Professional Documents
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AERO
SHEET
330
METAL
331
BEND
PAGE 3-5
LAYOUT
sheetmetal parts. Most of these parts have been given form by bending.
Very preoise methods have been developed for the lIlR.king of sheetmetal
layouts where bends are involved. Whenevesr formad sheetmetal parts must
be made to olose tolerances or when they must fit, or match other parts,
an aoourate flat layout is neoessary. In almost any type of fabrication
aocuraoy in layout saves time, material, rework and trimming. Layout is
the initial step, all processBs whioh follow are built upon the layout
foundation.
DRAWING
LAYOUT
PART
FIGURE-I
The ~neral ;:>rocedure for laying out the nat ahape of a part can be divided into
pi-
;.
to
1.
2.
J.
cut.
to
to bend.
drill or
punch.
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AERO
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33:1
PAI3E :3-6
B0fore beginning the study of bend layout 70u lmst have a clear understanding
of the terms involved.
'l'ermE Used in Bend layout
'oIben sheet metal ,ie bent, the angle formed vill not be
sharp but vill folloll the arc of a circle. The radillS
of this arc i9 called the "bend radiUl!l. The bend radius is 1I>9a=ed ~m
a radiue center to the inside S'tlrt'sce of the metal.
BEND RADIUS (R)
Bending both stretches and shrinkll the mtal. The I!lBtal on the inside of
the bend ahrinkB or is squ6l'l:MId together, lIhile on the outBide of the bend
it i8 stretched. Figure:2 SholiS the change that takes place in a bend. Most
sheet metal u5ed in aircraft is l!lBi!e of etrong and corre !3]lOndingly brittle
alloys lIhich 1!Il8.y crack or become 1'10 li9aXaned as to fall in service if bent
too sharply. The kind of metal, ita thickness and ita tamper determine the
mini= eat'e bending radius. The recol!!l!lended minimum bend radii for several
aluminum alloys and magnesium are given in the Standard UAL bend radius chart
in Figure 13. These bend radii are normally given on the print.
,,
r---BEND RADIUS
--,
\
,
,
,
--
BEND RADIUS
FIGURE 2
Bending has the effect of strein hardonlnf; the metal vith a resulting increase
in brittleness. \lith cladded =terial it is poaail:>le for cracks to have occuI:r'6d'in the alloy, but not be visible through the sort coating. Bending
brakel!J or form blocka l!Jhould ahlBYS be checJcad to eee that they viII' provide
the proper radiul!J.
liE1J1'R!L LINE
\Ii thin the mlr'Ved portion of metal loIhich has been bent, there
111 an imaginary 11ne called the "oeutral line". On this J ioo
the eompresl!Jion on the inside of the bend changes to tension on the outside of
the bend. The oeutral line repreeentB that part of the mtal, in the bend,
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AERO
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331
PAGE 3-7
whieh is the saJ>e length af'teIr bending lUI it WItS before bending. When _tal
ill bent, the bent area ill 10 to 15 percent thinner than before bending. 'l'hil!
1m beoause the JIlet..U !!!Ovel! IlION eaeily in Ualll3ion than in ooBpre!!sion. Af'ter
the zetal !IIOYeS beyond its elastic liJcit the I!ltrength of the IC0tal on the
inside of the bend (compresaivo I!ltr-ength) beCOJ:lS1I greatar thllIl the I!ltrength
of the metAl on the outside of the bend (tension IIItrength). Due to thiB
thlnnl ng the neutral line of the _tal moves in tovard the radiUl! center.
P'igare .3 sboVl! the position of the nll>utrd liOll vithin a bend.
---._ _--,-.l
-------- T
..
