How to make a homemade sheet bending machine: from idea to implementation. Homemade sheet bending machine with your own hands video How to make a sheet metal bending machine
Preparing the tool is half the job done. This truth is good if the master has a ready-made tool. However, if in the course of work you suddenly need something more complex than a screwdriver and a hammer, then you often have to invent real machines on the fly to perform complex functions. A striking example of such a machine is a sheet bender, which is necessary when working with sheets of metal.
During many works with sheet metal, for example, in roofing work, there is often a need to bend metal sheets, including those with different coatings. If you need to bend a small sheet, this work can be done using hammers, mallets, and pliers.
The result will be disastrous - a curved, jagged surface, a scratched coating, a crooked fold line will not allow all the work to be done efficiently, and will not bring aesthetic pleasure to the owner. It is generally impossible to bend a sheet of large size and, especially, a complex shape with such tools.
For such work it is necessary to use quite complex equipment - a sheet bender. You can buy a ready-made manual machine, like the one shown in the photo, made by a well-known manufacturer. However, this will entail additional, very significant costs, which will lead to an increase in the cost of all work. A cheaper way to purchase such a machine is to make a homemade sheet bender with your own hands. For a person who is familiar with physical labor and knows how to handle other tools, this will not pose any particular problems.
Device
Inventing such a machine independently will be problematic even for a person who is well acquainted with the basics of strength of materials. However, in the era of the Internet, no one needs invention in this area - drawings and descriptions of how to make a sheet bending machine with your own hands can be easily found on the relevant websites.
The main parts of the sheet bender shown in the drawing are:
- The base is a surface intended for installing other equipment and securing the workpiece. Made from steel channel. Dimensions are selected depending on the size of the metal sheets whose processing is planned;
- A clamp is a device that allows you to bend a sheet. In a conventional device, the bend angle does not exceed 90 degrees. It is made of a steel angle, installed on the frame with the top up. For ease of installation, another corner of the same type is welded to it, as shown in the drawing. The length of the clamp should be slightly less than the length of the base to ensure its reliable fastening and unhindered operation. Attached to the base using clamping bolts;
- Crimping punch is a structure made of a steel angle with a metal handle welded to it, which allows bending of the sheet. The axis of the punch must coincide with the edge of the angle. A steel rod is used as an axis.
The dimensions of the parts indicated in the drawing may vary depending on the area of application of the machine.
Assembly
The assembly of a homemade sheet bender, shown in the video, begins with fixing the base and punch using a clamp. In this case, it is necessary to ensure that the surface of the base and the working surface of the punch are in the same plane. The punch axis is threaded through the holes of metal plates, called cheeks, welded to the ends of the base. The axle is attached to the cheeks by welding or screwed with nuts.
The exact location of the clamp is determined after several test bends. After drilling holes in the base, we attach the clamp to the base using clamp bolts. The nut for fastening the bolts is welded to the base, which makes it possible, if necessary, to easily install or remove the clamp, using only one nut on each bolt, which can be replaced with a knob.
Job
Thus, the drawings of a manual sheet bender with your own hands allow you to assemble a device, the operation of which is shown in the video. The operating procedure is as follows:
- The punch is brought to a position in which its working surface is installed in the same plane with the surface of the base. The punch handle in this position is directed vertically down;
- The clamp is removed from the base;
- A workpiece is placed on the base - a metal sheet, the width of which corresponds to the distance between the clamping bolts;
- The clamp is installed on the base and secured using clamping bolts;
- Using the handle, the punch is set in motion and firmly presses the sheet against the clamp. In this case, the sheet is bent at the desired angle around the axis of the punch. The handle is positioned at an angle of 45 degrees relative to the surface of the base.
The result is a sheet of metal with a straight fold line.
Applications and Benefits
A manual sheet bender is used when it is necessary to carry out any work related to bending metal sheets: manufacturing metal casings, cases, decorative works. Such a device is good to have in the country house, in the garage. It may be needed by a private entrepreneur engaged in metal processing and the manufacture of metal products in small quantities.
