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Andrews Web Site
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Date: 11-25-2011
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Number of Hours: 5.00
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Manual Reference:
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Brief Description: Flanging Dies
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For a change of pace, I started working on the flanging dies for the wing ribs. I have used Bob sticks and rotary flanging tools in the past, but I do not like the potato chip effect that they have on the resulting part. That is, if the flange is not stretched while forming, it will make the final part oil can quite a bit. So....flanging dies are the answer. Sonex makes dies of 3" and 4" diameter so I ordered those ($25 each). But that leaves many holes of different diameters that need flanging. Looking at the plans, there are all kinds of weird off diameter holes. I decided that rounding holes to the nearest 1/2 inch would be close enough. Therefore, I will need flanging dies in the following diameters. 2.0", 2.5", 3.0", 3.5", 4.0", 4.5". After buying the Sonex dies, that leaves me 4 dies to make.
Image 1 shows the process of cutting the bevel on the plastic forming die. I used plastic cutting board for the donor material. My thinking is that the plastic will be gentle on the aluminum during forming, and will not degade much after making several flanges. The belt sander was set up with a pivot oriented to give a 37 deg chamfer. In searching the web, I read that 37 degrees yeilds a 30 degree flange after springback. (by the way, the pivot tool falls into a catigory I hate...that is,...making a tool, to make a tool, to make a part...)
Image 2 shows the process of fly cutting one of the many disks needed for the dies. I used the high quality tight ply version of wood for this.
Image 3 shows parts that will be needed for a typical die. Note: there is a 1/8 ring at the base of the plastic die made of wanscot. This was done so that the plastic would not be a feather edge right were the forming takes place.
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Beveling the plastic form.
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Flycutting a disk
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Parts that will be used for the dies
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