Making Press and Hammerforming Dies

[Music] welcome back Knox tools I'm Tom so today we have kind of an interesting project it's a sheet metal forming project and it's a part for the Marvel series a vertical bandsaw this is a tilting frame vertical bandsaw that I got recently it's kind of a weird-looking piece so let's get into the details of it here and you guys can check it out we're going to make a forming die that helps us form this sheet metal piece that we need here so let's check it out alright this is the lower band wheel for the saw and this is the it's kind of got an interesting gear reduction there's a little pinion gear that the a booth helped me repair he did some spray welding on the chef and help me repair that any way that drives against this gear and then the the blade tracks on the other side of this well there's a bearing assembly that goes in here and this is one of the bearings you can see it's cannon kind of crunchy and chattery and this is the piece that we need to replace here now this thing's all torn up here it's snagged on some mud on a wooden is all shredded and honestly it wasn't it wasn't designed very well it doesn't you know it was basically just covering a shielded bearing here so crud was able to kind of migrate into the bearing and you know didn't really do what it was supposed to do so we're going to create one that's a little bit different than this and hopefully better at least I think it's going to be better and well I'm going to make a sketch of it so you guys can get to get the general idea but there's some interesting stuff going on here and this is the shaft that the the wheel rides on and it's kind of an odd shaft and I want to share some of the details of this with you because this is how they do the blade tracking this wheel has to be able to tip so that the the blade will track properly and this is how the they handle the lower wheel tracking so let's take a quick look at that then we'll look at our sketch for our sheet metal piece and then go from there okay so this is the this is the lower wheel mount here and this this stub axle here actually fits in here like so okay what's interesting about this is how they and you can see that that this can tip right well what they've done this kind of interesting is and hopefully you can see that you see this is kind of not round it's kind of oval slightly oval what they've done is machined the sides of this away and left this little ring up in the front here or this little section up in the front and that's actually that's actually the pivot okay let's see if I get this going the right way so that's top so that should go the other way like so that fits in there like so and you can see that this has the ability to tip well this is the screw that allows that to tip so there's tension on it this way from the blade and when we screw this in here it comes down I should clean it out a little better see if I can get there goes see it's moving so this allows us to tip and and so we can adjust the tracking of the blade of the band blade there that's the saw blade I should say and then there's a there's a pin that that fits through this whole mess here that that keeps things oriented get it in there yes so that that keeps us from rotating in relation to that so anyways it's kind of it's a very simple tracking adjustment and the reason I show it is a lot of guys out there they want to make a belt sander for example so there you go there's a belt tracking mechanism for you there just leave a leave a ring here relieve this section here and then you've got a tipping tipping mount there so okay so let's go look at the sheet metal piece we're going to create alright it's all good projects start out with a sketch so let's sketch a cross-section of the the lower band wheel here to start with make sure I'm not all right so this is part of the wheel hub make it a little bigger and okay so this is the this is the gear here alright then it has a bore through it here and there's a little snap ring like that okay so it's got a snap ring like so okay so this is this a cross-section through the the lower band wheel that we just looked at then there's a there's a big bearing here like so okay and then another bearing sits right in this area all right like so okay and then there's a the shaft that we looked at that the tilting shaft that we that we looked at it's it's a I'm just going to draw it kind of disassembled because otherwise it let's get too confusing so shaft okay there's a thread in the end let's do that okay and then over on this side there's a little cap like so go hole through it and then there's a fastener not that big there's a fastener that retains it all okay so there's also a little spacer ring that sits right here like that alright okay so where this were this sheet metal cap fits is it fits actually in between here in this section here and it shields this bearing from all the crud that's dropping down when you're cutting right and so what we want to do is make a little cap and I'm just going to draw it kind of oversized here we're gonna make a little sheet metal cap and it's necked in like that okay so it's just like a little it's a little cap okay and it fits in between here and then when this is all assembled it will it will go over this hub diameter here and then as as stuff falls down on this little it will run off of it hopefully and yeah sure this will be a fairly close fit here but the stuff kit you know can still get in through that but it's better than just a flat cap on there so I'm hoping it'll be better and also the bearings that I showed you earlier it had a shield on one side and it was open on the other and I bought sealed bearings too so hopefully they'll be a little bit better and and then the open bearings too so okay so anyway that's the piece we're gonna make and I'll probably do another sketch of the you know what let's just get started on the die and then let's make our sheet metal piece [Applause] [Applause] all right so the first we're going to turn this down to the ID of our sheet metal cap that's the first step in making the die so we faced it we've got a clean up just so I can get a good measurement now we'll turn it down to the diameter okay so the next step here is we're going to use this this little 45 tool here and we're going to create a little recess that that goes down into the into this surface here and the diameter of that little recess is equal to the OD of this inner race here which is about 1 and 3/4 and the reason is is this is the fixed part of the the bearing so the rest of this mess rotates here right we don't want our shield to drag on on the moving part of the bearing so it needs to be stepped out just slightly you know maybe a material thickness or something like that you know the material thickness of the shield just to clear that so that it doesn't rub on that okay so let's do that all right so we got our 45 degree tool here this diameter this is a known diameter so what we're going to do is we're going to set the tip of the tool rather than the edge of that hole we're going to calibrate this tool for that diameter that way when when I'm feeding out I know what that diameter is a where I am okay so that's the general idea let me see if I can big head in there and with a camera and everything and this isn't particularly a fussy