The main advantage of such a machine is its mobility, small size, and relative simplicity of design and assembly. An undeniable advantage is the ability to use it in conditions of lack of electricity. Such a device allows you to qualitatively bend any sheet of metal of suitable size, while maintaining the evenness of its surface, without damaging the coating of the sheet, if any.
Flaws
With all the advantages, a homemade sheet bending machine also has disadvantages, which consist, first of all, in safety. The manufacture of such a device requires the use of welding equipment, the handling of which requires certain skills and compliance with safety requirements. Poor-quality welding can not only lead to a fire during its implementation, but also cause poor performance of the device itself.
A sheet bending machine is a fairly simple tool that allows you to produce blanks for construction work from sheet metal. In practice, such equipment is more often used by manufacturers of metal products, and household consumers, to solve household problems, prefer to buy finished products.
We can partly agree with this, because a new machine is an expensive and impractical purchase. However, with a little engineering thinking, you can make a simple manual sheet bender yourself.
What is a sheet bending machine?
Manufacturing high-quality products from such a durable material as metal is impossible without the use of special devices. In order to facilitate manual labor and increase productivity, new equipment is being created. One such discovery was a sheet bending machine.
A sheet bender is a metal rolling machine that is used for bending aluminum, brass, steel and other sheets of metal. A sheet bending machine bends sheets at a given angle, without disturbing the flatness of the material.
To organize a small production or carry out work on a personal plot, it is not necessary to purchase expensive equipment; you can make a manual sheet bending machine with your own hands.
The homemade version is capable of processing sheet metal with a thickness of up to 1.5-2 mm and a workpiece length of up to 4 m, with a bending angle of 180°. A manual sheet bending machine consists of a base, a crimping punch with a lever and a clamp.
Factory press brakes are often equipped with additional functions. One of the most popular is metal cutting. The roller knife is made of high-alloy steel, coated with a special varnish. The service life of the cutter is practically unlimited, however, the knife will need to be sharpened periodically (one sharpening is enough to process 25 kg of metal with a thickness of no more than 0.8 mm).
Scope of application of sheet metal bending machine
The sheet bending machine has a wide range of applications in the following sectors of the national economy:
Types of sheet metal bending machines
The main criterion by which all sheet bending machines are divided is the type of drive of the working element.
Manual sheet bender- the product bends due to the physical impact on the rotating beam. Some models are equipped with a pedal. The machine is designed for processing metal of small thickness at small angles.
A manual sheet metal bender is often found in the sheds and garages of domestic users who use devices to bend tin sheets. By setting staples or support beams to the desired bend radius, you can create complex parts at home.
Homemade manual sheet bending machine: video
Manual sheet bending models do not have sliding and friction units - this makes the equipment less demanding and more durable.
Mechanical sheet bending machine- a stationary machine powered by flywheel energy. The operating principle of a mechanical sheet bending machine is as follows: bending is carried out by pressing a lever. Changing the length of the lever (the connection between the pusher and the handle moves) leads to an increase in the force acting on the workpiece. The use of such machines is somewhat limited, since working with them requires the use of physical force.
An improved version of the mechanical sheet bender - electromechanical machine. The energy source in this case is the power of the electric motor. Electromechanical machines have gained popularity among users due to their versatility and ease of use.
The workpiece is placed on the matrix, the operator presses the start button, and the engine drives the gearbox, pusher and punch - the sheet is bent or deflected in the desired plane and with the specified parameters.
The force on electromechanical machines can reach several hundred kilograms, and with a powerful engine - even a ton
The modern mechanical engineering industry is 70% staffed sheet benders with electromagnetic drive. These installations have a number of advantages:
- small overall dimensions;
- quiet operation;
- high bending speed.
