Complex Sheet Metal Forming

[Jboy333]

Are there any sheet metal gurus out there that could recommend how to form a C-Channel type arm rest with the front two-thirds of the channel angled downward approximately 8 Degs. (Without any secondary welding operations.)

 

[MintJulep]

I think you'll need wrinkles.

 

[Jboy333]

Yeah, I figured that would be the case. Is there any good way to control wrinkling so that it looks natural? (i.e. use the wrinkles to form a design in the sides of the part)

 

[Christine74]

You might be able to use a shrinker:

http://www.skinpins.com/shrinkers-stretchers.html

-Christine

 

[Jboy333]

This is going to be a progressive die run part. We'll probably just have to experiment with a cheap and dirty die to see how bad the wrinkling is when we make the bend. Maybe we can control it and still make it look nice.

 

[dvd]

Don't know how thick the sheet metal is, what the dimensions of the part are, total quantity to be produced, etc. but it may be possible to form tubing and then trim to get the c-shape. Lasers are doing incredible trimming on tubes and other shapes these days. You might want to consider forming a closed section.

 

[berkshire]

Can you press your part from a flat plate then trim the flange. This way the forming would be in tension and you would eliminate the wrinkling.
B.E.

 

[Jboy333]

I'm kind of between a rock and a hard place. The problem is that, originally, the toolmakers said they could do it as a progressive die run part...now they're back pedaling. So we're held to the original cost that we quoted our customer and we can't add any labor beyond the die run part. (i.e. no welding or secondary operations.)

"Berkshire" I may be able to do a drawing operation on the metal and trim the edges....it will probably end up being a secondary operation (or at least the part would need to be turned in the die).....as long as it's cheaper than welding, it might be worth a shot.

Equally difficult will be trying to convince SolidEdge to make a sheetmetal part that looks like this. Thank goodness for surfacing.

 

[MadMango]

Without knowing all the details, have you investigated roll forming these channels?

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