Press brake for a 20 ton hydraulic press

[DaveH]

Hi,
I decided I wanted a press brake to bend the odd bit of metal. Looking around I came across this one http://www.swagoffroad.com/20-TON-Press-Brake-DIY-Builder-Kit_p_40.html
I quite liked this one so I based my design on the swagoffroad press brake - (loosely based on) 

Sorry guys this is a really good start I can't seem to find my folder with the photo's.
              
Don't go away I'll find it.
 
DaveH

[DaveH]

The angle iron is 40mm x 6mm and the base plate is 150mm x 480mm x 12 mm thick

This is a drawing showing the bottom die my design on the right and the swagoffroad on the left ( I did say loosely based)


Having no way of bending 6mm thick steel I decided to weld two pieces of angle iron to a base plate to form the bottom die.

 
DaveH

[DaveH]

Cleaned the angle iron and base plate ready for welding


As my welding is usually crap, I tacked it first and then welded a bit at a time so as not to cause too much distortion 


Finally all welded up, also cleaned up some of the welding to make it look a bit more presentable 


So far so good 
 
DaveH

[vtsteam]

Following along Dave 

[greenie]

Here's a suggestion, with the base plate, drill a couple of holes in it, where the two bits of angle iron touch, so that you can get a weld onto those two inside edges. 20 ton and a couple of 6mm bits of angle iron will be a "no contest" and the angle iron will spread in the middle, without something holding it in place.

Just a suggestion only, use it wisely or not, choice is yours.


regards  greenie 

[DMIOM]

Here's a suggestion, with the base plate, drill a couple of holes in it, where the two bits of angle iron touch, so that you can get a weld onto those two inside edges. 20 ton and a couple of 6mm bits of angle iron will be a "no contest" and the angle iron will spread in the middle, without something holding it in place.

Just a suggestion only, use it wisely or not, choice is yours.


regards  greenie 

and, in a similar vein, not just as a 'liner' but also as an anti-spread mechanism ....

Take a third length of the angle and drop it into the V of the current two angles and you can weld along the top edges as the original design did with their M.

Also, if you plug-weld like greenie suggested, you could consider going deeper and maybe even reach the bottom of the new V

Dave

[GordonL]

Too late now but the included angle in the bottom die should be less than 90° to compensate for spring back. With heavy duty press brakes they can get away with 90° because they are actually coining the part. When you are operating at near capacity of the brake you have to allow for spring back. I always bought 85° bottom dies when I owned my fabricating shop.

[DaveH]

Sorry guys, it is not clear from the photo's the two outer edges of the angle iron are welded all the way along to the base plate.
Thanks for your comments - keep them coming 
 
DaveH

[DaveH]

Next was to make the guide posts and guide bushes.
The posts are 20mm dia the ends were stepped down to 16mm dia x 10mm long so that I had a shoulder to register on. Helps to keep it square, the guide posts were pressed into the base plate and welded on the underside.





The underside of the base plate with the weld cleaned up


 
DaveH

[DaveH]

Next up the top die. This is a chunk of steel 20mm thick x 100mm high x 380mm long. This top die needs a 'pointy' bit along one of the long edges. I don't have a mill with a tilting head and I only have one vice that tilts. So in the end I just used the one vice I was a little apprehensive holding a 380mm long piece of steel in one vice but it worked out fine. May be because it was 20mm thick helped. 
The 'pointy' bit being cut on the mill the angle of the V is 70deg. (included)
 

Finished



Just making sure it all fits

 
DaveH

[DaveH]

Welded the top die to the guides, also notice a removable bottom die - just a piece of angle iron.



The welds have all been cleaned up to make them look respectable 
 
DaveH

[DaveH]

Time for a quick paint job


Whot!!! ....................... I like yellow and it goes very nicely with the blue press 






A couple of things to notice I had to clean all the paint off the guide shafts - it didn't slide up and down very well with the paint.
The extra supports under the base of the press brake.
 
DaveH

[DaveH]

I made a couple of locating 'lugs' helps to keep the brake press in the same place.



A 'cup' was made and fixed to the top die again to keep everything inline.


That's about it - finished. With removable bottom dies



 
DaveH

[shipto]

very nice I might make a smaller version for my fly press 

[philf]

That's about it - finished. With removable bottom dies
DaveH

Dave,

Most importantly - does it work?

I know little about press brakes but the fillets in the removable dies look rather too generous to me.

Phil.

[vtsteam]

Very nice looking brake!

It would be great to see something bent with it.

[micktoon]

Hi Dave , You have made a nice job of the press brake  , you will have to do a few trial bends and show the results, how thick plate do you think it will bend ? What paint did you use to paint it yellow it seems to have covered really well , yellow is not good for coverage normally .

 Cheers Mick.

[DaveH]

Whot!!!! you want me to bend something 

I post all these lovely pictures how I made it - that's after I lost the folder with all the pics  - Still haven't found it.
And you are still not satisfied and now I am expected to bend something. I didn't make this to bend bits of metal and scratch it all up. 

I'm kidding guys 

I have a few bits I bent I'll post some pics.

 
DaveH

 

[DaveH]

Hi Mick,
The paint was horrible - Rust-oleum 2X Ultra cover. Paint and primer in one can.
It is definitely twice the cover - if not 10 times    It goes on really thick and I just wasn't use to it I suppose.  Normally with a rattle can I waft it with the paint and put 4 - 6 coats.
The press brake had two coats and it looks like it was dipped, sort of looks like it has a thick coat (which I don't care for much).

I think it is a different type of paint that just needs a different technique to use it.
 
DaveH 

[DaveH]

I know little about press brakes but the fillets in the removable dies look rather too generous to me.

Phil.

I can't do much about that - it how the angle iron comes 

Actually I can by stacking smaller angle sizes and if I finish with some aluminium angle 25 x 3 mm.
Also bending 5mm thick steel then those fillets are fine. 
 
DaveH

[DaveH]

This was one of the first bends I did,  30mm x 5mm flat bar
Over cooked it a bit.




I have a few more bends I'll take a couple of photo's and post them.
 
DaveH

[dsquire]

Dave

Every thing looks great but couldn't you find a brighter shade of yellow?

Looks like you'll be able to build that better mouse trap now. 

Cheers

Don

[DaveH]

Thanks Don,

That was the brightest shade of yellow I could find 
I've got fed up with greys and dark blues. I'm into the "brights"
Wait til you see the log splitter I'm building ...... Pink is looking good 
 
DaveH

[dsquire]

Hi Dave

With the price of every thing these days you can't be too particular any more.The main thing is that there is something to cover it up to save it from the rust for a while.

I'll be watching when you build the log splitter. It will remind me of the years when I wished I had one. 

Cheers

Don