The operating principle of an electromagnetic sheet bender is based on the creation of a magnetic field between the punch and the matrix. The punch is loosely attached to the spring, the matrix is installed under it, based on the shape of the future product. In the punch, or under it, there is an inductor, which creates a powerful magnetic field when voltage is applied to its winding. The magnetic field attracts the punch and the matrix to each other - the workpiece is tightly clamped between them and takes on the specified geometry.
Using this method allows you to “stamp” several hundred parts per minute.
Design of a manual sheet bender
The design of a manual sheet bending machine consists of the following basic elements:
- the clamping beam clamps the bent or cut sheet metal;
- a bending beam bends a metal sheet; bending capabilities differ in different models - usually the bending angle ranges from 0° to 180°;
- circular blade made of high-strength steel and coated with powder paint; on average, the service life of a knife is 2500 linear meters. tin with a thickness of no more than 0.5 mm;
- protractor - a dimensional disk that allows you to quickly bend sheet metal at any angle without installing a limiter;
- back table (feed limiter), on which the metal worksheet is placed and moved;
- the clamp handle allows you to bring the clamping beam into working position;
- tension device for bending and main beams - adjusting the shape of the beams to create high-quality bending of the product.
Some models of machines are equipped with rotating wheel blocks with brakes - this allows you to freely move the sheet bender and fix it in the selected position.
Making a sheet bending machine with your own hands
Let's consider an example of manufacturing a manual sheet bender, since its design is the simplest, and the productivity of such a machine is quite enough for processing metal for domestic purposes.
Development of specifications and machine drawings
A homemade sheet bending machine must be designed in such a way that during operation the main load falls on the most enduring and strong muscles (biceps, broad backs, calves and thighs), and the recoil of the machine (reaction) of the machine presses the feet to the floor. With such a device, the work will not be exhausting.
The layout of a homemade sheet bender will depend on its purpose:
The first version of the device is more acceptable for the household consumer. To develop a drawing of a machine, it is necessary to determine the technical characteristics that are assigned to the equipment:
- maximum thickness of processed metal: 0.6 mm - galvanized, 1 mm - copper, 0.7 mm - aluminum;
- metal sheet width - no more than 1 m;
- flexion inclination - at least 120°;
- number of uninterrupted operating cycles - about 1200;
- processing of non-standard workpieces or special steels is not desirable.
Drawings of sheet metal bending machines can be found on the Internet. The design below is quite successful for self-production.
The machine will produce stable results, and the maximum tilt angle is 135°.
Selection of materials
To manufacture the working components of the machine, you can use the following materials:
- wooden beam - to create a “pillow” (in the drawing - a wooden insert);
- channel 100-120 mm - base of the sheet bending machine;
- metal sheet 6-8 mm - right cheek;
- It is better to weld the pressure beam from corners of 60 and 80 mm;
- a pin with a diameter of 10 mm for making the punch axis;
- the punch can be made in the form of an angle of 80-100 mm or a channel of the same size;
- The punch lever is made of a rod with a diameter of 10 mm.
Advice. It is better to make a punch from a channel rather than a corner. The return from the bent metal to the punch is uneven across its width: in the center it is maximum, and at the edges it is minimum. This leads to the fact that the corner bends in the middle and the fold becomes swollen. The additional side side of the channel takes on tensile stress, converting it into compression.
In addition, practice shows that a punch from an angle can withstand about 200 bends, and a channel of the same width can withstand more than 1200 bends.
Design detailing and assembly
The assembly diagram of a manual sheet bender is shown in the figure, where:
- clamp (screw M8-M10 with heel and knob, angle 40-60 mm);
- cheek;
- base;
- corner 110 mm - bracket;
- pressure beam;
- punch axis;
- punch.
The lower surface of the pressure beam must be milled. This must be done after complete welding of the entire assembly. Moreover, “smoothing” the clamp with a grinder or a file is unacceptable.
