Machsupport Forum
General CNC Chat => Show"N"Tell ( Your Machines) => Topic started by: bigtoy302 on November 24, 2009, 09:54:16 PM
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I have been planning this for a long time. I just have not had the time or money to start on the project. I have changed my mind on the design many times. I think I finally have it down the way I want. for the most part it is going to look like any other C-frame style brakes with a few improvements.
Specs:
48" wide
58 tons
6" inches of ram travel
2 axis servo backgage
Mach 3 control with a Dynomotion motion controller for the control of the +-10V analog Parker Proportional valve.
5hp, 2.5GPM pump.
I will be building the entire thing including the cylinders. ( That's what I do for a living.)
I am going to start of with building the 2 cylinders first. The cylinder are 5" bore, 3" rod, and 6" stroke.
Pile of Parts
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0443.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0444.jpg)
Rough machining of the base heads. I will finish machine them after I weld them to the barrel.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0445.jpg)
Pistons are next.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0446.jpg)
Checking the threads with a Go gauge.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0447.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0448.jpg)
Rod heads next.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0449.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0452.jpg)
Piston rods next
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0454.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0455.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0456.jpg)
Weld prep on the barrel.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0457.jpg)
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Beautiful parts, it will be great to see how the project comes along. On your 6-jaw chuck, what do you call those pads on every other jaw that act at parallels? That would be amazingly handy, I'm not sure how I've gotten by without that!!
Dustin
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Beautiful parts, it will be great to see how the project comes along. On your 6-jaw chuck, what do you call those pads on every other jaw that act at parallels? That would be amazingly handy, I'm not sure how I've gotten by without that!!
Dustin
It's a 4 jaw and there are 4 bars bolted on the chuck then the blocks bolted on them. I have many different length blocks for any kind of setup. The bars are tapped all along the length so you can move them up or down. We just call them chuck stops.
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That is great!!!! I want one!!! Can't wait to see it as you progress along.
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Seems your off to a great start. :) Very interesting project. What gauge metal will you be able to bend at 48 inches long? What radius will the bend be?
Brett
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Seems your off to a great start. :) Very interesting project. What gauge metal will you be able to bend at 48 inches long? What radius will the bend be?
Brett
It will bend 48" of 3/16" steel. Radius is dependent upon lower die v opening. V width is usually 8 times metal thickness. So for 3/16" you use a 1.5" die opening. I think it will give you around a .234 radius.
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That's going to be some machine looking at the quality of your work so far.
Can't wait for more photo's.
Tweakie.
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Very interesting build.
Is it a down stroking machine? I have done them with PLC controls and it gets quite tricky to synchronize Y1 and Y2 in real time. It will also be interesting to see how you handle the tooling and program libraries in Mach.
Regards
KTM
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Very interesting build.
Is it a down stroking machine? I have done them with PLC controls and it gets quite tricky to synchronize Y1 and Y2 in real time. It will also be interesting to see how you handle the tooling and program libraries in Mach.
Regards
KTM
Yes, down stroking machine. The upper die holder will be riding on Hiwin 35mm linear rails so don't need to worry about synchronization.
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I finally got some time after work tonight to work on the cylinders again. I got the ports welded on and the Id threaded. I also ordered 2650 pounds of steel for the frame. I should have it next week.
(http://i122.photobucket.com/albums/o269/bigtoy302/barrel.jpg)
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I'm really looking forward to se this project developing.
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Will enjoy following along as you build it so keep posting pictures.
RICH
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Nice work, please keep posting updates.
JH
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I got the caps welded on the barrels and milled out a slot then drilled a few bolt holes through. I also got the wrench flats milled on the rods.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0463.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0464.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0465.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0466.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0467.jpg)
I then went and picked up the flame cuts. I had a buddy that works at a steel place get and cut me out a bunch of 1.25" HR plate.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0470.jpg)(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0471.jpg)
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Excellent pics, this is real engineering.
Hey, looks like your buddy has drawn Wylie Coyote for you on that top sheet. ;D
Tweakie.
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Poor truck. :D
Looks like your making progress!
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Quite a good work! Good pictures also.
You look a kind of guy that could use a lot of seals. If you ever need a machine for making seals...
http://www.youtube.com/watch?v=22lsgJOHVUU
or just the seals ... ;)
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Thats a BIG project. How did you get that unloaded ? My back hurts....
JH
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I think the mag lift is the unloader, not the loader.
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Thats a BIG project. How did you get that unloaded ? My back hurts....
JH
Magnet and crane at work. When I get it home, tractor, cherry picker and straps.
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Oh, you mean it's not staying in that building? Better be one helluva cherry picker!!
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Oh, you mean it's not staying in that building? Better be one helluva cherry picker!!
All of the pieces will be bolted together. There is no way I can move it around my home shop without doing it this way. The side plates are 880lbs. and the smaller ones are around 425lbs.
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Today I started milling up the frame for the brake. I got the sides almost done and started on the upper and lower beams.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0482.jpg)
Upper beam
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0484.jpg)
Lower beam
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0483.jpg)
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You'll be bending before you know it.
