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  #41  
Old 10-02-2016, 12:21 PM
Futterama Futterama is offline
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So I finished the steel forming plates. Radius is about the same as on the wood plate, and it seems to work very well. I sanded the radius with 240 grit and it's very smooth.

A few things needed before I'm finish. I need a backing plate with an oversize hole for the half sphere to protrude into, the mark on the part is from inaccurate placement on the plates on the hydraulic press. It would also be nice to have a thick plate on top of the upper plate, with a hole that will fit the punch and keep it vertical and centered before pressing. And a stop mark is also needed, I over-pressed by about 10mm.

The blank was 90mm. I think I can go smaller, I'll check it out when the other stuff is done.

Boring the holes to size in the steel plates:
DSCF4228.jpg

Lower plate radius:
DSCF4237.jpg

90mm blank and 0.5mm spacers:
DSCF4229.jpg

Plates assembled with blank in place:
DSCF4230.jpg

On the press. See how I could use a guide for the punch and the black plates on the press has a V-cut in them, giving a hole, but the sphere hit on edge during forming:
DSCF4231.jpg

Sphere protruding from bottom plate after pressing:
DSCF4232.jpg

Got the correct shape from the punch:
DSCF4234.jpg

See the mark on the left - it made the part sit tightly on the punch:
DSCF4235.jpg

Finished part with a bit of over-pressing but it looks mighty fine to me:
DSCF4236.jpg
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  #42  
Old 10-02-2016, 02:06 PM
Ken Hosford Ken Hosford is offline
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very awesome
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  #43  
Old 10-02-2016, 02:59 PM
billfunk29 billfunk29 is offline
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Default mission accomplished

Very well done. I love the evolution.
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  #44  
Old 10-02-2016, 03:13 PM
galooph galooph is offline
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Fantastic work there, Martin! Thanks for posting the pictures
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  #45  
Old 10-02-2016, 03:27 PM
Futterama Futterama is offline
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Thanks, and thank you all for your help. I'm on my way to bed now, and it's work day tomorrow, so I can finish this tomorrow evening, and start making some spheres and I'll post some pictures for you of that also
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  #46  
Old 10-02-2016, 06:51 PM
zekeymonkey zekeymonkey is offline
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Thanks for documenting your process! It's very helpful.
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  #47  
Old 10-04-2016, 09:50 PM
leoitch leoitch is offline
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Quote:
Originally Posted by Charlie Myres View Post
It is not as scary as it sounds.

A plastic apron and gloves and some eye protection is wise, but I have been doing it for over 30 years without any issues.

The beauty of the method is that it saves a lot of mechanical cleaning.

I like the progress you have made so far!

Cheers Charlie
Ha ha... haven't heard that "done it that way for umpteenth years" reply for awhile...
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  #48  
Old 10-05-2016, 02:44 PM
Futterama Futterama is offline
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It's done!

Lower protrusion plate to the left, punch guide from hard wood mounted on the upper steel plate to the right:
DSCF4238.jpg

Punch guide mounting screws:
DSCF4246.jpg

Setup in the hydraulic press:
DSCF4241.jpg

70mm steel blank turned into a half sphere:
DSCF4247.jpg

Video of the press gauge while making the above half sphere (it's a cheap press but it works):
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  #49  
Old 10-05-2016, 03:53 PM
crystallographic crystallographic is offline
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Quote:
Originally Posted by Futterama View Post
It's done!

Lower protrusion plate to the left, punch guide from hard wood mounted on the upper steel plate to the right:
Attachment 39027

Punch guide mounting screws:
Attachment 39029

Setup in the hydraulic press:
Attachment 39028

70mm steel blank turned into a half sphere:
Attachment 39030

Video of the press gauge while making the above half sphere (it's a cheap press but it works):
Clean press job - grain print is normal with soft woods - rock maple is best of the woods. Phenolic, aluminum, etc.
No lube needed.
O-ring and a pressure washer - but reloading might take more time ...
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  #50  
Old 10-06-2016, 01:38 AM
Futterama Futterama is offline
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Yeah, the grain print was expected, I got a lot of different mahogany pieces with different hardness and density and that one was not good. The first punch was real good in terms of wood quality, but I just forgot that the sanding after turning, would decrease diameter so it got just a tiny bit too small which is showing in the final part. I do have a limited amount of both nylon, aluminium and steel to make the punch from, but I would rather save those pieces to make a part that can't be replaced with wood. I have more wood to try out before I'm 100% satisfied. Maybe I'll even upgrade the ball turning tool post I made along the way.
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