The maximum permissible unevenness of the clamping surface is no more than ½ the thickness of the sheet being bent. In our case, the minimum thickness of the sheet to be bent is 0.2 mm
The entire process of assembling the machine can be divided into the following stages:
Safety precautions when working with a sheet metal bending machine
A sheet bending machine is a traumatic device, and when working with it, compliance with safety regulations must come first.
Before starting to work on a purchased machine, you must read the instructions, determine what material the equipment is designed to process, and follow all prescribed safety measures.
Before starting a homemade or purchased machine, you must:
Without spending too much time and using inexpensive material, you can make a convenient and practical manual sheet bender with your own hands, which will become an indispensable assistant in your garden.
This publication presents the development of a homemade sheet bender, which was built by a YouTube channel blogger Hot master. In his video tutorial, the master will show a sheet bending machine of his own production, designed for processing rolls of endless sheet iron. It is end-to-end and you can stretch an as long ribbon of painted metal through it as you like. This machine can be used for bending galvanized iron and other metal up to 2 millimeters thick. If the thickness is 2 millimeters, then the length of the fold cannot be more than 30-40 centimeters.
Drawings for this bending machine were found on the Internet.
The presented machine is made of channels and angles. The corners are welded into a box. This is the worker node. The clamping bar is also made from corners welded together into a box. The sheet is clamped on 2 sides, on which clamping screws are installed. However, as experience has shown, it is enough to limit oneself to one side. Valve springs are installed between the working bodies into which the sheet is clamped so that the clamping bar rises freely when the clamp is loosened.
The rotating mechanism has hinges installed. The rotation angle is more than 90 degrees. The handle is made of a shortened hardened rod and does not interfere with the worker’s movement. The iron sheet can be installed both in front from the worker’s side and from the opposite side. The lever is located horizontally, which creates additional convenience when the worker does not need to bend down to grab the handle. In addition, the surface created by the handle can be used to feed sheets into the machine. If desired, you can install an additional table on the lever, creating a flat working surface.
The opposite clamp does not have to be a quick adjustable one, it can be a simple nut that can be turned occasionally to adjust the gap.
How work works on this sheet bending machine.
After the sheet is clamped, the lever rises and with a slight movement the bend occurs. By changing the angle of the handle, you can adjust the depth of the bend. If you need to bend a full corner, then, accordingly, the lever rises more. The result is a completely smooth and straight bend. If the bending is carried out with a reserve, then the result will be even more even. The work doesn't take much time.
At the back there is a table from which the iron is fed; it is convenient to cut off the excess.
The machine can be disassembled, for example you can remove the table. The entire bending machine is disassembled into parts, so it is easy to move. When disassembled, it easily fits in the trunk of a Volga car.
Explanations on the design of the sheet bending machine
Separate sheet bending units with comments. The machine has been in use in the workshop for a long time and has shown very good results. The most basic part is the clamp. This is the device that presses the sheet of iron to the base. The better and more accurately this is done, the better and smoother the bend will be. The clamp is made from corners welded together.
The work table or base of the sheet bending machine consists of one piece. This is a channel. The longer the workpieces, the more powerful this channel should be. In this case, its length is 1.5 meters. If you plan to bend workpieces 1.5 times larger, then the channel should be installed twice as powerful.
All the main work is done using a bending bar. A massive bending lever is welded to it. The bending bar is mounted on hinges that are cut in a special way. It directly bends the iron to the desired angle.
It is recommended to orient the bending bar together with the lever so that it is horizontal. In this case, the lever should be at waist level. On many factory sheet bending machines, the lever hangs down vertically, which creates great inconvenience during operation. You have to bend down and pick it up from below each time. It is much more convenient to push from chest level, which is especially important for large volumes of work.