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I got the cylinders assembled and tested.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0486.jpg)
Did a little bit more work to the lower beam.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0485.jpg)
More work on the upper beam.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0487.jpg)
Cylinder test fit.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0488.jpg)
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Finished drilling all the holes in the side plates.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0490.jpg)
Finished tapping the last hole in the upper beam.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0491.jpg)
Turned some 4340 spuds to mount the cylinders to the beam.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0492.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0494.jpg)
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Have you made any more progress on your project? I am very interested in the outcome of your design. Looks like great Craftsmanship so far. I have a four foot brake built by another individual that I purchased instead of building one as I originally planned but I haven't been satisfied and am now considering building a new one. I would like to see yours if possible when you finish. I am only up in Lebanon and make it to Eugene every once in awhile. I am curious what shop you work for? I have had a few large projects done down there in the past.
Only thing I would worry with the smaller linear bearings is if they will hand the twisting force if you tried to bend something off center. The last shop I managed had a 300 ton 12' Brake and we bent on the ends frequently when forming the corner of a tray or something similar. I realized it is best practice to bend in the center of a brake but clearance issues sometimes always don't agree.
Looking forward to your updates
Jason
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Have you made any more progress on your project? I am very interested in the outcome of your design. Looks like great Craftsmanship so far. I have a four foot brake built by another individual that I purchased instead of building one as I originally planned but I haven't been satisfied and am now considering building a new one. I would like to see yours if possible when you finish. I am only up in Lebanon and make it to Eugene every once in awhile. I am curious what shop you work for? I have had a few large projects done down there in the past.
Only thing I would worry with the smaller linear bearings is if they will hand the twisting force if you tried to bend something off center. The last shop I managed had a 300 ton 12' Brake and we bent on the ends frequently when forming the corner of a tray or something similar. I realized it is best practice to bend in the center of a brake but clearance issues sometimes always don't agree.
Looking forward to your updates
Jason
I made a few more little brackets for it and started the die holders. I am going to assemble the frame this weekend.
I work for Parker cylinder.
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Good luck with your progress. A friend of mine built some hydraulic test benchs for your shop last year I believe.
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I did not have to work today, so I went in and made the upper and lower die holders. Hopefully tomorrow I can start assembling the whole thing.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0496.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0497.jpg)
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They look good. Parker cylinders are top shelf and evidently they are pretty good to work for as well. :)
Brett
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looks great, are you making the dies too ?
JH
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looks great, are you making the dies too ?
JH
No, to much work. I will be buying them from Riteway. They are not cheap but well worth it.
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So, today I got it mostly assembled. I had to use some good old redneck engineering to put it all together but it all worked out great. I had my dad help me out with the tractor work.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0500.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0499.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0501.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0502.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0503.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0504.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0509.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0510.jpg)
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Damn....that looks really good !
Those look like Hiwin blocks.
If they are, are they ball or barrel roller type ?
Excellent job you got there.
Beautiful !
Russ
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Damn....that looks really good !
Those look like Hiwin blocks.
If they are, are they ball or barrel roller type ?
Excellent job you got there.
Beautiful !
Russ
They are Hiwin HG35 ball type. I called Hiwin and the sales guy talked me out of the RG roller type. He said if they are not loaded to over half of the dynamic load the rollers will just skid and burn.
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Nice, very nice. Looking forward to the videos of it in action.
Brett
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Looks real good.
I would have to say , flex won't be a problem.
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Today I got the backgage started. I machined up the ball screws and made the end supports. I also started machining up the frame for the backgauge.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0514.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0511.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0513.jpg)
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Today I got the manifold all done and also the Y block.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0517.jpg)
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Parker valves too eh? That's dedication. They should give you a raise.
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I made some spacers to hold the beams parallel. Then started to tack the cross braces into place. I also cut out all the parts for the hydraulic tank on the plas, then welded the tank all up.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0518.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0520.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0522.jpg)
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Lookin good. Is that a Mach controlled plasma cutter?
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Lookin good. Is that a Mach controlled plasma cutter?
Yes, it is. It also has a Candcnc mp1000 THC. I built it a few years ago.
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Today I mounted the tank, made the motor and pump mount and also mounted the manifold.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0524.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0527.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0531.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0528.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0532.jpg)
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Machine is looking great I wish I had the time and equipment to build such a nice machine. Keeping posting your updates I enjoy seeing the progress and can't wait to see the finished product. Keep up the good work.
Jason
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Yesterday I got the tank all pressure tested and finished, the backgauge all done and finished all the plumbing. I still need to finish making some support brackets for the hard lines.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0538.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0537.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0536.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0550.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0547.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0548.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0545.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0553.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0544.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0540.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0541.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0542.jpg)
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Today I got the electronics started. I mounted the control box, Wired the power supplies and the motor starter. I also cut out a front plate for a small fan and a db25 connector for the MPG. I also cut out a rear plate for the motor power wires, encoders, limits/homes switches and for the valve.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0554.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0555.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0556.jpg)
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Looking good. Getting close now. :)
Brett
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Certainly impressive! Nice photo's you've taken and shared with us.
