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Bending

Bending Doc

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Subramanya Seeta Ram Prasad
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60 views8 pages

Bending

Bending Doc

Uploaded by

Subramanya Seeta Ram Prasad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Bending:

THEORY OF BENDING AND SPRING BACK:

BENDING

Bending is the process of folding a sheet about a straight line axis which lies in the neutral plane.

Bends are made in sheet metal to gain rigidity, to produce a part of desired shape & perform a
particular function etc. The cross section of the bend inward from neutral axis is in compression,
outward from neutral axis is in tension as shown in the fig.

SPRING BACK

During bending the metal nearer to the neutral axis is stressed to the values below the elastic
limit. This phenomenon creates a narrow elastic band on both sides of the neutral axis. The metal
further away from the neutral axis is stressed beyond the yield strength and is plastically deformed
and permanently set. When the bending force on the metal is released the elastic band tries to
return to the original flat condition but cannot return fully due to the restrictions of the plastically
deformed zones . Some slight return does occur as the elastic and plastic zones come to an
equilibrium and this return is known as spring back.

The amount of spring back mainly depends on the ratio of bending radius to stock thickness.

Spring back can be reduced by over bending, Bottoming or stretch bending.


SIMPLE BENDING
The operation of Folding the sheet about a straight-line axis is called simple
bending.

FLANGING
It is similar to above in which the height of bend is shorter compared to the
overall size of the part.
 It strengthens the edges of sheet metal parts.
 It provides flanges required for assembling parts by spot welding or any
other joining processes.

HEMMING
Hemming is an operation in which the edge of a component gets folded by
1800 .
 It improves the rigidity of the edge.
 It facilitates joining of two parts as in the case of Bonnet assy. /Door assy.
Do’s & Don’t:

 Flanges that are to be bent should not have very inclined edges or large radii, this
causes the blank to slide during the bending operation. Sharp corners will make
bending of the flange easier.

 The edge of a flange that is to be bent should be straight and parallel to the bend
line, This aids in fixing the part correctly for the bend. A more difficult edge to fix will
require a special fixture to meet the required tolerances which in turn makes the
component more expensive.

 Placing two bends, in opposite directions, within the minimum flange length could
result in the need for a customized tool, a Z-bend punch and die,
 Two bends in the same direction, resulting in a U-shape, are often difficult to
achieve. Deep U-shapes are unfavourable but can to some extent be manufactured
with L-tools.
 For bends located close to an edge, bend reliefs and corner reliefs are to be used. A
bend relief is a small pocket cut next to a flange to avoid tearing in the neighbouring
edge and dislocation of the part, The relief should be at least two material
thicknesses wide, and the depth of the relief should be at least the sum of the
material thickness and the bend radius. An alternative to using bend reliefs is to
place the bend at least one radius outside from the edge.

 The minimum diameter of punched or laser cut holes should be equal to one
material thickness. Having holes smaller than one material thickness will shorten the
life of the sheet metal as well as that of the punch. Higher punching force will be
required and there will be excessive burr. Laser cutting holes too small could cause
the melting of the material being cut.
 The distance between two holes should be equal to at least two material
thicknesses. Punching holes too close to each other could result in the deformation
of the material between the holes. Keeping a fair amount of distance between holes
also acts to ensure the strength of the metal. Laser cutting holes too close could
result in the material sticking together as the laser acts as sort of a weld if the cut is
too narrow.
 The distance between a hole and an edge should be equal to at least the material
thickness but preferably one and a half times the material thickness. Punching a hole
too close to an edge could result in the deformation of the edge. Having a hole too
close to an edge also decreases the strength of the metal.
 All corners of the blank should always be rounded. This is to keep operators and
assemble personnel from injuring themselves on sharp edges.
 Holes should not be placed closer than half of the width of the vee die, to ensure no
distortion occurs in the hole. The alternative is to manufacture the hole after the
bending process. As this would require additional production steps, the result will be
a more expensive component. See the Figure below for an example of a distorted
hole.
DESIGN CONSIDERATIONS FOR BENDING

Radius of bend  T

Minimum height of bend  3T

Relief Notches for bend

DESIGN CONSIDERATIONS FOR HEMMING


BEND RELIEF PARAMETERS

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