tips on making a garage level press die

[rslaback]

Gentlemen,
I have a project coming up that I need to convert some pieces of 11ga x 7/8 wide flat steel into a handle by bending about an inch of each end up slightly.

While none of the dimensions of this are super critical, I have to make quite a few and would prefer that they be as uniform as possible. I have a 20 ton press brake that I can use but I've been tossing about the idea of fabricating a purpose built tool to use in my press (with or without preheating the pieces with my torch).

I'm hoping for some tips from anyone who might've already designed a tool like this. Below is a quick sketch of what the piece needs to look like when done and a starting point for the die. Any input is appreciated.

 

[MoonRise]

Heat not needed for 11 gauge material and a 20 ton press.

That approach would work. Cut material to length, deburr, put into die, press into shape. Repeat.

But the die would really only be useful for that one size/shape.

A standard V-die press brake could make that shape. And many other bent shapes too.

Just have to cut material to length and deburr (same as with the dedicated press die), then bend each end separately and pay attention to how much you are bending it.

Your call.

 

[Nor'Easter]

Mark depths from either end and stick in a vice, bend over with a hammer and use a gauge to repeat the angle.

11ga is easy to bend.

 

[kkroger]

Vise and a slightly modified adjustable wrench... like a Duckbill plier, set for thickness, clamp in vise bend with crescent wrench... rinse lather and repeat... I'll see if I can wonder out to the shop and show such a method in a few... Don't know if I have any 1/8" steel on hand...

 

[rslaback]

Guys, I'm making 50 of these at least in this batch. I have a SWAG press brake already. The issue isn't that I can't make each individually watching location, alignment and angle. The issue is I don't want to have to. I want to put a piece in, smash, remove, repeat.

I probably should've been clearer in my original post. I'm hoping for advice on things like if I need to round the upper corners or leave them angled. If I do round them should I make the die deeper so that the piece ends past the fillet. Stuff like that.

 

[E.rodz]

here is one of the handiest tools ever. i use mine for 11 gauge all the time just use a vice and some oil on your pieces to make them slide.

http://www.grizzly.com/products/6-Vise-Brake/H3245

 

[Nor'Easter]

Guys, I'm making 50 of these at least in this batch.

And you'll be there all day pumping on a hydraulic press. Unless you have powered machine that can do rapids you'll just be wasting time.

 

[cvairwerks]

Set up a stop...insert to stop, bend to a mark, release, repeat with other end.

 

[PelicanPines]

50 ? I'd do it in a vise with things measured... and ... I'd be done in an hour after setup.

 

[Superbec]

And you'll be there all day pumping on a hydraulic press. Unless you have powered machine that can do rapids you'll just be wasting time.

50 pieces? 1 min/piece but I bet it's more like 20 seconds...

it will take more to make a good die but if dimensions are not critical just do it

it will have some spring back so make the die at 2-3 degrees more

I don't get it why people get scared of "production" numbers but will spend days on a single project/thing that will never look right anyway .

 

[sberry]

Hammer vise and gage.

 

[MoonRise]

Guys, I'm making 50 of these at least in this batch. I have a SWAG press brake already. The issue isn't that I can't make each individually watching location, alignment and angle. The issue is I don't want to have to. I want to put a piece in, smash, remove, repeat.

I probably should've been clearer in my original post. I'm hoping for advice on things like if I need to round the upper corners or leave them angled. If I do round them should I make the die deeper so that the piece ends past the fillet. Stuff like that.

Metal bender.

Cut material, deburr, bend one end to stop block on bender, flip over and bend the other end to the stop block on the bender. Repeat.

Can bend over the small diameter roller or the 'right angle' bending block.

Floor mount version:

https://www.harborfreight.com/compact-bender-38470.html

Bench mounted version:

https://www.harborfreight.com/bench-top-bar-and-rod-bender-38471.html

Name-brand version would be a Hossfeld.

Way faster than pumping a hydraulic press. Unless you put in an air-hydraulic cylinder in your press. Plenty of oomph to bend 1/8" flat bar.

More than one way to do the job.

 

[dontlifttoshift]

Yeah, that ^^^ Best answer in the whole thread.

 

[matt_i]

I would use a Diacro rotary bender. Has work-stops, etc, to dial-in repeatability.

I would play around with 2x4 wooden dies until you get the bend angles right and then switch to a hardwood like maple or oak for the run.

 

[bullnerd]

Last time I bent something in a vise with a hammer was 5th grade, maybe 6th, then I started having some dignity in my work.

 

[sanddan]

Last time I bent something in a vise with a hammer was 5th grade, maybe 6th, then I started having some dignity in my work.

Now that's funny

 

[shawnspeed]

Or you can use the press brake style bender for your press, lay 20 pcs on a table , Making tape them together(flat , side by side) mark your bends and do like 20 at a time.. Just a thought...
http://www.homemadetools.net/homemade-press-brake-29.

 

[Kevin54]

If you have a press brake already, then all you have to do is set up a back stop for your location. Then make some sort of stop for your downward movement of your punch seeing that you will be air bending the material. then all you have to do is bend one end, flip the part 180 degrees and then bend the other end. It's easier to make a couple of stops than it would be to make a separate die for 50 pieces.

 

[1wook]

OP, if you want to make the Die then make it!

Rounding the upper corners should make the part drag less and will produce less scratches on the part that will make it more likely to stick in the bottom. I'd center a vertical slot on the side your lower die so you have a easy place to knock the part out of the die if it get's stuck. The inside die should have rounded corners too.

You could make a prototype out of something cheaper and easier to work with other than steel that probably would work fine for 11 gauge. Check out page 96 in MP&C's shop thread for some die Idea's

 

[gorilla]

You will need guide pins on the bottom die to guide the punch on it's down stroke. You will need locators on the bottom die to register the blank in place. Die springs to lift the punch so that you can get the formed part out would be nice also.
You do not have a press brake you have a bending attachment for a hydraulic press. I could bend 50 of those parts up on a real press brake in less than 30 minutes and still have time to drink coffee.

 

[Firstram]

Metal bender.


Bench mounted version:

https://www.harborfreight.com/bench-top-bar-and-rod-bender-38471.html


More than one way to do the job.

I have been using one of these since the late 80's. For the money, it can't be beat on those little jobs. It's fast and fairly accurate.

 

[rsanter]

The die you designed will work, however for what you are doing you can get by with less.

Take 2 pieces of steel and weld some round solid stock to it and you could fab up simple dies that will work great

Bob