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  #1  
Old 01-30-2015, 01:39 PM
threepiece threepiece is offline
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Default Bracket 102

Looks like I started this thread in the wrong section earlier so I'll start it here again.
I was asked today to make another of this bracket of which I already made ten. I will show the progression as I do each setup. I hope some of you find it interesting.

This is the blank drawing, it is 1:1 scale. I like blank drawings as they save me time, unfortunately not all engineers know how to make one. It's important to check the accuracy of the drawing for size. I glue the drawing to the sheet metal and rough it out with the band saw. The steel thickness is 1.6mm.
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  #2  
Old 01-30-2015, 01:41 PM
threepiece threepiece is offline
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After the band saw I trim to the line with files.
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  #3  
Old 01-30-2015, 01:43 PM
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The drawing.
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Old 01-30-2015, 01:49 PM
threepiece threepiece is offline
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Two holes are drilled and reamed. These holes will serve as locators for the first setup.
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Old 01-30-2015, 01:55 PM
threepiece threepiece is offline
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This is the tooling for the first setup. It will do two of the bends and all three of the stiffening darts. The punch for the darts is made from a 1/4" SHCS (Socket Head Cap Screw). The two pins protruding from the top of the form are the locators, they will be placed in the two holes that were reamed in the blank.
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  #6  
Old 01-30-2015, 02:05 PM
threepiece threepiece is offline
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Setup for the first bend, 5-10 tons of force is sufficient to keep things from moving. I use a four pound hammer with light taps until the blank follows the form tightly.
The other bend to the right in the picture will be done in the same way.
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  #7  
Old 01-30-2015, 02:19 PM
threepiece threepiece is offline
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This is the setup for the first two stiffening darts. 2-5 tons for this step. You can see the notch that was cut in the form so I am able to tilt it onto a square block and apply force in the right direction. I listen for a change in the sound of the hammer blows, this tells me I have completely seated the dart.
The V-block object to the left is the other top plate that will be used to make the third dart.
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  #8  
Old 01-30-2015, 02:51 PM
threepiece threepiece is offline
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This is the tooling for the next setup. The form in the middle will be located on the two reamed holes in the part. There are tabs on each end that will be formed.
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  #9  
Old 01-30-2015, 02:54 PM
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Setup to form one 90 degree tab.
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  #10  
Old 01-30-2015, 02:56 PM
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Setup for 180 degree tab.
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