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  1. #21
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    Partly because according to what I see various places, press brakes are leading guilty parties in amputations.

  2. #22
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    Quote Originally Posted by bryan_machine View Post
    Partly because according to what I see various places, press brakes are leading guilty parties in amputations.
    Yes, old mechanical s maybe, more modern the bigger risk is getting fingers trapped between the ram and part when bending channels even on a machine with light curtains. Just because the ram is only moving down at 10mm a minute, does not mean the ass end of the part is not moving around at significant speed.

    As to cutting the part off if over bending your amadas must be old, all the newer ones as in sub 15 years old i have been around every bend gets programmed in for length, tooling used, bend angle and material hence tonnage gets limited by defult, even on a 120 ton machine if its bending something thin it stops at the calculated safe tonnage if it does not make full travel. The control had a pretty extensive user editable and adable parameter table for both tooling and materials.

    Biggest issue i always found was the material varying across the sheet effecting spring back, hence real hard to bend better than about 0.5 degrees part to part on std cold rolled sheet. Better grades of sheet this was a lot less of a issue, unless the moron nesting had the grain going a different way! Would have loved a machine with in process gauging, would have made a real difference on the parts we were bending back then.

    Size wise the amadas i have used you can bend channels accurate to about 4 thou external dimensions all day long, they repeat great size wise, just the angle will vary a nats with material.

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  4. #23
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    Quote Originally Posted by rcoope View Post
    Hey Scruffy887, (or anyone else) could you comment on bend angle accuracy with a modern control? Is it reasonable to be within, say, one degree (.018" at the end of a 1" long flange) on your first bend if you have all your tooling parameters and thicknesses set up properly?
    Computer control and VooDoo. I use Solidworks for part design but punch in the bend dims at the control. SW gets me perfect blank dims and the DELEM control gets perfect bend centers. Neither one will get me both and F wasting my time. Gave up on perfecting either one as gotta get schit done. Bend, compensate, keep bending. Material thickness? Material Grain direction cuz you nested differently? VooDoo needed. Shop near me coins everything because it cuts down the variables, with a crisper corner. 90 degree work only though, unless you have a ton of tooling.
    My experience is that the smart control parameters never over bend a part. Easy enough to enter the difference of what you got and what you need. double hit the first part sometimes, then rock on.

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  6. #24
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    Was walking through the Plant this morning and saw coupe of interesting parts being formed...
    Attached Thumbnails Attached Thumbnails img_7229.jpg   img_7231.jpg   img_7224.jpg   img_7247.jpg   img_7248.jpg  


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  8. #25
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    I'm jealous of that press brake madness. For my part last week my son said, "Dad I'm doing a Socials project on the Cromwell (British) tank. Can we make a model?" He mainly has to do a research project (did they get them into production in time for El Alamein or only in time for D-Day?) but meanwhile I was like, "son, let me pull out Solidworks", and we spent way too much time on this on the weekend. And we have a tank. As you can see the turret and hull have slits in some of the bends because I was too chicken to do it properly as those bends were odd angles and we don't have ram control on the Atek. But we got it anyway and I'll be braver next time. This is a one off so only one set of parts so far. The not-bent seams are laser welded together and the turret top and sides are one piece bent and laser welded so that was pleasantly successful. Paint and 3D printed decorative parts (including what should be working 3D printed treads) to come...

    img_1535.jpgcromwell-unpainted.jpg

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  10. #26
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    Quote Originally Posted by digger doug View Post
    Is the controls the problem ?

    IIRC there is an Australian company selling retrofit kits for
    a bunch-0 old hydraulic Press brakes.
    Not to throw this topic off track, but what is the name of the company? I found an italian company that did retrofit controls, Esautomotion, but never got a response.

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  12. #28
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    The control retrofit I got from an Australian mfg is Icon. They have a new dealer in the US, not sure who yet. I've been working with the techs in Au on some issues I have yet, really nice guys to work with.
    iControl - The iCON controller for sheet metal machines.

