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The plot thickens- three roll bender build.

Trboatworks

Diamond
Joined
Oct 23, 2010
Location
Maryland- USA
I’m tickled- just got the plate in from the plasma shop.
Some welding and bolt up work to go and this will be good to go.

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Lucky find that old grinder base to bolt this to.
 
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I am turning the dies for the extrusions I have to roll.
I made up bearing cores/carriers for the idlers and just press on a shell for each die while the drive wheel is a keyed slip fit.

These are the idler cores from some 4140:

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This is the idler set with flats for shell:

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The first set are just flats.
These are 4” turned from some mystery plastic rod I had in shop- I think nylon.

The idler axles are 1-1/8” 4140 and the drive axle is 1-5/8” scrap keel bolt.

The drive axle not yet keyed for wheel or die.
The drive dies will slip over axle and also have 4” OD.

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I think the rig will have enough balls for the work I need it for.
If it all works out I might power the unit and left room on the drive shaft for a pulley.

It will take a few minutes to change out but this is an occasional use rig so that’s fine by me..

I am kinda winging this and really have no ideal if it will work..
This is the first extrusion I have to roll to a 12’ radius:

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That one is 3” x 1-1/4”
Next up is 1-3/4” x 3/4” of the same shape but with two internal stiffeners.
I intend to try both on flat die wheels.

If this bender does the trick it will be a hoot- job well done.
If not I will be wondering what the hell I have been doing for the last couple of days...
 
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As it turns out the first stock I need to roll is a 2” x 1/8” architectural angle in 6063-T52.
I need half hoops rolled the easy way to 1’-4” radius.
Does it sound possible to roll that stock that tight?
 
As it turns out the first stock I need to roll is a 2” x 1/8” architectural angle in 6063-T52.
I need half hoops rolled the easy way to 1’-4” radius.
Does it sound possible to roll that stock that tight?

What do you mean by 2" x 1/8" angle? usually angle uses 3 numbers, leg, leg and thickness, like this: 2x2x1/8 or 2x1x1/8. You mention the easy way so one leg is shorter than the other...
 
Thanks- yes just equal leg: 2x2x1/8

I was saying easy way for the leg in plane of bend on outside of loop.
Given that I have never rolled any angle that is just my guess as to which way yields better..

Edit- looked it up- this is called “leg out”.
 
If you have never rolled angle, you can be in for a big surprise. I have never rolled alum angle and without a good setup for angle, it can be real rough

Sent from my SM-G960U using Tapatalk
 
Thanks- let’s see how this rolls...
I should have this finished tomorrow and put to work next week.

If I post bragging about some 1/4” flat rolled in a hoop the easy way you will know there is a problem...
 
Ok - it’s a wrap and it works:

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It rolls (no angle yet as I haven’t had a chance to make the dies) but, the oval rolls to the radius I need and an obligatory hoop...:

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This whole thread sorta has a HSM feel to it already so I have nothing to lose..::

I had thrown out the shaper which I never used so had to do the lathe trick to cut the inside keyway for the drive wheel which I had never done- it works

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One oversight- In the fullness of time I am going to replace the top axle and carry it further out the back side to have a set of open dies.
I had wanted full support for the primary rollers so I could really lay into them for heavy work but seeing this now a open set would be a snap for small stock in closed loops etc.

Shoot- now that I supposedly know how to weld I can weld on a stub axle and save me the work of turning the whole thing again.
 








 
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