'
'l'bere are &ovoral ways of dimensioning formed lIheetIlOetal parts on drawings. The lOst common 1a the
outside Dr "llIlOld l.ine" diloension (MID). A mld line dimenaion is the distance
troll! the edge of the metal to e. point in space called the RJIIOld point". The
llIlOld point is the point of inter!l$Otion of lines extended from the outside
lI1Irfaees on either sid!! of the OOM, ! ~ld ~ 11: m.n ~~'7 11M in
flPaee. parl!i.l:""l to t.'>", ooz:d, ez>5. Pi.l.fS,,:1.l:;g-through ~ ][DId pc:.l.:i!t!>. l4!l1::lld
line would be the outside oornsr of the part i f there vilre DO r-euiius.
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AERO
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331
PAI3E 3-8
A
BEND TANGENT---....
LINE, BENDING
STARTS AT THIS
POINT.
T
l--BTLD
MOLD LINE
-...,1
BTLD
I.:
..+.
',-
'.
,',
BA
DW
BTLD
DIMENSIONS OF A BEND
-
;.
FIGURE-4
AERO
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PAGE 3-9
A simple axiom \Thich can be spplied to finding developed vidth iSI liThe \Thole of
anything is equal to the Blll!l of its parts n Referring to Figure 4, DW
A+ B+
c.
Using the chart, find the BAfor a 90" bend in .032- material on
a 1/8" radius.
Step 1.
Step 2.
00243
x
90
.21870
The a.ll.ovance" tor this bend is .2187". Using!;. decilnal
equivalent chart it may be changed to 7/32".
The bend ailm;ance chart lias developed from the bend allollance formula. This
formula is called an empirica.l formula because i t vas arrived at by experimentation rather than by aIrY precise calc::ulation. The empirical fOnmlla for bend
al1croH1nce iSI
BA
= (.01743
the bend.
This formula is seldom used since charts are generally availabls. As a matter
of interest, the formnla \la!! derived by taking into account the length of a 10
arc on a given radius. It has been found. that .01743 x R best represents the
length of a 1 0 arc. The formula also COIlBideres the radius required to reach
the neutral line of the lIIetal. This vill vary \lith the thiclmess. The second
empirical value of the bend allovance formula, which corrects for the radius
required to reach the neutral line, is .0078 x T.
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AERO
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331
PAI"E 3-10
S8tba.ek (SB)
To find tJ:w DW of a part uaing BA, \Ie must have the bend tangent line dimensions to whioh are added the bend allowance for each bend. '1'0 find the bend
tangent line dilll9naiona when IIlOld line dimensions only are given, as is often
the oase, it ill necessary to subtraot a di stanca oalled ft setbaok" from each
lIXJId line dilnension. Setback is the dietance from the bend tangent line to
the mId point. \./ben a part has IrOM! than one bend, setback III!lst be subtracted
for eaoh bend. The majority of benda in ehefltmetal are 9{l0 bends. Sotbaok
for all 90 bends is equa.l to the sum of the ln9tal thicknBBB plus the radiua
of the bend, ILB shown in Figure 5. The folloving formula iB used to find. the
EnD for a part vith one 9{l0 bend when IIlOld line diD:enaione only are given,
BTLD
=lIALD -
59
I~'-t-I----'I
---..
SETBACKf.-BiLD~
1-0--- M L 0
---oj
FIGURE-5
AERO
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PAGE 3-11
\/ben the tanos ueed in layout \/Ork are olearly mrlerstood, ms.ka a. flat layout
of the ohannel seotion illustrated in Figure 6.
CHANNEL SECTION
FIRST STE:P
SEOOND STEP
Find the dEl"leloped width. Looldng at the end rlev of crar channe 1 , Figure bE, we BJJ:y divide the I!III tal into bem tangent line
and bend allo\l!UlOEl diBtalloos. Dimensions A, C e.nd t are bend tangent liM
diJlleneions. Sections B a.nd D have /I. flat width, before bending, equal to the
bend tI.:l!'!.ovs.=e. The developed vidth (DY) will be equal to the length of
eection A. + B + C + D + E. The .tepa in finding the dOTe loped width of _thill
ohanne1 are I
.
