What I'm basically trying to achieve is a solid(no hole) and deep dimple(3 times material thickness) that will be close(.275 including bend and dimple radius) to a bend. Material is cold rolled steel .048 thick. Is this possible?
You dont mention how many you wish to produce which can have some influence on this answer. One method would be to heat( if heat is permissible) the area with induction heating and quickly follow up with an indentation of the type you require made by a ball bearing of a sutable size pressed on to the heated area.You will no doubt have to support the underside of the fixture with plate on the underside of where the dimple is to be pressed The plate should have a pre drilled or slightly larger indentation to allow for the requied expansion of your required dimple when pressed into the plate Perhaps if its a one off or small batch flame torch could be used, the dimple/indentation ball bearing could be siLver soldered into a tool holder for the pressing process.
