good video on making small connectors? (complex spring forming) - Page 1
Forum section: electronics / general

author: coppercone2
author_rank: Super Contributor
timestamp: March 24, 2025, 06:27:54 am
content: \For tiny leaf springs for high density connectors or just whatever else, is there a good video that shows the forming operation and dies and stuff that a connector manufacturer would use to turn stamped sheet brass into the correct geometry?

author: thm_w
author_rank: Super Contributor
timestamp: March 24, 2025, 10:13:45 pm
content: I think small and big is the same process

author: coppercone2
author_rank: Super Contributor
timestamp: March 24, 2025, 10:17:40 pm
content: the last one is good the other are just advertisements that I was getting sick ofthat one gives you an idea how much work per operation

author: coppercone2
author_rank: Super Contributor
timestamp: March 24, 2025, 10:23:31 pm
content: but he does not show the forming tools. I wanted to see those the most. Because for the cutting part, you can probobly etch it into shape, its just slow. But you can't get around the bending.There must be another plate of stuff that has the interesting geometry that makes it fold and curl and stuff. I wanna see that one. It must sort of look like the jaws of a crimp tool. It looks like its a 5+stage operation. I assume thats how its folded?I was wondering before if maybe they bend it around a pin or something like that. Like inserting forming tools sideways (reciprocating machine parts).I.e. Is it all done from up to down, or do they have structures that are inserted sideways? Like if you have your cutting, then from the side you put a anvil, and then form it over it. It does not look like that machine has anything moving other then up/down but I am not sure if there is a little contraption in there thats positioning a roller or something over the strip before it gets bent.Like I thought maybe you put a mandrel there and roll a roller over it to conform it around the mandrel. ?? Is that another technique? Perhaps a low production volume and speed one? (like bending a loop in a wire using pliers). Particularly around the last operation where you need a curl, when you make a crimp, the wire supports it. I am suprised they don't have problems related to buckling if you are just using purely compression dies without a interior mandrel/anvil. I would expect it to buckle and crinkle.... they really work on forming parts when they are hollow???To me I am imagining its like mountain climbing past a right angle (overhang climbing)... very difficult, you can't use your feet anymore since there is nothing under them!No one shows the forming dies and it leaves me to speculate :'(

author: thm_w
author_rank: Super Contributor
timestamp: March 24, 2025, 10:36:27 pm
content: Yeah its hard to find.I think you are right its just many many incremental steps.

author: coppercone2
author_rank: Super Contributor
timestamp: March 24, 2025, 10:37:54 pm
content: but do they really form it when there is nothing inside for doing bends past 90 degrees? you would need something to come in from the side to support such a bend IMO.You can stamp it to a right angle. It seems like it would be imprecise and haphazard to go further without support under neath. It seems like bootleg to do that operation with just pressing. Its like getting 'combed' or rolled into shape or something at that point, seems strange. I thought it would need to be like formed to get high precision....

author: coppercone2
author_rank: Super Contributor
timestamp: March 28, 2025, 08:19:02 am
content: Basically what I wanna know:Is there any benefit to 'curling' everything or if its OK to form something on a small pin or specialty anvil if you get the same shape? Because making molds that do everything from being banged on is hard and it clearly facilitates mass production. Bending the same shapes over various forming tools is slow and tedious, but you can just make a bunch of little tools to use and measure easily without like needing complicated machinery (it can basically be ground). Is there a quality difference?

author: Doctorandus_P
author_rank: Super Contributor
timestamp: March 28, 2025, 02:50:58 pm
content: Quote from: coppercone2 on March 24, 2025, 10:37:54 pm

author: coppercone2
author_rank: Super Contributor
timestamp: March 28, 2025, 08:42:03 pm
content: i see they use a wedge which is why you never see the side way hydraulic or whatever and it does sides while still going up and down. aI thought about what two wedges can be used for when I had a bucket of cuttings from joists in a structure, I could never bring myself to throw away like 100 wooden triangle pieces