Metal bending is a technique of deforming metal by pressing down the subject, causing it to bend at an angle and produce the desired shape. A press brake is a tool that bends sheet metal with the help of a punch and dies. Although press braking appears to be simple, maintaining accuracy throughout the process can be tough. Mechanical, hydraulic, pneumatic, and CNC press brakes are just a few examples of several types of press brakes that deliver different levels of force. If you are deciding to make a sheet metal bender at home, follow these simple steps to get your job done.
Making a sheet metal bender at home
It is not a particularly difficult construction, and no expensive materials are required. The total cost of materials will be less than 30€. You will find the specific machine tools other required things in your locked storeroom if you are really into bending machines and stuff. Before we start the process, I urge you to research the basic machines i.e., flight forming machines, bending machines, and sheet metal bender.
Material/tools required:
- 2100mm long angle iron
- Metal door hinge set with 2 pieces
- 1 pc 12” plumbing pipe about 500mm
- Plumbing Tee
- 1 pc. 16x65mm round bar
- 2 pcs 2mm 45 turn spring coil
- Broad washers for spring
- 2 pcs M10x50mm bolts
- 4 M10x25mm Bolts
- Four M10 Washers
- I used my hydraulic portable table for the brake bed.
- Angle grinder 180mm 7”
- Grinding disc
- Grinding disc
- A drill
- A welding machine
- Tape measure and caliper for accurate cutting or marking
- Pen Scriber, 10mm center punch
- Use a flat file
- Clamps
- vice grips
- Drill bits: 4mm, 8.5mm, 10mm, and 16mm
Measure the sheet metal brake
Once we’ve gathered all of the necessary equipment, we’ll need to determine the length of the bender and brake to the desired maximum Full Width. The maximum “Full Width” is equal to the “Bed Length.”
The Bushing Base Width is the same as the Angle Iron Side width.
All cuts are measured from the edges, therefore the overall length of the brake is irrelevant.
Calculate the desired bender and brake lengths using the calculations below.
Brake Length=Bed Length + (2*Bushing Base Width)
Brake Length=Bed Length + (2*Bushing Base Width)
Bed Length+ (2*30mm) Bender Length=Bed Length + (2*30mm) Bender Length=Bed Length + (2*30
If the bed is 805mm long, the braking length is 805mm plus (2*50mm) = 905mm.
805mm+ (2*30mm) = 865mm Bender Length
The desired space at each side where the mounts would be welded is 30mm.
Also read: Canberra laser cutting services
Disclaimer
- Keep in mind that safety comes first.
- Do not attempt to recreate this article if you are unfamiliar with metalworking tools.
- Welding tools are Dangerous
- Always put on the appropriate safety gear.
- You’re doing it at your own risk.
Preparation
- It is not necessary to cut the head from two hinge pivots.
- If you’re using channel iron or a tube, mark and cut the parts for the brakes and bender
- Measure from the edges to mark the cuts on each of them.
- Use your grinder slowly and carefully and make sure your slices are straight.
Welding the parts
The key aspect of a sheet metal brake is the bender’s rotational axis must be parallel to the bending line. Twist a 1.2mm steel wire around the pivot and place it in the bender’s gap. At the side of the axle and the upper corner of the angle-iron, adjust and tack weld. If necessary, reposition the joint and make tacks adjacent to the angle-end. Carry on with the opposite edge. Check to determine if the pivots’ center axes and the angle’s top corner are aligned.
Assembling the benders
We’ll need to temporarily install a sheet metal strip 0.50mm between the bender and the brake’s bed to continue joining the bushing bases and bender to the brake’s bed. With the metal strip between them, place and adjust the bender to bed, and fasten it in place. The bushings should be placed on the hinges. If everything looks good. Now Check the Release System by Placing and Setting Up the Brake. Sharp the Edges of the Brake. Crushing and grinding the edges is the final step. And you are done.
