EDPT 604

Metal Forming Processes and Machines

Lecture 8
Sheet Bending and Stretch
Forming

Dr. Mohamed Harraz

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 Bending Process
Bending is a manufacturing process that produces a V-shape, U-
shape, or channel shape along a straight axis in ductile materials,
most commonly sheet metal. Commonly used equipment include
box and pan brakes, brake presses and other specialized machines
presses. Typical products that are made like this are boxes such as
electrical enclosures and rectangular ductwork.

A schematic of air bending with a backgauge

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Bending Process

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Air Bending Process

This bending method forms material by pressing a punch (also

called the upper or top die) into the material, forcing it into a
bottom V-die, which is mounted on the press. The punch forms
the bend so that the distance between the punch and the side
wall of the V is greater than the material thickness (T).
Either a V-shaped or square opening may be used in the
bottom die (dies are frequently referred to as tools or tooling). A
set of top and bottom dies are made for each product or part
produced on the press. Because it requires less bend force, air
bending tends to use smaller tools than other methods.

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 Air Bending

Air bending's angle accuracy is approximately 0.5 deg. Angle accuracy is

ensured by applying a value to the width of the V opening, ranging from 6 T
(six times material thickness) for sheets to 3 mm thick to 12 T for sheets more
than 10 mm thick. Springback depends on material properties, influencing the
resulting bend angle. Air bending does not require the bottom tool to have the
same radius as the punch. Bend radius is determined by material elasticity
rather than tool shape
Dr. Mohamed Harraz
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Air Bending (Animation)

Bending Process Dr. Mohamed Harraz

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 Other Bending Processes
Wiping

In wiping, the longest end of the

sheet is clamped, then the tool
moves up and down, bending the
sheet around the bend profile.
Rotary bending is similar to wiping but the top die is made of a
freely rotating cylinder with the final formed shape cut into it and a
matching bottom die
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Roll Bending Process

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Distribution of stresses during Bending Process

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Springback for different material

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Springback in bending

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Bending Patterns

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Bending: Hemming

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Examples of Operation Steps using Die Bending

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Roll Forming to Shape

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Difference Between Bending and Stretch Forming: Natural Fiber

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Sketch of Stretch Forming Process

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Stretch Forming Failure

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Stretch Forming Techniques

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 Calculations
The BA can be calculated using the following formula:

B=C-R-T

BA = bend allowance
BD = bend deduction
R = inside bend radius
K = K-Factor, which is t / T
T = material thickness
t = distance from inside face to the neutral line
A = bend angle in degrees (the angle through which the material is bent)

Dr. Mohamed Harraz

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Calculations: Bending Force

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Nesting

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Utilizing Scrap from One Piece as Material for Another Piece

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Utilizing Scrap from One Piece as Material for Another Piece
Utilize the scrap from one piece to serve as material for the other to produce
the following three pieces. Show your layout order on the metal sheet coil
and differentiate between the work piece and the scrap at each shearing
process stating whether the process is a piercing or blanking process.

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 Answer

Piece 3 Scrap2 Piece 2 Piece 1 Scrap1

Blanking Piercing Blanking Blanking Piercing

Cutting order

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