Because of bad luck with our china press brake
We decided to do an fast hack. Because we do CNC Mill and Lathes we are well equipped.
So you need
A Mill, Lathe, Welding tool drills gear cutter
and youre done
but it was great fun
Step 1: Make a Plan and Collect Needed Items
We do CNC Mill housing using a mechanical press brake
but unfortunately the machine did not work well see the picture ,..
so we decided to do a quick n dirty solution which helps us in more ways
1) We reuse the steel blades form the china brake
2) We have an turning lathe Klippfeld K10B
3) We do milling machines so we have an Thojomech 12
4) We have an Harbour freight type of Press
then we simply have an U Shaped Steel as base
then an milled bar (you will see the pictures )
and turn an guiding rod and have some pipe welded to the bar.
on top an ring wich has to be exactly centered.
Step 2: Prepare the Square Bar Mill It
Prepare the Square bar.
Make the step a little less deep than the press modules are. (6mm in our case)
Mill the step we had to mount it 2 times because our mill can "only" do 440 mm
then we programmed peck drilling and had all 80 mm an hole.
Then we cut the M8 gear. We used the Mill table as working platform worked well.
Next time we would probably go for an synchronized spindle and also cut the gears by cnc but that is another story.
Step 3: Doing the Center Ring
We decided to have an perfect centered ring
So first we had to turn
The ring to the diameter of the Press bar.
Then we Drilled 4 Holes and (see Foto)
Cutted gears in
then we put the ring back on the mill
and cutted an exact nut into the ring to tight fit the bar
This should ensure 90° Angle and gives more room to weld.
Step 4: Preparing the Base
So now we prepare the base
1st We prepared the 2 guiding rods by turning them a little step
then we took the u-shaped profile steel and cut out the ends and drilled the 2 holes
they have to be really precise
look at the picture this shows where we pointed the rods to get them proper angeled
Step 5: Finnishing the Top and Align With the Base
We now cutted the 2 tubes same length
Then we cut the L Shaped profile steel exact in length.
Then wen welded it to the base and assured that because of heat it doesn't bend.
And now we made sure that it all fits together
we had to mill the ends of the main bar on both sides to the perfect wideness
On the picture you see the final fit test.
It is important that all is proper angeled that you have less friction.
Before we final welded everything
we did the holding plate from an flat steel bar. which we clamet to the main bar and drilled the holes for exact fit.
We then used the "fingers" to align everything for final welding.
it is important that the round tubes are welded angeled and centered which we did by welding it as shown at the picture. (the welding trafo we used is more than 45 years old and started to smoke ) so we had some welding issues but finally it worked.
Step 6: Finnish
We used the brake in plain condition
But we need to grind the welding parts and paint it
so we simply want to encourage people to build their own stuff