Chapter: 02

Topic: BENDING
INTRODUCTION:
Most product of sheet metal presswork is not flat blanks that can be produced by
die-cutting operations alone. They generally have a third dimension obtained by a shaping
operation, which deforms the metal to various degrees. The shaping operation may be
performed in progressive dies or it may be done separately.

CLASSIFICATION:
Shaping operations are generally divided into three groups, based upon how the
parent material flows or deforms during the shaping process, namely, Bending, Forming,
and Drawing.

Fig2.1 illustrates Bending, forming, Drawing.

BENDING:
Bending, is the simplest of the three, is defined as shaping metal around a straight-
line axis, which extends completely across the material. The result is a plane surface at an

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angle to the original plane of the work piece material. Metal flow is uniform along the bend
axis, with the inner surface of bend in compression & the outer surface in tension.

FORMING:
Forming is similar to bending, except that the form or bend is along a curved axis
instead of a straight one. A part that is formed generally takes the shape of the punch or
die. Metal flow is not as uniform as in bending because it may be localized to some extent,
depending upon the shape of the work piece. The metal flow in forming is not severe
enough to affect the thickness or total area of the work piece material to any great extent.
Bending along a large radius in a straight line may also be referred to as a forming
operation.

DRAWING:
Drawing is the most complicated of the three sheet-metal shaping processes. A
drawing operation begins with a flat blank, which is transformed into a cup or shell. The
parent material is subjected to severe plastic deformation. Shell forms produced may be
cylindrical or rectangular with straight or tapered side.

BEND ELEMENTS:

Fig 2.2 illustrates bend elements.

1. BEND AXIS:
The bend axis is a straight-line axis around which the material is formed at the
desired bend radius. The bend axis is the neutral center of the bend radius. Length of the
bend axis is the same as the width of the work piece at the bend area.

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2. BEND RADIUS:
It is the radius of the inner arc of the bend. The extreme position of the bend radius
is tangent to the inner flat plane surface of the work piece. Therefore, the extreme position
of the bend radius is perpendicular to the inner flat plane surface.

3. BEND LINES:
These are imaginary lines created by the tangency of the bend radius with the inner
flat surface. There are two bend lines associated with each bend.

4. BEND ANGLE:
The bend angle is the angle included between the two extreme positions of the bend
radius. It originates at the bend axis.

5. BEND AREA:
The bend area is the area included within the bend angle.

6. NEUTRAL PLANE:
It is a theoretical plane and an imaginary separation between the material in
compression and the material in tension. The neutral plane occurs at a distance of 0.33T to
0.5T from the inner surface. The exact distance varies according to the type of material and
the circumstance under which bending takes place. The length of the neutral plane does not
change as a result of bending.

7. BEND ALLOWANCE:
In bending operation the material near the bend radius is under compression while
the material near the outside of the bend is under tension, as shown in fig2.3. A neutral
plane exists between the area under tension and the area under compression. If the material
is uniform in section and its elastic limit is not exceeded, the neutral plane will coincide
with the centerline of the material. However, when the bending forces causes the elastic
limit of the material to be exceeded, the neutral plane moves towards the inner surface at a
distance of one-third to one-half the thickness of the material. This is because the material
under compression resists bulging much more than the material under tension resists
stretching, and therefore the greatest among of plastic flow takes place on the tension side
of the bend. The length of the neutral plane does not change as a result of bending.

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 Fig 2.3 illustrates Bend Terms for general Angle.

Formula to calculate bends allowance:

B= A x 2 [IR +Kt]
360
Where,
B=Bend allowance (arc length of neutral axis).
A=bend angle,
IR=Inside radius of bend in mm
t = Metal thickness
K=constant for neutral axis location.
K is equal to 0.33 when IR is less than 2t and 0.50 when IR is more than 2t.

Calculation:

B = A x 2 [IR + Kt]
360
B = 90 x 2 x 3.14 [2+(0.33x3)]
360

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B = 1 x 6.28 [2+0.99]
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B = 18.77 = 4.69
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Develop length =A+B+C+D+E (As mentioned in drawing)
=35+35+30+4.69+4.69
=109.38mm
Develop length is the size to be blanked before Bending.

BENDING DIES:
Bending is normally done across or perpendicular to the grain direction produced in
rolling mills. Bending, in this manner allows sharper bend without the danger of cracking.
Work piece is oriented at an angle when bending has to be done in two different directions.

Bending can also be done parallel or along the grain direction depending upon the
hardness of the material, as explained in materials for bending.

