Re: 3-axis wire-bending? - Part 2

Brian,

Ok, we're talking small stuff. The benders I had in mind for retro
fitting are large.

It's kinda interesting how this list seems to know what I'm doing. I
was investigating wire bending by cnc just before this thread came
up...

Making the machine you have in mind should not be too difficult. The
design described below could be used for much heavier stock than you
require, and a simpler approach could meet your needs.

If you use a 5c spin indexer as a "head" you can have the clamping at
given length, and rotation, simply. (Use a solenoid/air cylinder to
lock and unlock the collet closer lever arm. Replace the index wheel
with a timing belt pulley, to a motor for rotation) Add a brake to
keep it from turning while bending.

A leadscrew driven "bar feeder" behind the head will give you
increments between bends.

A single "bending arm", either leadscrew driven, or air cylinder
powered and "stop-limited" by cnc will perform the bending duties.
This could also be done with a suitably positioned rotary table, like
the sherline 4" model.

The tricky part is if you need more than 90 degree bends, as the face
of the collet will get in the way. Same type of problem as with press
brakes for bending sheet metal. And "gentle" curves need either to be
done in the same sort of "linear segments" way that arcs are done in
some cnc, or by using different "bell" housings in front of the
collet.

Hope this helps.

Ballendo

P.S. Would you please send me offlist a pic of the type of railing
you hope to do?

P.P.S. One "wiring harness" thing that might be helpful, but won't be
cnc is a "nail board". This is simply a board with nails driven in
where the wire harness needs to turn/terminate. If you account for
springback, and use removeable pins, rather than nails, this may be a
quick way to make some rails... (if you pull your PB stock through a
3 or 4 pin "straightener" first, you could even use coil stock)

P.P.P.S. I'd like to see that organ factory myself...

--- In CAD_CAM_EDM_DRO@y..., "cornbeltroute" <cornbeltroute@a...>
wrote:

> Learned great stuff from each response to my question:
>
> Steve - I didn't realize the bending device has one pushrod and
> that the stock is rotated. Key info.
>
> Brian F. - I wish to manipulate .008 and similar diameters of
> phosphor bronze wire into scale model railroad details,
> particularly the long handrailings found on diesel locomotives.
> Anything in wire harnessing that could be used in my area?
>
> Bill - I will check into spring-making methods; I have seen some
> Web sites that deal with that, but I passed them by. I'll go back.
>
> Ballendo - Existing benders might be retrofitted, you say? Are
> there info resources you can point me toward?
>
> Chris L. - I'll search for tool show locations and show dates; this
> hadn't occurred to me. Do you recall the sponsor of the show you
> attended?
>
> Jan - Perhaps Austin Organ Co. will take pity on a poor Iowa boy
> who cannot travel so far to investigate. Just a tip or two where to
> look in the literature (if any should exist) would be well worth

the

> phone call.
>
> I send you all my gratitude,
>
> Brian Chapman