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Old 08-31-2009, 06:08 PM
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so i have to make some very very tiny press brake dies ...

60* knife edge upper die .... and the lower die has to have a die opening of .175"

yes thats typed properly, lol

the material thickness is 20 gauge and im making some decorative bumped cones that are pleated like a folded paper fan (like THIS )

my bend length is approx 5.5 inches, and judging by the calculator available on the accupress website it should only take about 2 tons of force to make each bend

i have to make 52 bends total, should i even bother hardening the dies for this? shouldnt be to hard to flame harden such small dies

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Old 08-31-2009, 09:25 PM
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I make press brake dies periodically and have made hundreds of them over the years. You do not need to harden them as long as you take care of them and watch that you don't ram the punch too hard into the die. If you think that will happen, get some air hardening steel, or some O-1 tool steel, or some pre-heatreated 4140 and go that route. But just by being careful, you should be able to run quite a few hundred pieces before anything happens to them.
BTW....if you are cutting the top punch at 60 degrees, how are you cutting the bottom. I am assuming 60 degree included angle or 30 degrees each way off of 90 degrees. Correct?
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Old 08-31-2009, 10:33 PM
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i was considering taking some 1/2 plate and ripping a bevel on the edge with the marvel saw we have, then placing them back to back, beveled side out, with some scrap sheet as a spacer between them. This will allow me the widest die opening while still having clearance for the previous bend to clear the die when the piece is flipped.

it would be a bit of a hack job to make them, but oh well, they will be dumped in the scrap bin when im done anyways. this is a one time job AND its a freebie
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Old 08-31-2009, 10:36 PM
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I would look at making the lower die two tapered rollers and use a second set of identical rollers to index the blank. For such a small die it could be hand powered with a long handle, lots faster than cycling a press.

Hardening the rollers would depend on how many you have to make, if you have to make 10000 I would make them out of SPS 45...for a 100...mild steel will work.

You can hand bend 20 gauge at 5.5 inches long!

Golden rule for forming, wrap the material around the punch...don't force the punch into a cavity..this is forming not drawing.
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Old 08-31-2009, 11:22 PM
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well the final design ive come up with calls for less then 3cm of stroke total, so i think ill just use the press brake as its CNC, allowing me to set up the machine based on ram position out to 3 decimal places. a few test pieces and ill be all set to just eye up my alignment points and hit the foot pedal

i don't believe im familiar with the tapered roller idea, care to elaborate?

pictures of the part are attached, final size is 6" wide, 5" tall and 3" deep. opening on the small end is roughly 1/2" by 1/4". i have to make 4 of these
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