As a hobbyist, how to go from a metal sheet to a metal box (1 hollow side) by using (set of) dies only?
All videos I watched involved :
bending 1 side at 90° then
- A) cut twice and discard a square portion of size : height * height
- B) cut along the height of your box
... repeat 3 times ...
fold the 4 sides
If you chose A then weld the 4 sides at the corner.
If you chose B then bend the sides along next sides then weld.
I want to avoid welding, could those operations be replaced by a press against a die (and cut)?
I think it would have been possible maybe using heating and high pressure but I found nothing.
Anyways I don't have access to heating and high pressure (max 20T), so I think about making it in multiple steps (and dies).
Instead of going the full 90° in one go, I will bend each side by 10° at each time.
The problem is : how to deal with the extra-material at the corners?
With each step, I think it will make more an more pleats at the corners.
Any idea on how to proceed?
Should I force the corner to bend inwards at step N, then outwards at step N+1 (and repeat)?
Should I use a scallop shell shape for the corner?
Should I make the side straight and treat the corner as a special case?
Or, on the contrary, should I try to distribute all the extramaterial all along the side?
Final goal would be to turned a 330mm x 240mm x 1.5mm aluminium sheet into a 310mm x 230mm x 15mm box, using a 20T harbor freight press.
Any idea or suggestion are welcomed.