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Old 02-20-2020, 08:24 PM
lrubin28 lrubin28 is offline
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Question how to shape thin brass sheet or blanks

I buy a brass part from overseas and the quality keeps getting worse - I'm wondering if I can make them myself.

I buy thin wall brass tubes which I have no intention of trying to make. Each tube has a thin brass 'cap' that fits snugly on each of the tube ends, and extends about 3/16" up the tube. The caps that fit over either end of the tube each have a different sized hole in the center. If it helps, imagine holding the tube up to your eye and looking through the cap's hole on one end like a telescope. The other end has a bigger hole

I'm guessing that these are made by stamping (and punching) the brass with an industrial press but it's a total guess on my part. But, the metal is really thin...a little less than 1/32". And so I'm wondering if I can make these myself with a manual press or other tool. I don't really understand what shape of blank would be needed to make the edges even...unless maybe the brass is punched, pressed, and then cut around to make it even?

I hope this description of what I want makes sense. I have no idea how to do it, and no access to heavy machinery, but willing to buy a press or similar tool. If the answer is to buy a die and press, where can I have a die made? Sorry if this stuff is too basic, but searches on the internet give broad answers but nothing very specific that I've found. Thanks in advance!
Larry
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Old 02-20-2020, 09:23 PM
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I think you could do this, using a fly press.
You would need a tool to stamp out the disk. Blank.
Plus a tool to stamp out the cap.
Have a look on YouTube at fly presses. That should give you an idea, of what I’m talking about.
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Old 02-20-2020, 10:35 PM
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What is the diameter of the tube and hole sizes?
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Old 02-21-2020, 01:12 AM
steve.murphy steve.murphy is offline
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You might be able to use a Whitney hand punch to make the cap blanks.
And you might be able to spin them on a sutable mandrel with some basic tooling. How how many do you need? Can you rework the ones from india?
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Old 02-21-2020, 04:31 AM
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Look up metal spinning on youtube to get an idea of how it could be done also.
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Old 02-21-2020, 12:00 PM
astroracer astroracer is offline
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You will need to use a fully annealed brass to do any kind of draw forming. Most of what you can buy off the shelf will be 1/2 hard. You will not make anything pretty with it until it is annealed.
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Old 02-21-2020, 01:27 PM
Jaroslav Jaroslav is offline
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Larry. You must give a picture of the matter. In engineering, you have to be more precise. You can't even print it out of the air. After this step you can get maybe some good advices.
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Old 02-21-2020, 09:11 PM
fciron fciron is offline
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We need a bit more information. Are these caps 1/4" or 2"? Are you making dozens, hundreds, or thousands? How precise do the holes need to be, both in size and in position?

Then we might be able to give you some useful advice.
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Old 02-21-2020, 09:15 PM
lrubin28 lrubin28 is offline
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Quote:
Originally Posted by Joe Hartson View Post
What is the diameter of the tube and hole sizes?
The diameter of the tube is about 16mm or about 2/3 inch. The tube wall is only about .75mm. The hole in one cap is about 3mm. The hole in the other end cap is probably about 8mm or so.
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Old 02-21-2020, 09:18 PM
lrubin28 lrubin28 is offline
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Quote:
Originally Posted by steve.murphy View Post
You might be able to use a Whitney hand punch to make the cap blanks.
And you might be able to spin them on a sutable mandrel with some basic tooling. How how many do you need? Can you rework the ones from india?
Actually they are from Taiwan...how many - well a hundred of each would be ok, but ideally closer to 1000...I also was hoping that I could use round blanks that I've seen on the internet, so I wouldn't have to make those. But I don't know if a circle shape would work...
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