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Thread: 70mm discs
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1st Apr 2017, 08:32 PM #1Novice
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70mm discs
Hi,
I require about 200 X 70mm X 0.5mm metal discs in mild steel, gal or zinc.
I usually cut the required amount by hand with a pair of tin snips but that is getting a bit hard on my hands now. Also it is very hard to cut a near perfect circle.
I have tried all local and nearby engineering shops but they could not help me.
Hopefully someone out there can direct me to the right place.
I can be a little flexible on the diameter size by a few millimetres
Bill13.
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1st Apr 2017, 09:03 PM #2Most Valued Member
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I would think that laser cutting would 100% be the way to go?
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1st Apr 2017, 09:10 PM #3Diamond Member
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There would have to be several companies in Brisbane that offer contract laser cutting services, and/or plasma cutting services. You could do it in house with a cheap plasma and a template.
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1st Apr 2017, 09:59 PM #4Most Valued Member
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There's a guy that gets stuff zinc plated where I work who has Water Jet Cutter. How much you willing to pay per disc? If I see him soon, I can ask a price.
Nev.
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2nd Apr 2017, 12:25 AM #5
The low cost end for a job like that would possibly be a punch and die set - given that we are talking about 0.5mm sheetmetal. You didn't say if they were to have a centre hole or not, by the way. If you have access to a hydraulic press, to make 200 off them would not take too long and the tool would not be too expensive either, especially if this is likely to be a repeat job down the track....
The tooling would look something like this: http://sasnak.biz/images/tools/Hydra...h/IMG_0071.jpg
You may even be able to make it yourself on a lather from suitable tool steel, then harden and temper.
The tricky bit is locating the punch and the die accurately so all you have to do is slide the sheet metal strip in between and hit the go button or lever on the press....Cheers, Joe
retired - less energy, more time to contemplate projects and more shed time....
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2nd Apr 2017, 08:08 PM #6Novice
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Thanks all for your helpful replies. Very much appreciated for your individual advise.
I was told that there would be to much clean up of the disc when using Plasma cutting, so dismissed that way to go.
jhovel, buying a punch and die set along with a hydraulic press would be to expensive for me for a limited number of the discs.
Laser or water jet cutting seems the way to get the job done.
SurfingNev, I will take up your offer and if you can see ol mate and ask him to give me a ring on my mobile 0438622097 would be much appreciated.
Thanks again for your replies,
Bill
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2nd Apr 2017, 09:23 PM #7Most Valued Member
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Bill
Have sent his contact details via PM. Better to remove you mobile number from here I think and only give it out in a PM.Nev.
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7th Apr 2017, 08:28 PM #8Banned
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Hi,
I make pancake dies, which are good for short runs because of their cost (much lower than conventional dies sets) .
You'd need a press with smooth plates about 5" x 5" minimum, and maybe 6 tons minimum. I'm in the U.S. , so you may want to find a press to avoid overseas shipping, but I also run parts for people. The dies are hand cut ; I'm excellent at it, but I'm not a machine. The parts would have a small leftover tang you'd need to sand/grind off, but otherwise come out clean . A die that size would be about $125 or so, so it may not be worth it for the small run of 200, compared to laser cutting. here's what they look like :
This is one for a 3" disc in maybe 3/16" Al. I think I had it cut on a wire EDM , but I saw
99.9% of them with a contraption that accepts and holds a jewelers saw . Shoot me a pm if interested.
Dar
3inchcircledie-thick002.jpg
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10th Apr 2017, 01:12 PM #9Most Valued Member
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I think I've seen something like that used by jewellers? What thickness of steel can be punched with something like that? I was under the impression they were mainly for thinner materials.
When the question came up I looked up the tonnage requirement to stamp that with a conventional punch and die, and seem to recall it was about 16 tonne. That's just from vague memory, so could be way off. I thought it would be beyond the capabilities of something like this however so I'm keen to see and hear of some examples. It would be a very handy way to do low-run stampings that's for sure.
Edit: Indeed it seems like you guys went on to discuss the same process here //metalworkforums.com/f65/t2003...cs#post1919438 I missed the last part of the thread
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10th Apr 2017, 07:54 PM #10Banned
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Hi,
Yes, the process in it's current form was invented be a jeweler , and presented/sold to the jewelry industry by Rio Grande (Jewelry) Supply
in the mid 1980's. I've refined and perfected it over the years since then , mostly because it's been my career since then : custom dies
and parts using this process, as I'm not a machinist , and don't make conventional dies. My background is jewelry , but once I started doing work for other people, the odd kinds of things I was being sent forced me to expand the capabilities.
The dies will work on whatever ga. metal they need to, as long as the die is thick enough (for thick metals) , and tight enough (for thin metals).
As far as mild steel . I've made them for 3" discs cutting 3/16" Damascus steel (they said the die worked fine, but I don't know for how long), 1/8" mild steel for spur rowls , some others for jewelry made in 1mm - 1.5mm mild steel, and probably many I don't remember specifically
Most of the large runs I myself have done have been in 18 ga (1mm) copper , or thinner, and these dies will cut that for many thousands of times, in the tens , and possibly hundreds of thousands. I know one company that was getting tens of thousands in mild steel about .5mm , and that was using a punch press , which is not ideal because of the high impact.
With .5mm x 70mm discs, I'd expect it to take less than 10 tons to cut , but maybe not much less . I don't do the numbers , but go by experience. Right now I'm working on a different setup for my 50 ton press, cutting and embossing ornamental pieces about 6" x 4" in 30 ga. rusted steel . They only take a few tons to cut, but 30-50 to emboss . In that other thread, you may have found the link to my site , which has many examples of what the process can do .
Dar
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