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  #11  
Old 05-28-2023, 09:48 AM
daveb daveb is offline
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I would be very interested in seeing the process
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  #12  
Old 05-28-2023, 10:31 AM
Jaroslav Jaroslav is offline
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Guys, I'm glad you're interested. I have a minimum of secrets and I'm glad if it helps someone. Of course I am very well equipped. But it took me a lot of work to learn how to use this great technique. As you know, I don't like "American Tooth" and I've never been in a situation where it would be appropriate to use it. But of course it is a matter of opinion and a possible approach to another technology. I've been lucky so far. Please don't take this as dogma.
Take the basic principles from this product.
For me, it is always important not to disturb the structure of the material too much during basic shaping. This is very important at the beginning of the process. If you follow the rule that the material remains soft, you can make big shape changes at the end.
This is also the this case. The customer wanted major shape changes at the end, but it wasn't a big problem.
I will describe the procedure in several steps and try to explain the details. It could be instructive for beginners.
But I use the great power of the machines, which allows me to work very sensitively. The great power of the machine is meant so that the machine does not bend and takes exactly the force you need for shaping. The power is stable. You can focus on the result. I used AL sheet 1.5mm. Eckold KF 460, large and small bead roller with electronic control (they rotate 0-80 rpm - I used approx. 4 rpm) and my very strong EW.
For this part, I knew in advance what steps I would use and I knew exactly what I was doing.
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  #13  
Old 05-28-2023, 10:36 AM
Jaroslav Jaroslav is offline
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Default Preparation of shape template and material.

Preparation of shape template and material. Determining the shape of the fibers. Places where threads need to be edited.
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  #14  
Old 05-28-2023, 10:47 AM
Jaroslav Jaroslav is offline
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Default Shaping the part.

Shaping the part.
The material is aluminum sheet 1.5 mm semi-hard. For the second shaping, when the radii were reduced, I unpacked the 50-year-old new tool. Of course, the hardened central part of the instrument was falling apart again. I have used these aviation tools to their limit. I used steel tools for the smaller diameter. Basic shaping took place without cracks in the material.
I marked the bend edge with a bead roller with a polyurethane wheel.
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  #15  
Old 05-28-2023, 10:53 AM
Jaroslav Jaroslav is offline
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Default Marking and cutting the part.

Marking and cutting the part.
I measured an angle of about 10 degrees, supported the part at 3 points and marked a line on the board. I marked the second line for the border.
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  #16  
Old 05-28-2023, 11:03 AM
Jaroslav Jaroslav is offline
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Default Edge bending.

Edge bending.
Mark carefully in bead roller over polyurethane wheel. Careful leaning over the next few laps. Spreading the edge with jaws.
The material is compacted in this place, so you need to work carefully. But there was no problem. I spread the edge with hand jaws and a hammer over the edge of the table. Some smoothing of the shape in EW.
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  #17  
Old 05-28-2023, 11:15 AM
Jaroslav Jaroslav is offline
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Default Final adjustments.

Final adjustments.
The customer wanted to modify the shape. Smaller radius, perhaps flattened on one side. Lateral cone shape and straight. Pretty major shape changes.
At this point I could use a small hand hammer with jaws, some shape gently in Eckold and EW. And the modifications were successful according to his wishes. The material had enough thickness and was still soft. That's what I'm emphasizing. I changed the overall design very easily.
It remains to cut out the ribs.
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  #18  
Old 05-28-2023, 11:22 AM
Jaroslav Jaroslav is offline
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Default Ribs.

Ribs.
I made a simple tool for Pullmax.
He cut grooves with a sander and tried to shape. The lower rib already has an approximate shape. The customer doesn't know if he wants 5 or 4 ribs... I'll wait for that.
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It was easier to make than to describe the procedure.....
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  #19  
Old 05-28-2023, 11:48 AM
Brzeczyszczykiewicz Brzeczyszczykiewicz is offline
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Thanks for the description.
Did you do the rib at once or in several passes?
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  #20  
Old 05-28-2023, 12:51 PM
Jaroslav Jaroslav is offline
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I added gradually. I rested the edge against the edge of the tool as a guide.
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