BFF 3613

SHEET METAL PRODUCT

DESIGN
LO03
 Lesson Outcomes
2

By the end of this class, students should be able to:

 Bending Operations

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Chapter Outline
3

1. Sheet metal fabrication processes

 Bending Products
4

Samples of Bending Products produced by V-Bending Die at

Press Brake
5

Flat Blank Length After Bending Process

 BASIC OF BENDING
6

 Bending is a process by which metal can be deformed by

plastically deforming the material and changing its shape
 Bending is a flexible process by which many different angles can
be produced
 In bending process: the material is formed around a straight axis,
which extends completely across the material at the bend lines
7
 BEND RADIUS
8

 Tangent to the inner plane surface of the piece part

 Radius of the inner arc of the bend
 BEND LINES
9

 Bend line are imaginary line , occur at the tangency of the bend
radius with inner plane surfaces
 Perpendicular to the inner plane surfaces
 BEND AXIS
10

 It is located at the centre of the bend radius

 NEUTRAL AXIS PLANE
11

 Is a theoretical plane originated, by the inherent bending stresses

 Located at the 1/3 – ½ of the thickness of the part
 Rn (neutral axis line)
 BEND ALLOWANCE
12

 The curve neutral plane of the bend area

 BEND ANGLE
13

 Angle included between the extreme position of the bend radius

 BENDING STRESSES
14
 PLASTIC DEFORMATION OF BENDING
15
16

STRESS vs STRAIN
Diagram of a Stress-strain curve, showing the relationship between
stress (force applied) and strain (deformation) of a ductile metal.
 BEND ALLOWANCE CURVE
17
18

Computer simulation of material behaviour during bending

19
 Calculation of Flat Blank Length 90o by
using table
20

FORMULA

L = [(a + b + c) – (n x v)]

L = flat blank length

l = length of 1 plain length
s = thickness of sheet-metal
r = internal radius
n = number of radius
v = balance of bend allowance

For Bending 90o

 Calculation of Flat Blank Length by
using table
21

FORMULA

L = [(a + b + c) – v]

L = flat blank length

l = length of 1 plain length

s = thickness of sheet-metal

r = internal radius

n = number of radius

v = balance of bend allowance

 = angle required

k = korrekturfaktor
For Bending <90o and >90o
 Calculation of Flat Blank Length 90o by
using equation
22

90𝜋
𝐿𝑛 = ሺξ𝑇 + 𝑅𝑖 ) = 1.5708 ሺξ𝑇 + 𝑅𝑖 )
180

Ri/T 0.1 0.2 0.3 0.4 0.5 0.8 1.0 1.5 2.0 3.0 4.0 5.0 10.0
ξ 0.23 0.29 0.32 0.35 0.37 0.40 0.41 0.44 0.45 0.46 0.47 0.48 0.50

Value of coefficient, ξ

Bend Allowance, 𝑅𝑛 𝑅𝑖
If < 2, 𝑘 = 0.33
𝑇
𝑅𝑛 = 𝑘𝑇 + 𝑅𝑖 𝑅𝑖
If ≥ 2, 𝑘 = 0.5
𝑇
 Calculation of Flat Blank Length by
using equation
23

𝜋𝜑
𝐿𝑛 = ሺξ𝑇 + 𝑅𝑖 ) = 0.017453𝜑 ሺξ𝑇 + 𝑅𝑖 )
180
𝜋𝜑
𝐿𝑛 = 𝑅𝑜 𝑅𝑖 = 0.017453𝜑 𝑅𝑜 𝑅𝑖
180
 SHEET METAL BENDING FACTS
24

ADVANTAGES

Simple
Easy to perform Fairly precise
construction
SHEET METAL BENDING FACTS
25

DISADVANTAGES

Limited in the Springback quite Some material

shapes to be difficult to easy to necking
produce determine or tearing
 V-Bending Dies in Press Brakes
26
 PRESS BRAKE MACHINE
27
 PRESS BRAKE TOOLS
28
29

PRODUCT MADE
BY PRESS
BRAKE
MACHINE
 Bending action at V-Dies
30

 In term analysis, broke down to 3 Stages

 ROCKING = punch descended until nose radius R tangent to the
top plane of die block
 PULLING = punch entered deeper into the die opening channel
 BOTTOMING = free or unrestrained bending action
31

