wood working tool.
GeddyT
ALLIANCE MEMBER
Not gonna lie, learning I was mistaken was a huge disappointment! At least the popcorn machine hadn't fully warmed up, so it wasn't a total loss.
We used to bake apple pies in our heat treat draw oven. We'd send our manager out to get ice cream.
SilverJimmy
Well-known member
Guys? You saying you’re not a one man band anymore? Those guys always impressed me, able to do 15 things at once!
rmack898
Well-known member
We all have “those” days and I guess it was Tom’s turn today but I understood the sander death.
I had a Makita sander for almost 40 years and when it died I replaced it with a little DeWalt version of the little sander and I beat the **** out of it sanding metal. I figure small tools like that as consumable’s, what are you going to replace it with?
I had a Makita sander for almost 40 years and when it died I replaced it with a little DeWalt version of the little sander and I beat the **** out of it sanding metal. I figure small tools like that as consumable’s, what are you going to replace it with?
Yes, guys. Grew the team from a solo operation to more than one. It has been incredible thus far.
The sander needs a bit more tuning. I am already happy to have it despite the need for some adjustments. These parts made two passes per side with no depth change.
I’m unable to differentiate which side had the dross. Really incredible difference. About 3 minutes total for both parts.
Shots of the previously discussed fabricated part.
I’m really happy with how these turned out. Bang on in every respect. And exciting to know what’s in store.
Packaged up for delivery.
The sander needs a bit more tuning. I am already happy to have it despite the need for some adjustments. These parts made two passes per side with no depth change.
I’m unable to differentiate which side had the dross. Really incredible difference. About 3 minutes total for both parts.
Shots of the previously discussed fabricated part.
I’m really happy with how these turned out. Bang on in every respect. And exciting to know what’s in store.
Packaged up for delivery.
SilverJimmy
Well-known member
Nothing wrong with expansion, I’ve always been expressed by someone like Roger Penske. At one time he ran Penske Truck Rentals, Detroit Diesel, ProLink Diagnostics, a highly successful NASCAR team, and also was able to win more Indy 500’s than anyone. I’m sure I‘m missing some of his companies too, but just like you, he wanted to be successful and was willing to do whatever needed to be done to get it done! I started watching your thread cuz I was interested in commercial sewing machines, now look where we are. Thanks for the journey, it’s been educational and enjoyable!,
Oven is powered up!
I found this slick 500ml powder cup for the Electron gun. Really nice part. Makes changing colors for small parts nearly effortless.
Once I had this stuff setup it was time to coat some coupons to see how the colors look. Coupons straight off the plasma:
Off the sander:
All I did to further prep was blow off with compressed air. The coupons with some of the powder I bought:
Looks like the sander oscillations are telegraphing through the powder.
Several things to check out to clear that up. First I’m going to use the Flir IR camera to check for metal temperature. I don’t think I cured the powder long enough. I can adjust the oscillation as well. I have a call scheduled with Apex Monday to discuss some adjustments. Hopefully that piece gets sorted out quickly. The sander is a real game changer, as is adding powder coating to the finishing options.
I found this slick 500ml powder cup for the Electron gun. Really nice part. Makes changing colors for small parts nearly effortless.
Once I had this stuff setup it was time to coat some coupons to see how the colors look. Coupons straight off the plasma:
Off the sander:
All I did to further prep was blow off with compressed air. The coupons with some of the powder I bought:
Looks like the sander oscillations are telegraphing through the powder.
Several things to check out to clear that up. First I’m going to use the Flir IR camera to check for metal temperature. I don’t think I cured the powder long enough. I can adjust the oscillation as well. I have a call scheduled with Apex Monday to discuss some adjustments. Hopefully that piece gets sorted out quickly. The sander is a real game changer, as is adding powder coating to the finishing options.
Was a really long week in the shop. Reverse engineering and making parts that fit something that someone else made is a very different thing than starting with a blank sheet of paper and designing it all yourself. I thoroughly got my *** kicked by this for a few days this week. Had to pull off to get a bunch of parts made to meet another deadline. It’s all working out. The fifteen plus hour days wear me down. It’s worth it of course.