THIRD STEP
1. Determina and IIrl. te dovn for fnture reference the Betback a.nd the
be nd a.1lo\l!Uloo.
+R
or .051 + .lB7
= .238"
AERO
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PAGE ':'-12
Find the 'Jidth of section A, the BTID of one flange of the channel:
.A
= 2"
- SB
kny decimal dimension 'Jhich must be transferred to the metal 'Jill have
to be converted to the nearest 64th common fraction i f a fractional
4.
= .00367"
x 90 0 or .330"
= 3.524"
7.
DW ~ 7.708" or 7 45(64".
-;~i~::';': '-"~'fe?
F',G!;:T
P'
.. hen several pieces are required, a template may be made for quickly duplicating
the layout. Normally a template "ill be more accurate than a layout on the actual stock since a scriber and divider can be used for all lines. For this ezrunple,
hOlJever, let us eS6Ulne that the layout is to be made on the stock itself.
1.
2.
Shear a strip to
6".
AERO
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330
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4.
PAGE :3-13
80. Figure 7.
UIrl:ng
3/1&"
-,-
....
3/18'"
..
/
~BRAKE :~ -"
REFERENCE
'.
s-s
[
ILl
g (
ILl
ILl
'"zF
!; (
u (
II:
<
3.524-
+1.7sj.
----1.-01.:1
~--------------------7~~-------------------------~
Before go 1ng IIl.b.s ad ,.." should tau t1E>s to 8 tOOy the de tails 0 f 0= beDding
lU.Chine, the cornioo br<Lke. in order to cllU1.rl;r understand the location of
l-_~~~~re~f~e~re~n~c!e~1~1~n~e~s~m~~~~the~~be~~~!0~er~a~t~io~B_i~t~~~lf~.__________________________=
'01
I
"I
"OJ
....,/'..
"
,\
CLAMPING BAR
..-cLAMPING BAR HANDLE
,\
.....'
.~
D
rn
;U
COUNTERWEIGHT ~
J
'.
,"
V~'~
"
.)
'.
,~
~CLAMPING BAR
I::' ':' .
\:~'.!I ";' '1
"(.
ADJUSTING SCREW
."~ I~ ",\' I
(0
(,
.U
f."
---t:ccENTRIC ADJUSTMENf
SCREW
"~i~;" /
.~
((I
"
.:-
u)
IC ADJUSTING
LOCK SCREW
,II
-v
J)
e,
BENDING
LEAF
IJ.'
CORNICE BRAKE
FIGURE-8
.t>
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PAGE 3-15
In order to function properly the cornice brake must be adjusted. for the thickness
of material being bent.
1.
2.
Eccentric adjU.9tment
An even presBUre IIDJ.St be applied to clamp the metal being bent.
To
provide for pressure throughout the "idth"of metal in the brake and
also insure that the eccentrics "ill go Rover center", there are
adjustments in each clamping handle.
A bending leaf stop consisting of a rod and collar is located at the right side of
the bed. This provides for duplicating angles of bend. When the collar is set it
'\lill llmi t travel of the bending leaf to the proper degree.
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331
PH(;'E 3-1 c.
>...--- BRAKE
REFERENCE LINE
CLAMPING BAR
PIVOT
POI~T
BENDING
- ..