MATERIAL FOR BENDING:

Hard: A hard shaft, springs, cold rolled strip intended to, flat work, where ability to
withstand cold forming is not required.

Half hard: A moderately shaft cold rolled strip suitable for limited. Bending right-angled
bents may be made at 90 to the grain direction around equal to the thickness.

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Quarter hard: A medium soft cold rolled strip suitable for limited bending, forming and
drawing. It may be bent to 180 across the grain direction and to 90 parallel with the grain
and around a radius equal to the thickness.

Soft hard: A soft ductile cold-rolled strip suitable for fairly deep drawing operation where
surface disturbances such as stretched strain or objectionable strip of the temper are
capable of being bent flat upon its self in any direction.

Dead soft: Soft ductile cold rolled strip produced without definite control of structure strain
and fluting. It is suitable for difficult draw application where such surface disturbance may
be tolerated. It is suitable for bending flat upon its self in any direction.

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BEND RADII:
The minimum bend radii is dependent on several factors namely, included angle,
length of the bend material properties and grain direction. As a thumb rule the min bend
radii is equal to thickness of the sheet metal also. The amount of bend radii also depends on
the thickness of the sheet metal. The greater thickness requires proportionately larger bend
radii than thin sheet metal.

TYPES OF BENDING:
The two bending methods used extensively in presses are:
1. Wiping dies and,
2. V-bending dies.

V-BENDING DIES:

Fig 2.4 illustrates V- Bending Die.

1. V-bending –dies are so called because of their cross sectional shape which resembles the
letter “V”.
2. V- bending dies accomplished by using a V-block for a die and wedge shaped punch to
force the metal into the die.
3. The desirable width of the opening in “V” is normally at least eight times the material
thickness up to 16mm.
4. Die opening up to 10 to12 times the metal thickness are used for forming heavier
thickness plate.
5. The included angle of the V-bend (in the component) can be changed by varying the
distance entering the punch into the V-die.

AIR BENDING:

1. When punch does not bottom out the die, the process is known as “Air bending”. Here
the press stroke does not reach the maximum possible distance, which the punch can travel
into the die.
2. Here the material contacts the radius of the punch & edges of the die.

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3. Air bending dies are made with sharper angle than required.
For example: for 90 bend, the sheet over bent to 89 .

ADVANTAGES OF AIR BENDING:

1. Wide ranges of angles can be formed from one set of dies.
2. Each set is capable of bending different types and thickness of material that is either it
can be aluminum or steel or brass etc. and also various thickness of metal can be bent.
3. Air bending dies permits bends to be made with least pressure, as the sheet metal does
not bottom out.
4. Dies do not have to be used in matched sets.
For e.g.: One male die can be used for a V die of another tool.

BOTTOMING DIES:

Fig 2.5 illustrates Bottoming Die.

1. Here the punch is allowed to bottom out the die.

2. Here the stock material is squeezed between male and female, die surfaces at the bottom
(end of press stroke) of the press stroke.
3. Bottoming dies are used when a higher degree of accuracy or sharper inside corner is
required.
4. By this method, spring back in the component can be minimised.
5. Bottoming dies requires more pressure than the pressure required in air bending dies,
depending upon the thickness & type of material. Here the sheet metal bottom out.

NOTE: Care should be taken to prevent over loading the press when bottoming dies are
used. It is preferable to use or provide tonnage indicator in the press to prevent over
loading.

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WIPING DIES:
1. Here, the work piece is clamped to the die block by means of spring load or a fluid
cylinder pressure pad.
2. As the ram further moves the punch wipes the material over the die
3. A bending radii is provided on the edge of the die block.
4. A radius or chamfer is often provided on the edge of the punch, this prevents the wiping
action from being too severe.

U-BENDING DIES:

Fig 2.6 illustrates U- Bending Die.

1. These dies are called as “U” bending dies, because the bending operations produced in
them bear a resemblance to the letter “U”. They are often simply referred to as U-dies.
2. U-bending dies are preferably equipped with a pressure pad as shown in figure.
3. In U - Bending, the pressure pad performs the following functions
a) They hold the work piece during bending.
b) They serve as bottoming blocks for setting up the bend (or bends).
c) They act as strippers or shedders to aid in removing the piece part from the die.

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U-BENDING PROCESS:

Fig 2.7 illustrates U- Bending Process.