I thought this stack of brackets fresh off the press brake made a nice photo.
If the bend angle is off much at all they won’t stack up nicely.
The oven design came in for approval for manufacturing. This thing is to be really nice. From the drawing package:
Forklift pockets on the top are removable so we can get it through the roll up door opening.
And some renderings:
The blower on the back wall circulates the air up to the ceiling heater box and air plenum. The air is distributed throughout the whole oven via that air plenum.
I thought this stack of brackets fresh off the press brake made a nice photo.
If the bend angle is off much at all they won’t stack up nicely.
The oven design came in for approval for manufacturing. This thing is to be really nice. From the drawing package:
Forklift pockets on the top are removable so we can get it through the roll up door opening.
And some renderings:
The blower on the back wall circulates the air up to the ceiling heater box and air plenum. The air is distributed throughout the whole oven via that air plenum.
Snapped a couple of photos of some parts prior to packaging. This was part of a big order for the shop.
The packaging continues to be satisfying.
Made some small adjustments to the wide belt. Parts are looking good coming off it.
These ended up not being needed. Client changed the hole location after they were cut. Perfect for trying some powder coat.
The sanding oscillation is visible, but much less so. I use this light when I’m checking out parts.
It’s adjustable for color and brightness. The softer color really helps show missed spots and such.
This is two different parts after a longer cure time.
Definitely getting better. Application of the powder has lots of room for improvement.
Customer will be really happy with these for the intended application.
The packaging continues to be satisfying.
Made some small adjustments to the wide belt. Parts are looking good coming off it.
These ended up not being needed. Client changed the hole location after they were cut. Perfect for trying some powder coat.
The sanding oscillation is visible, but much less so. I use this light when I’m checking out parts.
It’s adjustable for color and brightness. The softer color really helps show missed spots and such.
This is two different parts after a longer cure time.
Definitely getting better. Application of the powder has lots of room for improvement.
Customer will be really happy with these for the intended application.
MadeByMiller
Well-known member
Wow Steven, you're really raising the quality bar on all fronts. Those boxes are very tidy, and the new wide belt sander is a great addition. I like the adjustments to the sander too, looks like a straighter grain?
This one feels like a big step forward. I've been making parts daily on the plasma for about 18 months give or take. At first, I would cut up the remainder (aka the skeleton) with a hand plasma and/or angle grinder. That didn't last long, and I had a hand-coded program to cut them up. This is all post processing. Last night I finally built a setup so I can program cutting the skeleton along with the parts.
Now we just lift the parts, drops, and skeleton straight off the table. No post processing, and on to the next sheet.
Next up will be making manufacturing models to streamline even more.
Now we just lift the parts, drops, and skeleton straight off the table. No post processing, and on to the next sheet.
Next up will be making manufacturing models to streamline even more.
Thank you, Austin! We are constantly trying to improve quality, while getting the work done. The wide belt is doing better than the first day, of course. I got the head level to the conveyor which helped a lot. And, a more "depth of cut". It's working well. SO much faster, easier on the back/body, and the consistency is off the charts good.
lilscorpion
Well-known member
That’s a great idea. Never tried that, wish I had.This one feels like a big step forward. I've been making parts daily on the plasma for about 18 months give or take. At first, I would cut up the remainder (aka the skeleton) with a hand plasma and/or angle grinder. That didn't last long, and I had a hand-coded program to cut them up. This is all post processing. Last night I finally built a setup so I can program cutting the skeleton along with the parts.
Now we just lift the parts, drops, and skeleton straight off the table. No post processing, and on to the next sheet.
Next up will be making manufacturing models to streamline even more.
Shipped the biggest, most complex project to date this week. This is a section of switchboard to add to an existing lineup for a large tenant main from the utility. We made two of them. To say this was a huge undertaking is a wild understatement. These two assemblies represent a couple hundred hours of my time and nearly the same from my team, and from my trade partner/client. We all underestimated how much time it would take to get the CAD model done. I will say this, I am much more proficient and efficient with Fusion now. Especially in the context of a (to me) complex assembly.
The existing equipment was not able to be completely deenergized for measurements. So, there were some best guesses and things like that.
