Need Introduction to Die Design
Need Introduction to Die Design
(OP)
Hey guys! First time poster here. Need some help in designing a forming die for a curved angle. Please see photos below.


This is a part used to splice two other sheet metal parts together. We intend to use a press brake to form this part, so we will need a set of dies and a flat pattern to make this efficient. We are not making a couple thousands of these, so that's why we don't want to use a roll former.
Currently I used a online sheet metal springbuck calculator to calculate the radius I need for the big curve on the die and the bend radius for the flange. Assuming that the neutral line in both bend directions are in the middle of the thickness of the sheet, I then draw arcs that are of the same length as the neutral lines, but of the radii I got from the calculators plus half of the sheet thickness. So I now have a die form that accounts for spring back. The die form is highlighted in the photos below.



I have three questions:
I'm very new to die design. In fact I have another 3 sets of dies I'm working on for some different parts that I had been working on for over an year now. Still not quite right. So help with whis particular one would be much appreciated. I've attached parasolids of the part and the die form if anyone wants to look at them in CAD.
https://files.engineering.com/getfile.aspx?folder=...
https://files.engineering.com/getfile.aspx?folder=...


This is a part used to splice two other sheet metal parts together. We intend to use a press brake to form this part, so we will need a set of dies and a flat pattern to make this efficient. We are not making a couple thousands of these, so that's why we don't want to use a roll former.
Currently I used a online sheet metal springbuck calculator to calculate the radius I need for the big curve on the die and the bend radius for the flange. Assuming that the neutral line in both bend directions are in the middle of the thickness of the sheet, I then draw arcs that are of the same length as the neutral lines, but of the radii I got from the calculators plus half of the sheet thickness. So I now have a die form that accounts for spring back. The die form is highlighted in the photos below.



I have three questions:
1) Am I roughly on the right track in designing this die form?
2) Due to the shape of this part, do I have to tighten the big curve more on the die form to account for the flange that will have holes on the finished part?
3) Can I add the holes onto the flat pattern without them deforming?
I'm very new to die design. In fact I have another 3 sets of dies I'm working on for some different parts that I had been working on for over an year now. Still not quite right. So help with whis particular one would be much appreciated. I've attached parasolids of the part and the die form if anyone wants to look at them in CAD.
https://files.engineering.com/getfile.aspx?folder=...
https://files.engineering.com/getfile.aspx?folder=...
RE: Need Introduction to Die Design
I would expect that a straight bend to start and then using a shrink die on the vertical flange can draw the part into the curve you want. Look for a power hammer to run the shrink die. https://www.youtube.com/watch?v=01RnS6G6t30 for example.
RE: Need Introduction to Die Design
RE: Need Introduction to Die Design
RE: Need Introduction to Die Design
RE: Need Introduction to Die Design
look at youtube for rubber type of dies, very simple and economical. also allow for setback and spring back.
google that. 150 parts a simple die will do
RE: Need Introduction to Die Design
https://www.youtube.com/shorts/FyQsVzw4JH0
https://www.youtube.com/shorts/FyQsVzw4JH0
https://www.youtube.com/watch?v=Ph84YSHwmHc
TygerDawg
Blue Technik LLC
Manufacturing Engineering Consulting
www.bluetechnik.com
RE: Need Introduction to Die Design
https://youtu.be/YjGBZhGwxwg
RE: Need Introduction to Die Design
RE: Need Introduction to Die Design
https://www.youtube.com/watch?v=eZ062_wUWCE
RE: Need Introduction to Die Design
The angle is to be made out of .050 thick 7075-O material and then heat treated to T62 after forming. The two ends of the part are parallel and measures 6.62 in length. The vertical flange is 0.7 tall where as the horizontal flange is 0.67 mostly, with the tab at 1.27. I think we will need a .030 wide profile tolerance on the horizontal flange since this does have to conform to the contour of the part this angle sits on pretty well.
We are familiar with rubber press form as we are using this process to form some frames in this project. The dies we are using are not of my design and the people who designed them are all gone. In fact the dies were really for hammer forming. We have also tried 3D printed tooling. We have printed some with ULTEM 9085. They don't fail ductile, so they get a bit explody when they fail.
The question I have is really how do I get a good starting point with the springbuck to avoid having to go through, let's say 5 iterations of the die.
RE: Need Introduction to Die Design
For example: https://www.researchgate.net/publication/273628175...
RE: Need Introduction to Die Design
RE: Need Introduction to Die Design
https://www.youtube.com/watch?v=xw5yEMsDxR8
RE: Need Introduction to Die Design
No - the video is not excellent from the title. It is not a hydroforming process and no liquid used to make the deformation
RE: Need Introduction to Die Design
while I agree it's not hydroforming it's a cheap on a budget method. who's got 1/2 million or more for a real hydroforming equipment.
RE: Need Introduction to Die Design
Sure thing agree that cheap and ok if enough the pressure of press. For sure everywhere the question about parts quantity - it is the method for single parts production, not hundreds or thousand. And you are correct - real hydroforming is incredible expensive machinery