  13. #29
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    Want to hold angles? Amada HFE 220-4...

    The flanges do not over lap. They are in the same plain as the bigger flange. This was part was pulled from the middle of the run.

    Good Tooling, a good Machine, A highly skilled Set-up Lead and a very good operator is all it takes. We do this stuff all day and all night long.
    Attached Thumbnails Attached Thumbnails img_7260.jpg   img_7261.jpg  

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    Quote Originally Posted by 4 FN 27 View Post
    Want to hold angles? Amada HFE 220-4...

    The flanges do not over lap. They are in the same plain as the bigger flange. This was part was pulled from the middle of the run.

    Good Tooling, a good Machine, A highly skilled Set-up Lead and a very good operator is all it takes. We do this stuff all day and all night long.
    I didn't know porn was allowed in this forum

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  17. #31
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    Quote Originally Posted by DethloffMfg View Post
    I didn't know porn was allowed in this forum
    Close off...Shot Blasting Housing...made from Manganese and CRS.

    Stainless Filter Chamber...
    Attached Thumbnails Attached Thumbnails img_6271.jpg   img_6272.jpg   img_6270.jpg  

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  19. #32
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    Quote Originally Posted by Scruffy887 View Post
    Automec just does backgauge controls, not really retrofit controls for ram.

    Quote Originally Posted by JP Machining View Post
    The control retrofit I got from an Australian mfg is Icon. They have a new dealer in the US, not sure who yet. I've been working with the techs in Au on some issues I have yet, really nice guys to work with.
    iControl - The iCON controller for sheet metal machines.
    Can I ask how much the system cost?
    This video has me interested in the Esa control. Looks super simple to operate.
    YouTube

    Also I finally found another backguage company, and retrofit company in Michigan. ZAKRON - CNC Gauging Systems for Pressbrakes and Shears

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    As the risk of completely derailing the thread, I thought people might want to see how the Cromwell tank turned out, even though the sheet metal was all done by the last photos. This turned into an epic of 3D printing malarkey. The treads are composed of 124 elements each side, printed in strips of 50 in such a way that they will all break apart as each tread piece is separated by .01" but there's a touch of residual adhesion, which fortunately is consistent across the whole print. Then the strips were cut up on the build plate and all 248 holes were drilled with a .028" drill on our old (I mean like pre 1961) Dumore mini drill. We then threaded .025" wire into each joint and once they were all in, broke the treads off the support material and got all the pieces moving properly. Next time I'll find a way to get the little wire pieces pre-cut to length! Anyway, I thought it turned out great and though there are a few issues with fender clearance and not perfect paint, this sets the path to a next version with better bending and hopefully motorized treads. NB the paint colour is Tamiya's NATO Green. My Balkan friend laughed and this and point out if we'd made a T-34 it wouldn't have stuck!

    img_1542.jpgimg_1543.jpgimg_1547.jpgimg_1551.jpg

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  22. #34
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    Quote Originally Posted by rcoope View Post
    As the risk of completely derailing the thread, I thought people might want to see how the Cromwell tank turned out, even though the sheet metal was all done by the last photos.
    Nicely done derailment!!!!

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    A lot of intersecting parts and all were ONE OFs. Went together with a tiny bit of mallet tapping before spot welding, some TIG. Hand finished with a Metabo burnisher. Trumpf 3100 with Trumpf tooling. Delem 66 control and flat patterns generated in Solidworks, doctored with Autocad before dxf out. I am not even close to being a sheet metal guy and have only had the Trumpf for a few years, laser a year less. Don't critique the finish, I don't have any finishing equipment yet, and wanted the finish to look like restored from scratch. After the first few bends I knew what the material was going to do and compensated all other bends.
    This is my very first cabinet and some drawers went in today. Ball bearing and soft closing. Fit is perfect so far.
    20190218_182005.jpg20190218_182020.jpg

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