In V-bending, the clearance between punch and die is constant

(equal to the thickness of sheet blank).
 Bending radii for V Dies
32

 Sizes of bend radii depend upon circumstances peculiar to individual

job
 Average condition used ½ of thickness material
 Heavier material thickness requires proportionally larger bending
radii than large gage material
 Very heavy material may require bending radii of 2 times of
thickness or more
 Smaller bending radii tend to:
• have a better gripping effect
• more efficient for controlling the reaction of w/piece
• more accurate than larger bend radii
 Springback at V Dies
33

 Springback is defined as the elastic recovery of the material after

unloading the tool / punch
 Springback result in dimensional change in bent part.
 Springback varies according to the thickness, type and condition of
sheet metal
 The larger the bend radius = greater springback
 Overcome Springback problems
34
35
36

To overcome springback, reduce the required angle at tooling

 Air Bending Die
37
 Pressure-Pad Bending Dies
38

 Commonly actuated by spring or rubber cylinder

 Air cushion pin or hydraulic cylinders can be used to actuate the pad
 Pressure pad functions:
• Hold w/piece during bending
• Serve as bottoming blocks
• Act as a shredder / stripper to remove piece part from die
 PRESSURE PAD BENDING DIE
OPERATIONAL SEQUENCE
39
 Pressure-Pad Construction
40
 U BENDING
41

 Is perform when two parallel axes produced in same direction

 Internal springs or shoulder pad is used in die
 Spring actuated plunger or hook strippers is used to strip work piece
 U-Bending Die
42
 Stripping U Bends
43
 L-Bending Die
44

 Part produced similar like V-Bending dies product

 Air cushion pin or hydraulic cylinders can be used to actuate the pad
 Air Bending technique can be practice at L-Bending Die
 Overcome Springback – Die Design
45

Offset punch for Punch sidewall

Convex pad Rotary bending
corner setting relief - angular
 EFFECT ON BURR SIDE
46

 The location of the burr side of the piece part can have an undesirable
effect on the bending and forming dies.
 It is undesirable for the burr side to be located on the outer surface of
the formed piece part, because the burr drags around the bending
radius and into the die opening.
 This condition causes excessive wear on the die members.
 A burr-side specification on the piece part drawing supersedes the
possible deleterious effects of the burr on bending or forming dies.
 GRAIN DIRECTION
47

 Directionality of sheet or strip metal is a factor, which must be

considered in relation to bending and forming operations.
 Assuming that it is feasible to bend (or form) a given metal, the
most favorable condition exists when the axis of the bend is
perpendicular to the grain direction.
 Conversely, the least favorable condition exists when the axis of the
bend is parallel, strains increases as the angle that approaches 90°.
 EFFECT OF GRAIN DIRECTION TO BENDING
48
BENDING IN PROXIMITY TO PIERCED HOLES
49

 Holes pierced before bending will be distorted if they are too close
to the bend area. As a rule, distortion will minimize if distance P
(Figure 11.2) is held to a minimum of 1.5t
 EXERCISE 1
50

Calculate the of the flat blank length of this 90o bending product if
the thickness material is 2mm.

Please use table given to get the correct answer

 EXERCISE 2
51

Calculate the of the flat blank length of this 135o bending product
if the thickness material is 2mm.
Calculate the bend allowance first.
 Calculation formula for bending curve
Curve 0o to 180o =  x [(180o - ) / 360o] x diameter
Not applicable for exact 90o bending
53

Calculate the of the flat blank length of this 50o and 90o bending
product if the thickness material is 2mm.
Calculate the bend allowance first.
Neutral axis is ½ from inner side of bend radius
 EXERCISE 3
54

Please calculate flat blank length of the material by using the table given
55
 BENDING FORCE FOR AIR BENDING
56

Fa(u)= 0.2 x l x s x Rm

l = overall length along bending axis

s /t = thickness of material
Rm / s = tensile strength (N/mm2)
 Example of Bending Force Calculation
57

l = 2 x 50 mm (this part have 2 bending axis)

= 100 mm
s = 3 mm
Rm = 320N/mm2

Fa(u) = 0.2 x l x s x Rm
= 0.2 x 100 x 3 x 320
= 19200 N
59

Fb(u)= 2.5 Fa(u)

= 2.5 x 192000 N
=48000 N
= 4.8 tons
BENDING FORCE USING PRESSURE PAD
60

F= 1.3 Fa(u)

= 1.3 x 19200 N
= 24960 N
= 2.5 tons

F = Fa(u) + Fp

Fp = 0.3 Fa(u)
Calculate bending force required (air bending, bottoming bending & bending with
pressure pad) for the product that shows in figure 3 above if the thickness of the
product is 2mm and tensile strength is 320N/mm2. Give all answers in tonnage