If you cut a hole in the base plate under the 'R' you could have a bar run down to a foot pedal. With a little extra geometry, that could also power the compression for the bend. Much like a shrinker/stretcher in automotive body work.
Very cool! Thank you for sharing this. My experience with hydro-forming is that, yes, different thicknesses will definitely have different springback angles. For a given alloy and heat-treat, thinner metal is springier and needs to be over-bent more, while thicker metal is less springy and will come closer to just staying where you bent it. This makes sense if you think about it; When you bend something thick, the stresses that you put on the outer and inner surfaces are much higher (i.e. more yielding will happen) than when you bent something thin, if you think of it in terms of "beam height". Anyways... I'm a huge fan (currently also developing my own ultralight), please keep up the great work!
Oh, and: The bend radius will also impact the springback. Again, think about stresses in beam-bending: A sharper radius will cause higher stresses and more yielding (so, less springback) than a wider radius (which would therefore need to be over-bent more).
I wonder if you stuck something like a ring sizing mandrel on the outside or " feeder" side, it would take a flat slat and begin the curve on a consistent basis.
What you’ve done creating the initial form is excellent but you need to be aware of a tool known as a “shrinker”. Also, the proper hammer and dolly technique can accomplish the same thing but is more of an art whereas the shrinker is a simple sheet metal tool.
Great idea and video! Would it be possible to account for the extra 8-11° in the original press form?
Thank you for all your videos you’re cool
If you cut a hole in the base plate under the 'R' you could have a bar run down to a foot pedal. With a little extra geometry, that could also power the compression for the bend. Much like a shrinker/stretcher in automotive body work.
Very cool! Thank you for sharing this.
My experience with hydro-forming is that, yes, different thicknesses will definitely have different springback angles. For a given alloy and heat-treat, thinner metal is springier and needs to be over-bent more, while thicker metal is less springy and will come closer to just staying where you bent it. This makes sense if you think about it; When you bend something thick, the stresses that you put on the outer and inner surfaces are much higher (i.e. more yielding will happen) than when you bent something thin, if you think of it in terms of "beam height".
Anyways... I'm a huge fan (currently also developing my own ultralight), please keep up the great work!
Oh, and: The bend radius will also impact the springback. Again, think about stresses in beam-bending: A sharper radius will cause higher stresses and more yielding (so, less springback) than a wider radius (which would therefore need to be over-bent more).
I wonder if you stuck something like a ring sizing mandrel on the outside or " feeder" side, it would take a flat slat and begin the curve on a consistent basis.
What you’ve done creating the initial form is excellent but you need to be aware of a tool known as a “shrinker”. Also, the proper hammer and dolly technique can accomplish the same thing but is more of an art whereas the shrinker is a simple sheet metal tool.