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Bending Radius
On principle, the should assume the values
recommended by DIN 6935, i.e. they should
be selected from the following series
(preferably using the values in bold type):
1 1,2 1,6 2 2,5 3 4 5 6 8 10 12 16 20 25 28
32 36 40 45 50 63 80 100 etc.
1
Rolling direction
When bending sheet metal, particular
attention should also be paid to the
rolling direction.
The most suitable direction for bending
2
Bending
FIGURE 7.15 (a) Bending terminology. The bend radius is measured to the inner surface of the bend. Note
that the length of the bend is the width of the sheet. Also note that the bend angle and the bend radius
(sharpness of the bend) are two different variables. (b) Relationship between the ratio of bend radius to
sheet thickness and tensile reduction of area for various materials. Note that sheet metal with a reduction
of area of about 50% can be bent and flattened over itself without crackling. Source: After J. Datsko and C.
T. Yang.
Ref: Schulder, Metal Forming Handbook, Springer, 1998, chapter 4.
Bending Allowance
An approximate formula for the bend allowance, Lb, is given by
Lb
R kt
Bend angle
R Bend radius
k constant
t Sheet thickness
3
Minimum Bend Radii
Theoretically, the strains at the outer and inner fibers are equal in magnitude and are
given by the equation
A0 100
e f ln
A f
ln
r Reduction of area of the sheet
100 r
R t
0 ln
1 e0 ln
1 1
ln
2R / t
1 R
t / 2
The curve that best fits the data shown in the figure to the
right is
4
Minimum Bend Radii
TABLE 7.2 Minimum bend radii for various materials at room temperature.
Springback
The angle ratio is the so-called springback factor kR,
which depends on the material characteristics and
the ratio between the bending radius and sheet
metal thickness (r/s):
5
Ref: Schulder, Metal Forming Handbook, Springer, 1998, chapter 4.
Springback
6
Residual stress
Bending causes residual stresses in the
workpiece.
The smaller the bending radius relative to the
sheet metal thickness, the greater these
stresses are.
When a subsequent heat treatment is used to
reduce residual stresses in the workpiece, it is
important to remember that heat treatment
alters the workpiece radii and the angles.
7
Determining the blank length for
bent workpieces (I)
The blank length of the part to be bent is not equal to the
fiber length located at the center of the cross section after
bending.
The extended length of bent components 1 [mm] is
calculated as
whereby a [mm] and b [mm] stand for the lengths of the two
bent legs, and v [mm] is a compensation factor which can be
either positive or negative
8
Length of Bend And Edge
Condition/Ratio of Bend Radius
9
Springback in Bending
Bend allowance t
i
Ri
t
R f Ri , R f Initial and final bend radii
2 2f
f 2 R / t 1
The springback factor is defined as Ks
i
i
2 R f / t 1 (7.9)
Springback in Bending
3
Ri R Y R Y
4 i 3 i 1 (7.10)
Rf Et Et
10
Negative Springback
FIGURE 7.20 Schematic illustration of the stages in bending round wire in a V-die.
This type of bending can lead to negative springback, which does not occur in air
bending (shown in Fig. 7.26a). Source: After K. S. Turke and S. Kalpakjian.
Ref: Schulder, Metal Forming Handbook, Springer, 1998, chapter 4.
Methods of Reducing or
Eliminating Springback
11
Roll forming: roll bending in
several stages
12
Ref: Schulder, Metal Forming Handbook, Springer, 1998, chapter 4.
13
Roll bend radius
Strain=(R+0.5s)/R
ReL=Strain*E
14
Start-stop roll forming line
Roll stands
15
Width adjustable telescopic
roll set
16
Stand for a complete stand
exchange
Bending and counter bending must each take place within the
plastic range of the material in order to ensure that the bending
direction is retained following elastic recovery, i. e. the yield
strength of the material must be exceeded.
On the other hand, care must be taken to ensure that the
straightened material does not sustain damage.
If bending is too pronounced, brittle materials can develop slight
cracks at the surface.
Ref: Schulder, Metal Forming Handbook, Springer, 1998, chapter 4.
17
Reduction of residual stress
18
The feed value
The feed value zw for the
rollers is limited by the
geometry of the straightening
machine
19