[Bigtoy302]

I have been planning this for a long time. I just have not had the time or money to start on the project. I have changed my mind on the design many times. I think I finally have it down the way I want. for the most part it is going to look like any other C-frame style brakes with a few improvements.

Specs:

48" wide
58 tons
6" inches of ram travel
2 axis servo backgage
Mach 3 control with a Dynomotion motion controller for the control of the +-10V analog Parker Proportional valve.
5hp, 2.5GPM pump.

I will be building the entire thing including the cylinders. ( That's what I do for a living.)

I am going to start of with building the 2 cylinders first. The cylinder are 5" bore, 3" rod, and 6" stroke.

Pile of Parts



Rough machining of the base heads. I will finish machine them after I weld them to the barrel.


Pistons are next.


Checking the threads with a Go gauge.



Rod heads next.



Piston rods next




Weld prep on the barrel.

[ViperTX]

How about including some guidance on bore versus piston size.....whatever you're using for the ring material, etc. It would help those of us that maybe thing of building our own hydraulic piston assembly.

Thanks,
Paul

[Bigtoy302]

How about including some guidance on bore versus piston size.....whatever you're using for the ring material, etc. It would help those of us that maybe thing of building our own hydraulic piston assembly.

Thanks,
Paul

On this design the piston is .018 under bore size because I am using a 1" composite wear band on the piston. The piston never touches the bore so the major is just for clearance. I am using regular lip seals also on the piston, no actual steel rings. The wear band to bore only has about .001-.002 per side clearance For oil.

[BobWarfield]

Very cool!

And the material you're using for each of the components is?

Cheers,

BW

[Bigtoy302]

Very cool!

And the material you're using for each of the components is?

Cheers,

BW

Barrel: ST52.3 DOM
Piston and rod head: Nodular Iron. I will look at the grade monday when I go back to work.
Piston rod: IHCP
Base head: A36

[Bigtoy302]

I finally got some time after work tonight to work on the cylinders again. I got the ports welded on and the Id threaded. I also ordered 2650 pounds of steel for the frame. I should have it next week.

[Steve_Watkins]

Very nice turning work I am watching with intrest!

[Bigtoy302]

I got the caps welded on the barrels and milled out a slot then drilled a few bolt holes through. I also got the wrench flats milled on the rods.







I then went and picked up the flame cuts. I had a buddy that works at a steel place get and cut me out a bunch of 1.25" HR plate.

[Steve_Watkins]

WOW, How much did that plate weigh?

[DanOSB]

from looking at that size aprox 3000 pounds

am i correct?

looking really good so far

[Bigtoy302]

The 4 pieces where about 2600lbs.

[lowpull]

How about a quick sketch of what your completed press will look like. This is a very interesting thread. Thanks for sharing.

[multiplex]

awesome project! can't wait to see how you control the valve with mach.

we just completed a 40 ton, 2 axis hydraulic press at work using bosch / rexroth controls. would love to see how to do these types of things on a 'budget'.

[Bigtoy302]

Today I started milling up the frame for the brake. I got the sides almost done and started on the upper and lower beams.



Upper beam


Lower beam

[MyCattMaxx]

Nice home shop equipment...LOL.

Looking good.

[Bigtoy302]

I got the cylinders assembled and tested.


Did a little bit more work to the lower beam.


More work on the upper beam.


Cylinder test fit.

[BobWarfield]

Fast progress!

Best,

BW

[Bigtoy302]

Finished drilling all the holes in the side plates.


Finished tapping the last hole in the upper beam.


Turned some 4340 spuds to mount the cylinders to the beam.

[Bigtoy302]

I did not have to work today, so I went in and made the upper and lower die holders. Hopefully tomorrow I can start assembling the whole thing.

[Bigtoy302]

So, today I got it mostly assembled. I had to use some good old redneck engineering to put it all together but it all worked out great. I had my dad help me out with the tractor work.