okay we just look in the camera to come out a little bit yeah okay I like that better all right so right about there and then we're gonna calibrate that diameter is 0.75 okay and let's see oh we need to calibrate the tool on that surface like that which is zero and we're going to go in about forty thousand thirty forty and then we're going to feed out to about one and three quarter one inch probably go a little bit further just cuz say I look at the bearing again zag 26 seven one two three four eight all right so that's the should be our diameter that stuff uh-huh let's just do a bozo check there yeah it looks good okay and so now the sheet metal will be I'm going to think about the thickness of the sheet metal and where that ends up so let me review that real quick alright so get that and we broke the corner here the last thing to do is since we're going to use this as a as a forming die and we want to wrap that sheet metal around this corner here I need I need a little draft angle on the backside because the sheet metal has spring back right so what we want to do is we want this to be more acute than ninety degrees that way I can kind of over bend slightly to get the sheet metal to cooperate so I'm just going to use this angle that's on the front of this this tool here and we'll we'll just color this in so we can see what's going on here like so basically I'm just going to plunge it in there and it's going to create a couple of degree relief behind the behind that corner right but I don't want to I don't want to reduce the diameter either right so I really just want to bring it out right to that right to the oops move your pen tom right to the intersection of that chamfer is really what I want to do there so let's do that it's pretty easy so let's let's calibrate this tool and then we will get it in the right spot the flange is going to be you know like a quarter of an inch or 3/16 or quarter so we want to go a little more than that let's say two and okay well that seems like a lot but I think we're going to go slow [Music] okay we're just going to plunge in like so until that blue this starts to fade into that corner you get my little magnifier on here see the blue getting thinner thinner thinner thinner a that's probably fine all right and now we got a little back angle on that till out for the spring back of the the sheet metal there yep that should work fine yeah that was a damn good idea alright so I should probably make a sketch of what these forming dyes look like here just for everybody so the piece that we want to form looks like this okay I'm just going to draw it thick you know okay so what we need is we need we need a dye that kind of mimics that shape right okay and you saw what we were doing over on the lathe right so this is our little relief angle that we were talking about okay and now that comes down okay goes to the rest of our the rest of our dye now has a center hole here too okay like so okay so we put a flat disc in here like so and then we're going to we have a top piece that's going to come down and clamp this and actually force that material into that recess and then we're going to hammer form these rate the the radius all the way around using our little our little angle deal there so the top piece is kind of looks like the top right except it's a little shorter okay and it's a little simpler actually so it's just a Boop sign okay that'll work and it also has an alignment hole in it too so this is this is the part that's going to actually do the forming and push that material down into that recess so that has to be smaller okay we have a material thickness here like that right so that has to be smaller than that one to allow there to be material inside there so which we showed this we're going to work on this piece next and then we need a little peg that goes down in there and then we need to cut out a blank here okay and that's our blank all right let's get the let's get back at it so this is a leftover disc that you know it's a drop from water jet and it's actually a drop from the the king maker project where we made a four jaw centering machine for the bar z bash anyway that was the leftover disc that I saved and it's going to work good for what we wanted to do so I think first we're going to smack a hole in the center and then we'll create our our step in that after that [Applause] [Music] yeah sure why not it's okay to me this is a test piece here this isn't the correct thickness this is just something I had we just want to kind of try it here see how see how the thing works and then we'll cut the real blank out there all right let's give it a go a little bit of distortion but I think that'll be okay because it will go away when we when we hammer form this edge here over the side so okay all right so far so good and a little depression oh let's let's compare it to the bearing actually first before we get to forego a patent each other on the back here [Applause] [Applause] [Applause] so they care it's like a depression to me okay stay pretty flat so let's form the edge yeah because this'll be fun okay so it's real important to clamp this really well okay we're going to put we're on the corner of the bench here so we can kind of get at the whole thing and they'll clamp it like so so this is called hammer forming all right so that's nicely clamped now what's important here is that we get the bend started in the right place and to do that I'm going to use a caulking tool and this is just a piece of hardwood here and it's to help start the bend in the right place and the other thing is you got a choice of a couple kinds of hammers here what we don't want to use we don't want to use a metal hammer we don't want to pinch metal metal between metal because that'll stretch it we're trying to do is we're trying to shrink this flange a little bit as we roll it over so what we really want is hard plastic or hard wood or something like that so although I'm going to use this one to hit the to hit the the caulking tool so let's go ahead and start so you can see I'm just going to work my way around and you don't want to get greedy and try to do the whole thing at once and then with the clamp you can swing it like that I'm gonna switch to this you [Applause] [Applause] that's pretty good flail pop off without [Applause] so you can see that you can see the flange is a little wavy after you roll it over but it's it's pretty easy to flatten that out and I have to open that hole up a little bit too so anyway let's go see how it fits on the our bearing mm-hmm it's pretty good and you get the idea now right see it rolls over the corner and keep stuff from from falling in there but we have a little little offset that's just going to hold this up too so see this to whisk right [Applause] Oh okay okay sweet [Music] [Music]

Channel: oxtoolco

Views: 179,624

Rating: 4.9192853 out of 5

Keywords: Machinist, Bridgeport milling machine, Lathe, Autodesk, Solidworks, Lathe threading, CNC, Five Axis, Steady Rest, Broken Tap Removal, Albrecht, Jacobs, Cincinnati, Kearney Trecker, Hardinge, Monarch 10EE, Starrett, Morse Taper, McMaster Carr, Mori Seiki, Wilton, Etching press, Intaglio, toolmaking, oldshool machining, Sheet Metal, Hammerform, Forming Die, Marvel Saw, Marvel Series 8

Id: XdgTk1_oeUU

Length: 29min 55sec (1795 seconds)

Published: Sat Dec 31 2016