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Looking forward to seeing this working :)
Hood
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I got a little bit more done this weekend. I mounted the the linear scale on the ram, wired the motors, valve and started tuning the motors and valve. I still need to mount the home and limit switches. I got everything tuned pretty good. I can move the ram up and down several times and have it repeat within .0005. It is not real fast but it will get the job done. I even bent a piece of scrap I had laying around. I took a short video of the ram doing some 1" moves. I will post it up shortly. Hopefully next weekend I can totally finish this thing up up a bend a bunch of stuff. I will take a good video of the machine when I get it all running.
I still need to tidy up all the wire once everything is final.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0558.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0559.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0564.jpg)
I know I said i was going to use a Newall SPB-TS encoder but I was running out of cash and this accu-rite was half the price. They are both 5 micron scales.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0561.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0565.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0567.jpg)
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Crappy Iphone video.
http://www.youtube.com/watch?v=-WDkmankePU (http://www.youtube.com/watch?v=-WDkmankePU)
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Looks great !!!!
JH
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I stumbled on this thread late. Really impressive work. Looking forward to seeing it in action.
Zafar
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I got a little bit more done on it tonight. I finished wiring the limit and home switches. Here is a quick video of the back gauge in action.
YouTube - Mach3 dynomotion Cnc press brake (http://www.youtube.com/watch?v=T5R7O8GPSSg)
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Very impressive video - great work.
Tweakie.
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Good going. When do we expect to see it doing some bending.
Zafar
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Today I bent up a tray for the computer to sit on and made a articulating arm for it to mount to. I still need to figured out how to get the backgauge to home in the dynomotion software. Everything is written in C+ and I don't know jack about it.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0572.jpg)
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Excellent work. What's the gauge of sheet and what's the bend radius.
Zafar
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Excellent work. What's the gauge of sheet and what's the bend radius.
Zafar
11 gauge steel, bent using a 1.5" lower die. I think its about a .250 radius.
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You should be able to do the homing routine in Mach3
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Finally got some more time to mess with it. I bent up a bunch of test pieces getting everything dialed in. I bought Solidworks 2010 this week so I am trying to get the K-factor dialed in on the software. Here is a better video of the brake and a test part.
http://www.youtube.com/watch?v=38hfwvIbnjo (http://www.youtube.com/watch?v=38hfwvIbnjo)
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Hi, very nice project and very impressive.
For myself, the best way to configure Solidworks for sheet metal, is to build your own Excel sheet with value you get from bending on your press.
K factor is good but very limited.
Before bending, try with a scrap piece of the same material and enter in your Excel sheet the value you got.
Best luck.
Jeff
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Hi, very nice project and very impressive.
For myself, the best way to configure Solidworks for sheet metal, is to build your own Excel sheet with value you get from bending on your press.
K factor is good but very limited.
Before bending, try with a scrap piece of the same material and enter in your Excel sheet the value you got.
Best luck.
Jeff
I had to go down to a k-factor of .34 on .250 and .188 HR steel to get it to hold tolerance. Should I use bend allowance instead? I am new to all this.
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Solidworks sheet metal is driven by an Excel sheet.
http://www.sheetmetalguy.com/tips_gauge_table.htm
http://www.sheetmetalguy.com/tips_bend_table.htm
http://www.youtube.com/watch?v=rL3bjgcLW-4&feature=related
http://espanol.video.yahoo.com/watch/5296159/13967039
http://www.metacafe.com/watch/2864503/solidworks_tutorial_sheet_metal_applying_k_factor/
http://www.youtube.com/watch?v=FkxJ3JchLuc
Just take a look at this website, very very good.
I bought all 3 of his books and it help me a lot.
http://www.sheetmetalguy.com/swsmg03.htm.
Hope this help.
Jeff
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Very impressive! Are you using proportional valves or the servo valves. What procedure did you use to tune both the valves to operate in sync. I wonder if this thing can be done with Galil motion controlers hooked with servo valves.
Zafar
Finally got some more time to mess with it. I bent up a bunch of test pieces getting everything dialed in. I bought Solidworks 2010 this week so I am trying to get the K-factor dialed in on the software. Here is a better video of the brake and a test part.
http://www.youtube.com/watch?v=38hfwvIbnjo (http://www.youtube.com/watch?v=38hfwvIbnjo)
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So today I bent up my first project. This is the reason I built the brake. I have other products planned but these will be them main thing that I will be building. Even though this thing has a lot of steel bending 2ft of 1/4" still flexes the machine several thousandths. So I have to add more angle to the longer bends then the shorter ones. Not a huge problem but I still have bend some longer parts to really see.
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0616.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0619.jpg)
(http://i122.photobucket.com/albums/o269/bigtoy302/IMG_0618.jpg)
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good job, But , you'll need some more weld. lol. :D
Also you need the winch on the rear with an anchor, cause them Toyotas don't want to stop.
Thanks for sharing.
Ed
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Super nice work ! Start cranking out the parts man...
JH
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Awesome. I'd love to see the finished part (with paint and fittings).
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Hi Bigtoy,
Have you finished and painted it yet ?
How does it perform, as well as expected or better ?
So many questions, please let us know the latest and perhaps some more pics.
Tweakie.