Reducing 20mm x 20mm x 1.6mm Square Tubing

[RoganRa]

Hey Guys,

I am currently working on a personal project for myself, please note I am not an engineer just a person with a big shed with tools.

I am trying to create a swage machine, which will reduce 20mm x 20mm x 1.6mm RHS so it can fit into another unaltered piece and hold. Video Link

I am quite handy with hydraulics but just would require some direction on how I can manufacture a die to accomplish this, I have attached a crude drawing on what I believe the formed material would look like.

My main question is how would I calculate the size of the reduced material, work out the force required and design a die.

Any direction will be quite helpful

 

[Achy47]

Hello,

It's great to see someone taking on a personal project like this! Creating a swage machine can definitely be a challenging but rewarding task.

First, let's talk about the process of swaging. Swaging is a method of forming metal by using a die to compress the material and reduce its size. The size of the reduced material will depend on the design of the die and the amount of force applied.

To calculate the size of the reduced material, you will need to know the initial dimensions of the material and the desired final dimensions. In your case, you mentioned reducing a 20mm x 20mm x 1.6mm RHS. Let's say you want to reduce it to 15mm x 15mm x 1.2mm. Using these values, you can calculate the percentage reduction in each dimension (25% reduction in length and width, and 25% reduction in thickness).

Next, you will need to determine the amount of force required to achieve this reduction. This will depend on the type of material you are working with and its properties. You can use a formula such as the Barlow's formula to calculate the required force. However, keep in mind that this is an approximation and the actual force required may vary depending on factors such as friction and the accuracy of your machine.

As for designing the die, you will need to consider the material you are working with, the shape and size of the die, and the desired final shape of the reduced material. It's important to keep in mind that the die needs to be strong enough to withstand the force applied during the swaging process. You may also want to consider using a lubricant to reduce friction and make the swaging process smoother.

I hope this information helps guide you in your project. If you have any further questions or need more specific guidance, please don't hesitate to ask. Best of luck with your swage machine!