The lifting clamping device is a set of springs from the cylinder head of a passenger car, along with washers, rings, to center the entire device on the threaded rod. It not only presses the clamping bar, but also lifts it to the position when the upper wing nut is pressed to the desired lift level. If you leave the wing nut, the bar rises and is at a certain height. Hinges - hinges are ordinary garage hinges. The hinge should fit into the groove all the way to its axis. The axis should rise from the base by no more than 2 millimeters. The level of pressure is adjusted by a thumb, which is tightened on a pin, pressing the bar against the sheet of iron. Under the wing there is a nut to which a 6 mm wire is welded, forming a lever.
The indicated shape of the lever has been verified by a large number of works performed with its help. A large nut is placed on the stud, which is loose and not threaded. Next, put on the washer from the block head. Under no circumstances should small threads be placed at the top. It should be taken into account that if you make the lever extending horizontally from the nut, it will interfere with working with some types of workpieces. Therefore, it is better to make the form shown in the video. If you make a flywheel with two handles, as shown in some drawings, this shape will interfere with inserting and removing the workpiece.
The length of the hairpin must be adjusted. It is necessary to ensure that the thread fits completely when the thumb is turned away to the upper maximum position. So that your fingers and palms can fit at least halfway into the clamping bar. What height of lifting level of the clamping bar is required?
Bending machine drawings
Is it possible to make a box using a sheet bender?
Suppose you have a piece of galvanized steel from which you need to make a box. Skeptics believe that this is not possible with this device. However, this is not the case if we use this model. Moreover, with its maximum length equal to the width of the working machine. And the height of the sides is practically not limited by anything at all.
First, watch the video to see how the whole process will happen. Next, the master explains the theory behind this for large boxes.
The most important thing is to correctly mark the future product. Let's assume that we conditionally need a box with sides of 5 centimeters.
To do this, we must set aside 5 centimeters from each corner. When the marks are ready, we connect them with the previously marked marks in order to make it easier and more accurate to make the necessary cuts and not cut everything out, but leave a little in order to bend, rivet or spot weld.
When the markings are ready, we need to make cuts. Since everything will be done using electric resistance welding, it is advisable to leave the outlets. That is, the master leaves tentative cutting lines. The selected parts will remain on the workpiece, that is, they will not go to waste. And the shaded parts will go to waste.
Another development example
Homemade made of black metal. The base is a 12-gauge channel, a hinge is welded to it, and a 16-gauge pipe. A rod is embedded in the bending roller. It was all welded. The lever is made of a reinforced design. The bending beam is made of 75 angles. Half of the shelf has been cut off. The pressure beam is made of 75 angle and reinforced on one side with 50 angle. Additional emphasis was placed, since the beam in the middle was arched. Along the edges there is an eyelet from 75 angle, a bolt, and valve springs. A primitive eccentric has been made.
Nowadays, sheet metal rolling is gaining momentum. More and more often, one or another person has a brand new fence made of metal profile sheets.
The question arises, what kind of machine creates this wonderful and necessary building product for humanity.
Bending machine design.
Plate bending machine
This is a specially created device with which you can bend sheets of galvanized metal of a certain thickness. This miracle machine is usually used for production purposes.
Such a device never became widespread among skilled craftsmen. However, nowadays there are people who were able to reproduce the prototype of the production module and make their own sheet bending machine.
This thing is quite easy to do with your own hands; it will not take up much space in your garage or workshop.
Direction of application
It would seem that this is quite simple equipment, but it covers a huge industry. This invention is capable of producing products in the following fields of activity:
Widest scope of application
This is construction. It is in this area that you can find a huge selection of corrugated sheets, metal profiles, metal tiles and their components. Also metal siding - it is used for interior decoration of houses and buildings. Ventilation shafts are also produced using sheet benders.
Mechanical engineering and aviation
And also shipbuilding. This area is very expanded, as various parts for bodies, aircraft skins, and also skins for shipping equipment are created.
Electronics
Not everyone knows that sheet bending machines are used to create housings for household appliances (microwave ovens, ovens, refrigerator and washing machine housings, computer housings, and much more).