This shows the main framework, the main bus, as well as the line side run backs to the breakers, the CT metering compartment, and the neutral bus. The only thing I didn’t design and make in my shop are the four corner posts, the meter socket, the breaker, and the black vertical main bus supports.
There was a bit of a false start early on.. I failed to check the overall outside measurements after I made the upper and lower framework. It was somewhat devastating at the time because a lot of parts were made. The width was off about 3/8, and we could have lived with that. The 1/2” additional depth was a show stopper because the main buss would not have aligned and the section would have been deeper than the existing.
I took this as an opportunity to get the model right before proceeding. I logged about 120 hours of CAD work from that point forward. I’m happy, and I dare say proud, to say the entire thing was modeled and all parts were made from the model. The entire assembly bolted together. No modifications to parts, no step bits, no slots, no grinding, no pry bars, none of that. It all bolted together.
The CT compartment has to be isolated from the rest of the section so an end user can’t tap unmetered power from the bus. That’s why there are barriers in place.
I have never seen one of these meter sections. The standard has two views with their dimensions, but I’ve not seen one. That was a real challenge.
While we didn’t have problems with part sizing, etc.. there was plenty of opportunity to make mistakes. Mostly in forming. I’ve found that aluminum bar bends almost exactly the same as copper. I use aluminum for setup parts when testing programs. I think this photo says it all:
We all had a good laugh at this one. It’s crazy how challenging forming can be. I’m finding part of what’s helping is to have the bend conversation at the desk before the shop drawing goes out. Even (especially?) when I’m the part designer and fabricator.
The wide belt sander has been a huge contribution to improving the quality and consistency of the steel parts.
The parts are so consistent off the sander. They look great for plasma cut parts. I long for a fiber laser.
I spent considerable time dialing in the plasma, brake, and Fusion. It paid off. All the bus fit first try.
A couple of bus parts have four bends with two mounting points as well as having to line up on the end and it all just fit. All holes are 1/32 over their nominal size (13/32 & 17/32).
These side barriers also bolted on without incident.
I mention it all fitting because it was such a huge milestone and accomplishment. The CAD, CAM, machines, processes, and workflows are dialed in enough that we can design, manufacture, and assemble things like this. It’s both amazing and quite humbling.
My guys, my trade partners guys and I put in some very long weeks and days to make it all happen. We snapped this photo while the last doors were in the paint booth.
Once they were dry, we wrapped the sections up and they went to the jobsite.
For those curious, a UL field evaluation will be conducted prior to final inspection
Been a long, intense couple of weeks. I’m really excited about how things are taking shape.
The existing equipment was not able to be completely deenergized for measurements. So, there were some best guesses and things like that.
This shows the main framework, the main bus, as well as the line side run backs to the breakers, the CT metering compartment, and the neutral bus. The only thing I didn’t design and make in my shop are the four corner posts, the meter socket, the breaker, and the black vertical main bus supports.
There was a bit of a false start early on.. I failed to check the overall outside measurements after I made the upper and lower framework. It was somewhat devastating at the time because a lot of parts were made. The width was off about 3/8, and we could have lived with that. The 1/2” additional depth was a show stopper because the main buss would not have aligned and the section would have been deeper than the existing.
I took this as an opportunity to get the model right before proceeding. I logged about 120 hours of CAD work from that point forward. I’m happy, and I dare say proud, to say the entire thing was modeled and all parts were made from the model. The entire assembly bolted together. No modifications to parts, no step bits, no slots, no grinding, no pry bars, none of that. It all bolted together.
The CT compartment has to be isolated from the rest of the section so an end user can’t tap unmetered power from the bus. That’s why there are barriers in place.
I have never seen one of these meter sections. The standard has two views with their dimensions, but I’ve not seen one. That was a real challenge.
While we didn’t have problems with part sizing, etc.. there was plenty of opportunity to make mistakes. Mostly in forming. I’ve found that aluminum bar bends almost exactly the same as copper. I use aluminum for setup parts when testing programs. I think this photo says it all:
We all had a good laugh at this one. It’s crazy how challenging forming can be. I’m finding part of what’s helping is to have the bend conversation at the desk before the shop drawing goes out. Even (especially?) when I’m the part designer and fabricator.
