SPECIAL DIES WITH V OF 300 m/m

METALMAQ manufactures two special dies with a “vee” of 300 m/m at 70º, for a Bystronic-Beyeler press brake of 1000 Ton and 6 meters length. They have been built for a French customer in the quarry machinery construction sector.

THE ISSUE OF THE PIECE

Our customer wanted to manufacture new excavator shovels with HARDOX 450 material, which is a highly resistant, anti-wear steel material, ideal for the job he wanted to do.

But it should be borne in mind that the HARDOX 450 material offers a lot of resistance and it takes a lot of tonnage to be able to bend it, this is NOT the problem of our client, since they have a Bystronic-Beyeler press brake of 1000 Tons and 6 meters length. According to our calculations, to bend HARDOX 450 with a thickness of 20 m/m, it takes about 330 Tons per meter (see HARDOX Material table), since our customer’s piece is 2 meters, it will take 660 Tons to be able to bend the piece without difficulty.

Another characteristic of the HARDOX 450 is its elastic return, which in thickness of 20 m/m can be as high as 20º. As our client wanted to bend a part at 90º, the dies have been designed with a 70º angle, to compensate for this return and give it a little more margin of safety.

THE DESIGN OF THE DIES

As we mentioned earlier, the characteristics of the dies were clear;

– Lower mooring type Beyeler-Bystronic, to be able to adapt it without problems to the press brake of our customer.

– V with a dimension of 300 m/m (defined by the HARDOX Material tables)

– Die angle at 70º to compensate the flexing of the HARDOX 450 material

Given these points, this is the design that was presented to the customer.

Apart from the points mentioned, we can also see that at the entrance of the V it has some spigots, these are made so that the friction of the sheet is only done at these points, thus reducing friction and reducing the bending tonnage.

A fairly large radius of entry is also observed in the V, which is 30 m/m and this reduces the marks caused in the folding operation.

THE MANUFACTURING

The dies have been made of C-50 steel tempered in the work areas, to avoid wear and extend their useful life, and were lastly rectified.

As can be seen in the images below, the dies were manufactured with threaded holes on the sides, to facilitate the assembly operation on the press brake and thus contribute to safety in changing dies.

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RESULT

The result is two incredibly large dies made each in one meter length, weighing 700 kg for each 1 meter die and a total of 1.400 kg between the two dies!!.

In the photo below the CEO of Metalmaq is seen with the manufactured dies before being sent and the dimensions of these can be verified.