Furniture manufacture
In this area, boxes, lockers for changing rooms, lockers for storing things, etc. are created.
Many areas were covered in the operation of a sheet bending plant. Each of the above areas is very common among the population.
Types of sheet bending devices
Like many other machines, sheet bending machines differ according to one of the most important criteria - this is the type of drive action.
Consider these types:
Manual drive action
This type is used mainly in everyday life. These include homemade inventions. It is with the help of this device that you can make any devices from galvanization for your home or garden. And if you correctly install support beams and staples on a manual sheet bender to the required bend radius, this will allow you to create complex elements.
Mechanical impact
Such units belong to stationary machines. The acting force is distributed from the flywheel. This design has limitations in its use. The fact is that the device is equipped with a special lever, through which the sheet is folded. The downside is that it requires physical force.
Electromechanical option
Electromechanical drives have received widespread approval among their owners. This is because this machine is very convenient and versatile. The process begins with laying galvanization on the surface of the matrix. After pressing the start key, the punch, pusher and the gearbox itself come into force. Due to this, the galvanized sheet bends or bends with the necessary parameters. The force produced by such a machine is at least 100-200 kilograms, in some cases this characteristic can reach up to one ton.
Electromagnetic drive action
Electromagnetic machines, nowadays, are mainly used in the metal rolling industry. The percentage of use of such equipment in mechanical engineering is 70%. It has only one advantage. Small dimensions, high productivity (this device is capable of producing about several hundred parts in just one minute), it is completely silent.
Hydraulic drive
This category belongs to the category of press brakes. Presses with hydraulics are used in the serial production of parts. They are very productive, high quality, fully automated, and have control over the bending angle of the sheets.
Zig machine
This device has a very important side. They are used in the manufacture of components. Using a zig machine, you can make flanging of galvanized sheets, corrugating edges, rolling connecting bends and much more.
Making a sheet bending machine with your own hands
If you look at it, detailing a sheet metal bender is not that difficult.
Types of metal profiles
Bending beam
Due to it, the metal sheet is bent at an angle from 0 to 180 degrees.
Pressure beam
This part holds the sheet with clamping force and prevents it from sliding.
Goniometer disc
A special disk that displays all the necessary angle dimensions.
Disc knife
A sharp, sharpened blade made from high-strength steel that cuts steel without problems.
Back table
Consists of end-to-end designs with a flat, top surface on which the galvanized workpiece will move.
Clamping handle
Due to it, the pressure beam is brought into readiness and action.
Stretching device
Allows you to select the position and shape of beams to produce high-quality bending of rolled metal products.
Development of a technical device
Advice: Before you get ready to draw drawings, look for various details for your future brainchild, it is very important to make a choice, choose what is most suitable for you. It is also important to take into account the area in which your homemade module will be used.
During the design process, it is important to assemble it in a way that is comfortable for you. So that the entire load is distributed to the most enduring muscles of your body and to the support posts of the device. When developing a unit that you want to create with your own hands, it is important to consider the following parameters:
- The width of the galvanization should not exceed one meter.
- The bend angle should not be less than 120 degrees.
- The number of continuous production cycles should not exceed 1200 units.
- The use of various alloys of steel and other metals as workpieces is strictly prohibited.
- Permitted thickness of the following metals:
- Aluminum - permissible thickness 0.7 millimeters.
- Galvanization - optimal thickness 0.66 millimeters.
- Copper - a thickness of one millimeter is allowed.
When all the necessary criteria are taken into account, you can safely assemble your instrument.
This is what sheets of steel and metal will look like when they are bent and passed through rollers. In addition, the figure shows in what ways the sheets can be bent to obtain the desired shape.
Variety of folding galvanized sheets
Drawings of a sheet bending machine
Drawing of a bending machine made from simple parts.
