Bending

the bend radius is measured to the inner surface of the bent part
 there is a plane which separates the tension and compression zones.
This plane is called neutral axis.

The position of neutral axis depends on the radius and angle of bend.
 the width of the part L in the outer region is smaller, and in the inner region it is larger,
than the initial original width.

Metal on inside of neutral plane is compressed, while metal on

outside of neutral plane is stretched
 BEND ALLOWANCE

It is the length of the neutral axis in the bend This determines the blank length
needed for a bent part

Lb = α ( R + kt )

where, Lb = bend allowance (mm)

a = bend angle (radian)
R = bend radius (mm)
t = thickness of sheet (mm), and
k = constant, whose value may be taken as 1/3 when R <2 t, and as 1/2
when R 2t .
Example
A 20 mm wide and 4 mm thick C 20 steel sheet is required to be bent at 600 at bend
radius 10 mm. Determine the bend allowance

R = 10 mm , t = 4 mm

R > 2t, k = 0.5

Bend allowance
 MINIMUM BEND RADIUS

As the ratio of the bend radius to the thickness of sheet (R / t)

decreases, the tensile strain on the outer fibres of sheet increases.
 If R / t decreases beyond a certain limit, cracks start appearing on
the surface of material. This limit is called Minimum Bend Radius for
the material

Minimum bend radius is generally expressed in terms of the thickness

of material, such as 2t, 3t, 4t, etc
R 60
Minimum  1
t r
r: percent area reduction
True strain at fracture is
7.65 Calculate the minimum tensile true fracture strain that a sheet metal should have in
order to be bent to the following R/t ratios: (a) 0.5,(b) 2, and (c) 4. (See Table 7.2.)

R 60
Minimum  1
t r

60
0 .5  1   f  0.51
r
 Types of Sheetmetal Bending
• V-bending - performed with a V-shaped die
– Bottom-bending
• Workpiece is in complete contact with punch on one side,
and the with the die on the other side
• Angle is set by the form of the tooling (punch & die)

– Air-bending
• A form of three-point bending
• Angle is continuously variable* - set by a stop

• Edge bending - performed with a wiping die

8
V - Bending

• For low production

rates

• Performed on a
press brake

• V-dies are simple

and inexpensive
 Edge - Bending

• For high
production
rates

• Pressure pad
required

• Dies are more

complicated
and costly

10
 Spring back :
• In Bending ,after plastic deformation there is an elastic recovery
this recovery is called spring back.
• Spring back can be calculated approximately in terms if radii Ri
and Rf
• Ri/Rf = 4 ( Ri Y / Et )3 – 3 (Ri Y /Et) + 1
Spring back Increases as (R/t ratio & yield stress of material )
increases as elastic modulus E decreases
The part tends to recover elastically after
ending,and its bend radius becomes
larger.
Under certain conditions,it is possible for
the final bend angle to be smaller
than the original angle(negative
spring)
Compensation for spring back
• Over bending of part
• Bottoming the punch – coin the bend area by
subjecting it to high localized compressive between
the technique tip of the punch and the die surface.
• Stretch bending – Part is subjected to tension while
being bent.In order to reduce spring back bending
may also be carried to reduce spring back bending
may also be carried out at elevated temperatures
 Springback and Compensation

Compensation: •
Overbending Bottoming

Local plastic
deformation
14
 Bending force :

K – constant ranges from 0.3(wiping die) – 0.7(u-die)-1.3(V-

die)
Y – yield stress
L- length of the bend
T- thickness of sheet

For a V-die
Max bending force, F = (UTS)Lt 2
W
UTS – Ultimate tensile strength
 Bending Force
Maximum bending force estimated as follows:

(UTS ) Lt 2
F k
W
Where:
F = bending force;
UTS = tensile strength of sheet metal;
t = stock thickness; and
W = die opening dimension.
For V - bending, K =1.2 to 1.33;
For wiping die (edge bending) K = 0.3-0.34
Bending Force :
There are two general types of die bending :
V – die bending and wiping die bending.
V – die bending is used expensively in brake die operations and stamping die operations..
7.66 Estimate the maximum bending force required for a 1 8 -in. thick and 12-in. wide
Ti-5Al-2.5Sn titanium alloy in a V -die with a width of 6 in.

UTS= 125,000 psi

2
(UTS ) Lt
F k
W
1 2
(125000)(12)( )
F k 8
6
K =1.2 to 1.33 For V - bending,
 Common bending operations:

Press brake forming

– Used for sheets 7M(20ft) or longer and other narrow pieces
– Long dies in a mechanical or hydraulic press for small production runs
– Die material range from hardwood to carbides.
Roll bending :
– Plates are bent using a set if rolls,various curvatures can
be obtained by adjusting the distance between three rolls

Common die-bending operations, Showing the

die-opening dimensions, W, used in
calculating bending forces
 Beading :
• The periphery if the sheet metal is bent into the
cavity of a die

(a) Bead forming with a single die (b) Bead forming with two dies,in a press brake
 Flanging :
• Flanging is a process of bending the edges of sheet metals to 90o
• Shrink flanging – subjected to compressive hoop stress.
• Stretch flanging –subjected to tensile stresses

Various flanging operations (a)

Flanges on a flat sheet. (b)
Dimpling. (c) The piercing of
the sheet metal to form a
flange.In this operation,a hole
does not have to be
prepunched before the bunch
descends .Note however,the
rough edges along the
circumference of the flange.
(d) The flanging of a tube;
note the thinning of the edges
of the flange
 Bending Operations

Straight flanging Stretch flanging Shrink flanging

Hemming seaming curling

 Dimpling :
• First hole is punched and expanded into a flange
• Flanges can be produced by piercing with shaped
punch
• When bend angle < 90 degrees as in fitting conical
ends its called flanging
Hemming :
• The edge of the sheet is folded over itself
• This increases stiffness of the part
The metal strip is bent in stages by passing it through a series of
rolls

Seaming :
• Joining two edges of sheet metal by hemming specifically
shaped rollers used for watertight and airtight joints
 Roll forming :
• Roll forming is used for continuous lengths of sheet metal
• Used for large production runs

Fig: Schematic illustration of

the roll-forming process
 Tube bending and forming
• Special tooling required to avoid buckling and folding

Methods of bending tubes.Internal mandrels,or the filling of tubes with particulate materials such as sand,are
often necessary to prevent collapse of the tubes during bending .Solid rods and structural shapes can also
be bent by these techniques
 Bulging :
• Process involves placing tabular,conical or curvilinear part into a split-
female die and expanding it
 Segmented die :

• Individuals are placed inside the parts and mechanically

expanded in radial direction and finally retracted.

Stretch forming
• Sheet metal clamped along its edges and stretched over a
die or form block in required directions.
Bending and Forming Tubes

Using internal mandrels, or filling tubes

with particulate materials such as sand,
prevents the tubes from collapsing during
bending. Solid rods and structural shapes
are also bent by these techniques
A method of forming a tube with sharp angles, using an axial
compressive force. Compressive stresses are beneficial in forming
operations because they delay fracture. Note that the tube is supported
internally with rubber or fluid to avoid collapsing during forming
 Stretch forming

Fig: Schematic illustration of a stretch forming process.

Aluminum skins for aircraft can be made by this process