Work on the ribs for the solar panel racks began this past week with the finalization of the details by the solar teams. Test bends on the small stock (0.125" x 0.750") resulted in predictable high stress concentrations at the bend points, and risked breaking off the tabs required by the ribs. Solutions may include pre-bend heat treatment via butane or propane torch, scoring at the bend location prior to bending, or creating larger bend radii to reduce the stress concentration. The goal is to reuse material that was tested upon with the initial bender for these ribs, in order to reduce the amount of overall waste material. Additionally, all ribs will be ideally completed by next Wednesday.
A test bend block made out of 3/4" plywood.
Needless to say, the metal was more resilient than the plywood.
Making a new bending block from an aluminum block.
Drilling holes in the block to retain support rails.
All holes drilled and the parts separated.
The new bend blocks with support rails to hold them atop the vise.
Underside view of the blocks.
A cracked-off tab from making too intense a bend.
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