The drawings of any device are considered the basis of your invention. After all, it will indicate the dimensions and location of a particular part. When you have everything you need
dimensions and sketches, then assembling the device will certainly end in success. Nowadays, on the Internet there are a huge number of different drawings with dimensions. As they say, the choice is yours! Below we will look at one of the simplest drawings.
This variety is quite productive and successful model.
Selection of materials
All materials for this machine can be easily found in your garage. So, let's look at what these materials are:
Wooden insert
Indicated in the drawing by the number “1”, it is created from a simple wooden block.
Metal channel
Size 100x120 mm will fit well into the base design.
Right cheek
It is made from steel sheet, 6-8mm thick.
Iron corners
60mm and 80mm will serve for the manufacture of a pressure beam.
Punch axis
Can be created from an iron pin with a diameter of 10 mm.
The punch itself can be created from an iron angle 80x100 mm, or you can use a channel.
Steel rod
10 mm in diameter is suitable for creating a punch lever.
Tip: To create a punch, it is best to choose a channel rather than a metal corner. This is because the channel can withstand much more bending than the corner.
Detailing and assembly process
The assembly process is presented to your attention, as well as the description and location of the parts. A welding machine will certainly help you during assembly. The seams after welding must be processed so that the seams are flush with the plane of the part on which the seam is located.
So, let's look at the parts indicated on the assembly diagram:
Location of parts during assembly.
- A medium-sized clamp (the M 10 screw has a knob on one side and a heel on the other), located in a corner measuring 40x60 mm.
- The cheek is made of sheet steel, 8 mm thick.
- The base is made of channel 100x120 mm.
- Angle bracket 110x110 mm.
- Pressure beam made from angle 60x60 mm and 80x80 mm.
- The punch axis is made of 10 mm rod.
- The punch itself is made from an angle 80x100 mm.
After all of the above parts are in place and secured, you should prepare your machine for operation. To do this, you simply need to remove all construction debris that remains after assembly.
Rules and safety precautions during operation
Everyone has long known that safety is the key to health and longevity. And also a chance not to remain disabled. This machine, in its category, is extremely dangerous. The thing is that the machine itself can cause a huge number of injuries. In addition, the material itself that will be used on it is very sharp.
Therefore, it is important to take into account the simplest rules in order to avoid danger:
- If your machine is purchased, then it is important to check all components of the device for serviceability.
- Before work, it is necessary to tighten all clothes so that a hanging jacket does not stick out, a belt or lace does not dangle, etc.
- When working with a purchased or homemade machine, you need to purchase safety glasses and thick gloves that will be comfortable to work in.
- Check the condition of the installation fasteners to ensure that everything is tight and nothing is loose.
- All workpieces must be placed near the machine so that it is convenient to pick them up with your hands.
- Ensure sufficient lighting in the workplace.
- The workplace must be cleared and have free passage within a radius of one meter.
- The frame must be grounded if an electric drive is present.
- If you work with electricity, it is strictly necessary to have a rubber mat at your workplace.
- It is unacceptable to put various materials into the machine that are not intended for this work.
When these rules are followed, you don't have to worry about your safety.
Advice: Due to the fact that the work will be carried out with iron, it is imperative to protect access to the machine from children and not leave the workplace unattended! Also, always be on your guard, as metal is an unpredictable thing!
Video
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Overview of homemade machine assembly
How to bend metal with your own hands? When performing construction work, it is often necessary to bend metal elements. For example, it may be necessary to bend sheet metal or pipes. Pipes with a small diameter are bent using a vice.
Bending of metal sheets on a bending machine occurs without welding and does not disrupt the structure of the metal.
Often during construction work it becomes necessary to bend large diameter pipes. For such work, special machines are needed that bend pipes and metal sheets. In this case, the bending element does not receive damage.
When bending parts, the plasticity of the material, its thickness are taken into account, and the radius of curvature is determined.
What is metal bending technology?
Assembly diagram of a homemade sheet bender: 1 – base; 2 – handwheel nut; 3 – clamp; 4 – bendable sheet; 5 – clamp; 6 – crimping punch.
