USC STEAM 2024: Plate Roller Punches and Dies

Scope of Our Mission

EAFab has a steel plate bender (press brake) with a limited set of dies to bend thin plates. Our group aimed to discover a cost-effective way to create a punch and die set for the 90-ton press brake to bend 1/2", 5/8", 3/4" steel up to 36" wide; calculate the dimensions needed to bend materials to 90 degrees safely; and determine materials that can safely handle bending force pressure. Additionally, we needed designs and cost analyses for 120-degree and 150-degree vee-dies that could be alternatives to EAFab’s plate roller.

Our Journey

Our journey began with the goal of designing press brake punch and die sets capable of bending ½” thick steel. Initially, we focused on creating a 90-degree die set, relying on Autodesk Inventor to draft our designs and considering the capabilities of Eafab’s manufacturing resources. After some research, it became clear that collaborating with machine shops would be necessary.

As we reached out to different machine shops, we learned that creating these custom dies was more complicated and expensive than we originally anticipated. Many companies denied our requests, but luckily, Riteway Brake Dies and Power Brake Dies offered to manufacture our custom die sets.

Things took an interesting turn when we were asked to design 120-degree and 150-degree dies. These new dies would be used to form cones with specific radii, adding a new layer of complexity to the project. As we explored how to design these new sets, we used tools like Inventor to calculate the necessary number of bends.

The cost was a major consideration throughout the process. While A36 mild steel was a feasible option for the punch and die set, we also explored using A572 Grade 50, A2, and D2 steel. This material came at a higher cost, which added to the overall price of the project.

Final Solution

As we moved closer to completing our designs, we realized the importance of clear communication and collaboration with industry experts. Their insights have been invaluable in shaping our approach to design and manufacturing. This journey has been a great learning opportunity, one that will certainly influence how we approach future engineering challenges.

USC STEAM Students who worked on the project: Caleb Guarino, Cadence Forney, and Jacob Higgs.