LEAF --+I",
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PAGE 3-17
II
T-
f'C-
I I
I
I
FIGURE 10
The brakB must nov be readjUf!t.ed for the thickness of the metal being bent.
f5..s"t.(ii-1:.... - ~;,;.i.; :~'Jrit"-;n~~ n-'t;.;J~..rLi:-~'.-::; b"~,:.k.-sys.E'-~ .~;::: ?=l!r:tl::;.1oM'~~ ;::1.~\ tbe'::brm.ke so. that.
the bend Yill start at one bend tangent. line and end at t.ha oUler. \/hen the
metal 15 clamped in the brake end bent, the bend Yill etart baek under t.be
DOl'le II. distance exactly equa.l to the radius of the nose. One bend tangent
line should coincide Yith this point. Since thia point is hidden under the
nose of the brake, II. sighting or reference line is needed to properly position
the _tal for bending. This l1ns, called the "hrlll.ka refarenoe line", is locate<! at 'a distance equal 1:.0 the rM1ua of the brnm J.1!eMUred ouWyd fro]!! the
bend t.a.nge n t line be ne" th the c l.e.lnp ing bar. Seo Figure 9.
ThiB distance can most conveniently be calcttJ.Ated end mea.sured from the edge
of tho _tal.
The bram referenCB dimension in our CIlUlliple 16 equal to B'l'Ul, .!". 1.762
plus the radiUf! .187 or 1.949, changed to the nearest COlil!ll:m frCllCtion,
13Q
Q
___l_-6
__l/
__64
__'__BO
___th
__a_t__
i_t_c_an
___~
___l_O_C_a_ted
____
on
__th
__e__me
__tal
____by
___
~__a_snr
__ing
_________________________--__
AERO
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PAGE 3-18
'rue _tal is placed in the brake for bending eo that this rafertlncs line is
ro:a.ctly even vit.h tile nose of the brake. This can be sighted by eye from
- directly above, or measured. Arre\lS are often marked on the mUll to sho\l
in vhich direction it must be placed into the brake. !leo, it ie oometims
importam:. t.o decide the order in vhich bends are to be made. Usually the
bending leaf' will have to be carried a little past the desired degree of'
bend to allO\l for springback of the _tal.
If the layout i15 C81"ef'ully dODe and the bends properly made the finished part
should bold to the spec1rled dimensions. Apply the theory discussed thus far
by doing 'the follo\ling practice problems. !Devera will be fooni on the last
page of tile text.
!.
B.
2.
3.
4.
314-
., ". /.~5t'.32
' . -.
. R.'
I
}(f' '.
- ....
ID "
_ I
.064"
1.
'
:;..
-.L
3/4~fO-
I.
2.
FIGURE-II
,.
AERO
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PAGE 3-19
In some situations sheetmetal men may work for long periods of tilDe withont being
required to perfoI'm layout calculations. In others, bend layout may be a very
COmIron part of the job. The tolerance may be such that parts can be bent closely
enough \dthout going through all the layout steps. However, when channels or
brackets l!!Ust fit between other members or when holes or cutouts J!!I.lst match, the
layout must be made with great accuracy. Thus, the ability to make a good layout
is an important part of all-around trarle knoyledge.
.58
f-c--- nLD
OPEN A/'I6LE
CL05ED ANGLE
. FIGURE-I
C4r!r;le A is les5 than ')Go) or closed (Angle A' is greater thEL'1 ')G") angles illustrated in Figure 1, the setback distance may be found by applying shop trigunometry
or by use of a chart derived by use of trigonometry.
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PAGE 3-20
331
BOrne
of the
It is not frequent that shop trigonometry Yill ba needed for finding band tangent
line dimensions aince a K chart ia usually available. Hovever, the principles
may be applied to other eitu~tiona in layout york such as when insufficient infor_
mation is given on a print. There are alao various other problems in mechanics
.TIera a solution may be reached by setting up a triangle with ~iven !r~ormation
. and finding an unknown side or angle. For these reasons a short discussion of
shop trigonometry is included aa an appendix to this section.
The problems which follov illustrate methods of making flat layouts for parts
which have bends of other than 90.
Problem 1:
--------
b=
TLlJ
/i. ---'--1
4
-J
-3
-2
-4
-5
PERPEfYDICULllJ2 ~
eEFE.eHCE LINE
-6
-;;e,-
-.
~a ( L v!
!
!