Sheet metal bending is the performance of certain actions, as a result of which the metal sheet acquires the desired shape. The part is bent without the help of welding or any other connections that reduce the strength and durability of the material.
When a product is folded, its outer layers are stretched and the inner layers are compressed. Bending technology involves bending one part of a part relative to another to the required angle.
During bending, the material is subjected to deformation. The amount of possible deformation depends on the thickness of the material, bending angle, ductility and bending speed.
Bending is performed using equipment for bending parts. This equipment bends the element so that the finished structure is not damaged.
If an element is bent incorrectly, various defects will occur on its surface, as a result of which the material along the bending line will receive such damage that the finished structure may break. Bending is carried out for sheets of various thicknesses.
The bending stress of the material must be greater than its elastic limit. As a result of bending, plastic deformation of the material should occur. In this case, the finished structure after the bending operation will retain the shape that it was given.
Drawing of a sheet bender (details): 1 – clamp; 2 – cheek; 3 – base; 4 – bracket; 5 – welded clamp; 6 – axis; 7 – corner of the punch.
Advantages of the bending process:
- The process has high productivity.
- As a result of bending, a workpiece is obtained that does not have a seam.
- The finished structure is highly resistant to corrosion.
- The product is highly durable.
- No rust appears at the bend of the product.
- The design is solid.
Flaws:
- The manual bending process is quite labor-intensive.
- Bending equipment is expensive.
Unlike structures made by bending sheet metal, welded structures have a weld that is susceptible to corrosion and rust.
Products are folded manually or using equipment. Hand bending is very labor intensive. It is performed using a hammer and pliers. Folding material of small thickness is done with a mallet.
Sheet metal is bent using rollers, presses or roller machines. To give the sheet a cylinder shape, manual, hydraulic or electrically driven rollers are used. Pipes are made using this method.
Assembly diagram of the working stroke: 1 – wooden insert; 2 – base; 3 – right cheek; 4 – bendable sheet; 5 – clamp; 6 – punch axis; 7 – punch; 8 – punch lever.
Metal bending is used in home construction for the manufacture of gutters, profiles, metal frames, pipes and other structures. When bending sheet metal with your own hands, you can make pipes of various diameters. Using machines, zinc-coated material is bent.
If you need to bend metal at home, you can make a bending machine yourself. To make a machine, you need to make a template from wood that has a contour of a certain, curved shape.
When bending a product, you need to determine its dimensions. The length of the structure is calculated taking into account the bending radius of the sheet. For workpieces bent at right angles, without creating roundings, the bend allowance should be 0.6 of the sheet thickness.
With your own hands you can bend structures made of ductile metals: copper, brass, aluminum. The bending radius depends on the quality of the material and the bending method. Products with a small radius of curvature are made of plastic materials.
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DIY metal bending
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How to make a bracket using the bending method
When bending a steel strip on a roller machine, the top slot on the bar must match the size of the strip.
Materials and tools:
- a metal sheet;
- vice;
- hammer;
- frame;
- bar;
- electric saw for metal.
First, you need to calculate the length of the workpiece strip using the diagram and calculate the bending of the metal sheet.
When calculating for each bend, make a margin of 0.5 of the strip thickness and 1 mm for bending the ends to the side.
According to the diagram, the workpiece is cut out and marks are made for the bending point. The workpiece is bent in a vice with squares.
First you need to clamp the workpiece in a vice at the level of the bend. Then use a hammer to make the first bend.
Then the workpiece is rearranged in a vice and clamped with a frame along with a block. Then make a second bend.
After this, they pull out the workpiece and make marks on the length of the staple legs.
The bracket with the frame frame is bent in a vice, while both of its legs are bent. The bend is specified with a triangle. If the bend is made incorrectly, it is corrected with a hammer and a frame block. After the bending process, the structure is sawn to the required size.