The wide belt sander has been a huge contribution to improving the quality and consistency of the steel parts.
The parts are so consistent off the sander. They look great for plasma cut parts. I long for a fiber laser.
I spent considerable time dialing in the plasma, brake, and Fusion. It paid off. All the bus fit first try.
A couple of bus parts have four bends with two mounting points as well as having to line up on the end and it all just fit. All holes are 1/32 over their nominal size (13/32 & 17/32).
These side barriers also bolted on without incident.
I mention it all fitting because it was such a huge milestone and accomplishment. The CAD, CAM, machines, processes, and workflows are dialed in enough that we can design, manufacture, and assemble things like this. It’s both amazing and quite humbling.
My guys, my trade partners guys and I put in some very long weeks and days to make it all happen. We snapped this photo while the last doors were in the paint booth.
Once they were dry, we wrapped the sections up and they went to the jobsite.
For those curious, a UL field evaluation will be conducted prior to final inspection
Been a long, intense couple of weeks. I’m really excited about how things are taking shape.
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I haven’t had any client work thicker than 10ga. That changed recently with an order for some simple 7ga brackets. I got a sheet of cold rolled and today we did our work up on it. I’ve gradually developed a process that is working for us to get a new material dialed in.
I start with a coupon with some holes and slots to get the kerf offsets right. This ensures the flat pattern physical size matches what Fusion calculates. Then we do one 90 to check the brake’s X axis correction. At that point I add a second flange to start dialing in the part length. Since Fusion only has k factor and bend radius as inputs to bend deduction, I stick with a static k factor. 0.44 for mild steel. Then we make the C shaped part and measure its outside length. I adjust the Fusion bend radius until the flat pattern is the right length to make the C shape. Once that’s dialed in, I do it again with a hat channel. I take the average between those two and that’s my final bend radius in CAD. Parts that only reference the end of the flat pattern are consistently within a couple thousandths. Back to back bends (like hat channels) are within ten or so most times. This has been the sauce I needed. A conversation with Pat a while back catalyzed me sorting through this.
Now that I have a process, that I’m certain will evolve and improve, we dialed in the 3/16 (almost 7ga) in short order today. Ran the parts through the sander and this is what we had in about 15 minutes.
I’m powder coating small orders like this to start working powder into the workflow. For being completely new to powder coating I couldn’t be happier with how these turned out.
I start with a coupon with some holes and slots to get the kerf offsets right. This ensures the flat pattern physical size matches what Fusion calculates. Then we do one 90 to check the brake’s X axis correction. At that point I add a second flange to start dialing in the part length. Since Fusion only has k factor and bend radius as inputs to bend deduction, I stick with a static k factor. 0.44 for mild steel. Then we make the C shaped part and measure its outside length. I adjust the Fusion bend radius until the flat pattern is the right length to make the C shape. Once that’s dialed in, I do it again with a hat channel. I take the average between those two and that’s my final bend radius in CAD. Parts that only reference the end of the flat pattern are consistently within a couple thousandths. Back to back bends (like hat channels) are within ten or so most times. This has been the sauce I needed. A conversation with Pat a while back catalyzed me sorting through this.
Now that I have a process, that I’m certain will evolve and improve, we dialed in the 3/16 (almost 7ga) in short order today. Ran the parts through the sander and this is what we had in about 15 minutes.
I’m powder coating small orders like this to start working powder into the workflow. For being completely new to powder coating I couldn’t be happier with how these turned out.
rmack898
Well-known member
Outstanding work Steven!
It's got to fell great when things start to fall in place without having to tweek this or tweek that.
It's got to fell great when things start to fall in place without having to tweek this or tweek that.
larry4406
Well-known member
Impressive!
Seems so odd all of the electrical switch gear components coming out of your job site vs from the OEM suppliers but I am not in that market to fully understand.
Seems so odd all of the electrical switch gear components coming out of your job site vs from the OEM suppliers but I am not in that market to fully understand.
bugnut
ALLIANCE MEMBER
Steven, awesome stuff you and the team are accomplishing,