1. In view (a), the descending punch has contacted the work piece, forcing the work piece
against the pressure pad.
2. Since the punch force has opposition from pressure pad, the work piece is gripped
between the punch and the pressure pad.
3. The griping force is equal to the pressure exerted by the pad.
4. As the punch descends further the bend legs swing upwards as shown in the figure (b).
5. In figure (c) the bend legs have completely swung and the stock material is being
“WIPED” between the vertical surface of the punch and die opening.
6. Wiping continues until the bottoming occurs.
7. When the punch forces are taken back, the pressure pad is then actuated and thus ejects
the component out of the die.

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DEFECTS IN BENDING:
a. Spring back and,
b. Thinning.

a. SPRING BACK:
When a component is to be bent, pressure is applied and when the force is applied,
the bending operation is completed. When the bending pressure is released, elastic stresses
remaining in the bend area, will cause a slight decrease in the bend angle. Material
movement of this type is known as “Spring Back”.

Fig 2.8 illustrates Spring Back.

The magnitude of this material movement will vary according to type, thickness and
hardness of material. Spring back for low carbon and soft non-ferrous metal is from 0-2 ,
spring back for 0.4% carbon steel and semi hardness material is from 3-5 . Spring back for
hardness material may be from 10-15 .

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METHODS OF PREVENTING SPRING BACK:

1. In ‘V’ bending and air bending dies:

a) By over bending.
b) By coining or squeezing.
2. In wiping dies:
a) By ironing.
3. In ‘U’ bending dies:
a) Corner setting.
b) By providing convex radius in die, concave in punch.

OVERCOMING SPRINGBACK IN V-BENDING AND AIR BENDING DIES:

1.BY OVERBENDING:

It is the simplest way of over coming spring back problems. Here in this method, the
work piece is bending through a lesser angle than required and work piece spring back to
the required angle.

Fig 2.9 illustrates Over Bending.

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2. BY COINING OR SQUEEZING:

Here in this method, the metal is squeezed slightly in this corner in order to relieve
elastic stresses. This method is also known as “corner setting”. The material in the
immediate corner is made to flow plastically and set up compression stresses that over
come elastic stresses. In this method the punch nose is modified for corner setting
operation, when the punch is bottomed [The pressure is built up rapidly].

SLIGHTY CONVEX METHOD FOR PREVENTING SPRINGBACK:

Fig 2.10 illustrates Convex Method of preventing Spring Back.

In U-bending dies the face of the punch is concave and shedder will be provided
with convex radius to avoid spring back of the component so that after removal of the
punch it forms to the required angle.

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PREVENTING SPRING BACK BY IRONING:

Fig 2.11 illustrates Ironing.

1. In wiping dies, spring back can be prevented by “Ironing the material”.

2. To iron the bend effectively the distance between the punch and die must be slightly less
than the metal thickness.
3. When sever ironing is required a back HEEL may be necessary to support the punch.
4. Ironing in the corner will be effectively accomplished only by using a slight shoulder on
the punch that contacts the work material near the end of stroke.
5. Die may also be undercut to permit over bending when spring back is not too severe.

b. THINNING:

Thinning of sheet metal occurs when excessive pressure is exerted on the sheet
metal and the clearance is less.

BENDING PRESSURE:

The amount of pressure required to accomplish a bend is known as “Bending

pressure”. The amount of pressure required to bend, the work piece material depends upon
the stock, die opening, length of bend, amount of coining or bottoming ironing used and
also the type of material.

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The formula for calculating the bending pressure is
F=KLST2
W
Where,
F=Bending force required in tones
L=Length of bend part in mm.
S=Tensile strength of material.
t=Thickness of sheet metal in mm
W=Width of die opening between points.
K=1.33 when die opening is 8 times the metal thickness.
K=1.20 when die opening reaches 16 times the metal thickness.
For “U” and channel bending, the constant K=0.67

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 F = 0.67 LST2
W
For wiping dies, the constant K=0.333

F =0.333 LST2
W

F =0.67 LST2
W
F =0.67 x 40 x 42 x 32
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F = 920 kg
F = 0.92 Tons.

EFFECT OF BURR SIDE DURING BENDING:

The burr side is an important factor to be considered while bending the sheet metal.
If the burr side faces towards the die opening then the burr side rubs or drags against the
die surface during the descend of the punch causing scoring marks on the die surface. This
causes damage to the die.
The burr side of the sheet metal should be facing the punch during bending. By
facing the component in this manner scoring marks on the die can be avoided, as the punch
descends the burr side of the sheet metal just folds and wraps over the punch.

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