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  1. #31
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Powered workshop press build

    Finally got a chance to get to the steel supplier and get some flat for the ram mount.
    Hacked out a rough hole with oxy-lpg torch and bored it to take the cylinder.



    For those who think carbide can’t ever handle an interrupted cut, this was a rough hacked flame cut hole. I gave the insert a touch up on the grinder when the bore was about 90% cleaned up as it was getting a bit dull. It already had the ground face and edges - I was just dressing them.




    Steve

  2. #32
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,438

    Default

    Hi Steve,

    I like how you have ground the insert, very much like I would have ground a HSS tool bit.
    Best Regards:
    Baron J.

  3. #33
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    Thanks John.
    I can’t take the credit for the grind or the boring bar. They came with the boring head when I bought it off another member here.
    It definitely works well and has been very durable. The flame cut edge of this hole would have been very hard on a HSS tool.

    Steve

  4. #34
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Powered workshop press build

    Welded the channel to the lower plate, and machined the bottom side of the upper mount blocks so they sit snugly on the top of the ram with the pin fitted.
    Here’s a photo with the mount plates 90deg from where they will end up.




    What’s now obvious is the fluid fittings need to be at 90 degrees to the mount blocks as there wont be enough clearance between the fittings and the side plates as is.
    I was thinking about blanking the existing ones and welding on some new ones in the right place, then realized the much easier fix is to cut off the cylinder mount lug, rotate it 90 deg and weld it back on!

    Steve

  5. #35
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,438

    Default

    Hi Steve,

    Can you not just use a 90 degree elbow on them and turn the top cylinder one through 180 degrees ?
    That would get you away from the side plates without a cutting / welding job.
    Best Regards:
    Baron J.

  6. #36
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Powered workshop press build

    Unfortunately not John.
    Here’s a photo of some 16mm thick flat where the side plate will be. About 25mm clearance, and the bosses on the cylinder protrude about 20mm




    Turned out to be an easy fix moving the attachment lug.

    Couple of minutes in the bandsaw, quick cleanup with the grinder including beveling the lower edges for welding then glued it back on. Was literally done in under 30 mins








    Steve

  7. #37
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,438

    Default

    Hi Steve

    Thanks for the picture, I didn't quite understand how little space you had there, now I do !

    It is coming along nicely. A press for me would be a nice thing to have around. At the moment any bending I need is done with the vise and a hammer.
    Best Regards:
    Baron J.

  8. #38
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Powered workshop press build

    Was thinking that things were progressing quite well with the different projects I've got on the go, and that I hadn't had visit from the stuff-up fairies for a few days.
    Buggers must have sneaked in while I was asleep!!

    So... I'd cut the PFC for the head to length with about 5mm gap for clearance between the upper beams. All good.
    But I hadn't allowed for the fact that it was going to get welded to the 20mm plate along that edge. Not so good.
    And then I welded it....and it didn't fit. Not good at all

    My first thought was to just mill the weld and about 8mm off each end and re-weld, but although that would allow it to fit between the beams it wasn't going to give any sort of positive location of the head fore-aft since the weld would be tapered and there's a slight radius on the outside corners of the channel.
    Came up with this solution - mill the existing weld back to the channel face, and cut the center edge back to allow for re-welding there where it won't interfere with the beams.
    I'm a bit concerned about having cut the weld back at the high stress point between the channel flange and the lower plate. If I had a dovetail cutter or similar that would have reached in there and undercut the corner I'd have done that so it could be re-welded across the end. Thinking I might have to dig it out with the grinder just at the corner under the vertical flange and weld it.




    Also added a cutout to allow the cylinder bosses to pass through the bottom plate as I realised that the mounting lug height was bigger than the clearance between the lower boss and plate, so if I'd welded the side and upper mount plates on as it was the cylinder would be captive!




    Mocked up with the side and upper mount plates.




    Steve

  9. #39
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
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    2,651

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    Nice when a plan comes together.
    Partially welded up and can still get the cylinder out



    Started on the support trolley that will ride on top of the upper beams and and carry the ram mount.
    Some 2” cam rollers, and a bit of channel which I’ll weld into a rectangular frame. Made some threaded blocks for the roller shafts to screw into.
    Have a couple of ideas on how to attach it to the ram mount but haven’t made a final decision. Will need to have a bolted joint somewhere to allow it to be removed.




    Steve

  10. #40
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,438

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    Hi Steve,

    You seem to be progressing very nicely with your press build.

    I was at one of the engineering firms that I visit on Monday, they have an "Amarda" 100 ton CNC press brake. The amount of tooling that they have is enormous. I'm told that this thing can fold 6 mm plate and hold work ten feet long. They were making steel tool boxes for flat back wagons whilst I was there. An impressive machine.
    Best Regards:
    Baron J.

  11. #41
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    Thanks John.

    Yes, those big brake presses are impressive, and so is the price tag on the tooling!

    Got some more done today.

    Blocks for the cam followers welded in, some clamp bolts fitted to the corners of the carriage and welded it up.







    Spent about half an hour with a bottle jack and blocks of wood raising the ram support up to the top beams, through the carriage.





    I’ve decided to just use some 8.8 grade M16 bolts to bolt the ram mount to the carriage - 2 bolts either side, one above the other.
    Shear strength of the threaded section of each bolt is about 7T, and at most I’ll only get about 20T on the return stroke of the ram if I ever use it for pulling.
    Generally the bolts will only have to support the weight of the ram and mount, plus lift the table which is maybe 100kg.

    Steve

  12. #42
    Join Date
    Apr 2012
    Location
    Healesville
    Posts
    2,129

    Default

    It's imPRESSive

  13. #43
    Join Date
    Nov 2017
    Location
    Geelong, Australia
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    Painted the head area earlier in the week, and got the new cylinder seals installed and put it back together.
    Wasn’t planning to paint the cylinder when I did the head but ended up with some leftover paint so painted most of it intending to finish it after the gland end was back on.
    As you can see that never happened!

    Today I got a chance to hoist the cylinder into the head. Made a washer for one end of the pin and welded that on, and made a retaining collar with locking bolt for the other.






    Getting close to hydraulics time

    Steve

  14. #44
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
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    Hi Steve, Guys,

    Good job that you have a forklift ! You’ll never shift it otherwise. I wonder just how much it does weigh.
    Best Regards:
    Baron J.

  15. #45
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    Nov 2017
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    Geelong, Australia
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    Default

    Quote Originally Posted by BaronJ View Post
    Hi Steve, Guys,

    Good job that you have a forklift ! You’ll never shift it otherwise. I wonder just how much it does weigh.
    It will likely never feel the forklift tynes unless I'm dead and my daughters are cleaning up!
    The pallet jack works well for moving it though.

    Rough "back of an envelope" calc is just over 500kg...
    200kg of 250PFC
    100kg of 100x20 flat
    30kg of SHS for the base
    30kg of 150PFC for the head carriage
    50kg for the head itself
    50kg for the ram
    50kg for the misc plates/pins

    Steve

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