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Bending of Metals
Figure 12-1. A metal beam supported at two points, with a load applied at
the midpoint, resulting in bending or deflection.
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Die Maintenance Handbook
Figure 12-2. If the applied force does not exceed the material-yield strength,
the beam returns to its undeflected shape.
Figure 12-3. Simple beam deflection occurs in air bending. If the applied
force exceeds the material’s yield strength, the beam retains a permanent
set or bend when the load is removed.
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Bending of Metals
Figure 12-4. Springback occurs until the residual stress forces are balanced
by the stiffness of the material.
BEND ALLOWANCES
The exact length of a bend is determined by trial and error. The
assumed neutral axis varies, depending upon the bending method
used, the location in the bend, and the type of stock to be bent. The
direction of grain in a steel strip relative to the bend has a slight
effect on the length of metal required to make a bend. Bending with
the grain allows the metal to stretch more easily than bending
against the grain. However, this results in a weaker stamping.
Bend allowances depend upon the physical properties of the
metal, such as its tensile and yield strength and ductility.
Empirical Rules
The exact bend allowance is the arc length of the true neutral
axis of the bend (metal is stretched above the neutral axis; below
it, metal is compressed). The neutral axis only can be approxi-
mated. Many manufacturers assume the neutral axis is 1/3-stock
thickness from the inside radius of the bend for inside radii of less
than twice the stock thickness. For an inside radii of two times
the stock thickness or greater, the neutral axis is assumed to be 1/2-
stock thickness from the inside radii. One reason for the require-
ment of relatively less metal to make a tight bend is that the sharp
radius tends to be drawn or stretched slightly.
Many experts believe that the location of the true neutral axis
from the inside radius varies from 0.2–0.5 times the stock thick-
ness. An important factor that determines the neutral axis is how
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Bending of Metals
Springback Compensation
The most common method used to compensate for springback
is to bend material a sufficient amount, beyond the desired angle,
and allow it to spring back to the desired angle after elastic recov-
ery occurs. This method of springback compensation is termed
overbending. Because of the uncertainty of the exact location of
the neutral axis, it is best to use trial-and-error methods when
developing close-tolerance stampings.
Many complex factors determine the amount of springback that
will occur in a given operation. Because the exact amount of
springback is difficult to predict, data for a specific material and
forming method is often developed under actual production con-
ditions to aid process control and future product development. If
the die designer and builder fail to include correct springback com-
pensation in the die, correction will need to be done by the repair
facility of the press shop that uses the tool.
PRESS-BRAKE OPERATIONS
Press-brake tooling for air bending (see Figure 12-5) is quite simple.
Air bending is one of the most common press-brake operations.
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Figure 12-5. Simple tooling of the type used to air-bend sheet metal parts in
press brakes. The upper die is lowered and a hit is made until the desired
bend angle is obtained.
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Bending of Metals
Figure 12-6. Coining the bend requires high tonnage to obtain a sharp,
accurate bend.
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Bending of Metals
Figure 12-8. Close-up view is shown of the point of flange steel contact on
the bend radius in a wipe-flanging die.
This can result in a score mark that might weaken the stamping
and extrusion of the metal being coined.
If excessive coining pressures are applied, the metal at the top of
the bend will extrude and result in a weak and distorted bend con-
dition. An improved flanging method relieves the radius in the flange
steel so it does not contact the top of the bend radius. One way to do
this is to relieve the flange steel at an angle that is approximately
20° tangent to the radius. Another method is to machine the flange
steel to a radius that is larger than the outside of the bend. The
flange steel is positioned so the tightest point is 45–60° beyond the
top of the radius. The side of the form steel is relieved 5° or more to
permit the material to be overbent (see Figure 12-9). This method
is more effective than coining the top of the bend. In addition, the
improved bending process is not as sensitive to variation, due to
press adjustments and material conditions.
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Figure 12-9. The side of the radius is coined and a relief angle is provided in
the lower-die steel in this improved springback control method.
Figure 12-10. A Ready™ bender makes initial contact with the stock. As the die
closes, the bender clamps and bends the stock. (Courtesy Ready Tools, Inc.)
and bent by the rotating bender. As the die closes, the rotary-bend-
ing action progresses (see Figure 12-11). An optional relief angle in
the lower die permits the rotary member to overbend the stock at the
bottom of the stroke to provide springback control, as shown in Fig-
ure 12-12.
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Bending of Metals
Figure 12-11. A Ready™ bender bends the stock through rotary action of
the circular member. (Courtesy Ready Tools, Inc.)
Figure 12-12. A Ready™ bender overbends the stock at the bottom of the
stroke to compensate for springback. (Courtesy Ready Tools, Inc.)
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Bending of Metals
Figure 12-14. A wipe-flanging die has low cushion pressures nearing the
bottom of stroke. Note that the blank has a crown or bow.
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Figure 12-15. A wipe-flanging die shown at the bottom of the stroke. As the
pad forcefully contacts the bottoming blocks, the loose metal is forced into
the bend radii, resulting in a controllable overbending condition.
Figure 12-16. Examples of how bend angles can vary with pad-pressure settings.
Pad Pressures
Normal pad pressures typically are in the range of 5–20% of the
forming force. However, in the following case study, pad pressures
this high result in varying bend angles that are less than the speci-
fied 90°. In addition, coining or restriking the bend to control
springback is not possible in the wipe-flanging detail design. How-
ever, carefully controlling pad pressure at low values has been
found a workable method to obtain 90° bends on this type of job.
In fact, several degrees of overbend can be obtained if desired.
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Bending of Metals
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be formed at less than a 90° angle. The action of the metal being
forced into the bend radii at the bottom of a stroke is shown in
Figure 12-15. The product variation as a function of slight pres-
sure variations is shown in Figure 12-16.
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Bending of Metals
REFERENCE
Smith, D. 1990. Die Design Handbook. Section 6, Shear Action
in Metal Cutting. Dearborn, MI: Society of Manufacturing En-
gineers.
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