. -.Ie . l.il:~1
'" "--REFCK'ENCc
EOGE
B
FIGURE-2
Procedure:
I- - - - - - - '
in Figure 2B.
AERO
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330
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PHt~E
3-:21
To find the BTLD represented by "An in Figure 2B, refer to the setback chart. In
the column under AO, find 110. Under K read the ccnetant, which is 1.4281. TIsing
the formula SB
K (T-IR), IJUbstitute the koown values; T
.064 and R 3/1-6
.1875.
Then, solve as follo"s:
.
SB
- .. 1.250 - .359
= .891 = 57/64
To begin the actuaJ. layout on the material, l!Ieasure 57/64" from the perpendicular
eferenee line and mark line -4 (a bend tangent line) as shown in Figure 3.
MBaSUXE! 27/64 from line -4 and mark line -5, the bend allo"ance distance. This is
ur second bend tangent line. We have no" progressed around the bend to the
straight eection of the flange. 'To find BTU> "C" (Figure 2) subtract the previously determined setback from the lIlOld line dimsnsion _7/8 n
F/86
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f/t--I
331
-7
' - R,QP/U.:!>
-3
,<>
-4
It
PAGE 3-22
-5
-(;
"
%
\jJ
1:1
'<l
~
<{;".
U+ 33
(.4
b 4- ...
/5:3
(;4
~R.~FEeE
NeE
PE/ZPENP/CULAI.
.eErERENC LINE
FIGURE-3
The brake reference line dimension can then be found by edGing the radius distance
to the BTlD of the flange which will be under the clamping bar.
Brake Reference Line Dimension
= BTLD
+R
= 57/64+ ]2/64
= 69/64
=1
5/64
~rill
a No. 40 hole near each end of the brake reference line. Using a transfer
punch, mark the location on the stock. Draw arrows from these holes to indicate
the direction that the material 1s to be inserted 1n the brake. When making a
small part of this type, it is beet to put the longer flange or "leg" in the brake
eo as to have a greater clamping area. Cut out the template and file the edges
accurately to the scribe lines.
Label the template wit.h all pertinent data. (The dash numbers are u,"ed in this
text as an aid to understanding and would not be used on an actual layout.)
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PAGE 3-23
-,..-----------------------------i(
$ws-m-'
I.
--------
(A)
FIGURE-4
=K (T + R) = .57735 x
= .577J5 x
= .1452"
(.064 + .1875)
.2515
DiJrensi:Jn "a" \.Iill then be 1.250" - .1452" or 1.1048", rounJed off to l' 7/64".
Measure and scribe -line -4, a bend tangent.
f2-/~--i
''1
.. P!.L
.;'_~-.'"-~ ~
J
-
f'"
;;
_~~.'~~_
..
<:l
-4 '",
-5
\
-3
_6
~
"
Nov find th" bend allovnncc. From the chart read value .003"17.
or 7/32". M8aollre and mark bend tangent line -5.
This x 60 = .;~;>62
AERO
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PAGE 3-24
The remaining dimension "c" is equal to the ML dimension of 7/8" rr.inus setback
or .875 minus .1452 = .7298 or 47/64". Measure and mark line -6.
Measure 3/16" from tho BTL -4, tho line to be placed under the brake clamping
bar, and scribe referonce line -7. Drill transfer holes and mark tem!llate \11th
&Tro\l to sho'.l '.Ihlch '.lay the metal is to be placed in the brake.
Aleo mark the
degree of bend. This template layout is no'.l complete.
Problem 3: Make a template for a reinforcing channel section having more than
one bend and three holes to be accurately located.
Procedure :
Study the dra'.ling, Figure 6.
Secure metal a!lproximately tOt, x 3". Shear reference edge and scribe refe,-er.ce
line -1 as sho\ln in Figure 8. Set a square at 2" and mark points -2 and -3.
Connect these points \lith a straight edge. To begin the layout find dilr.ensio~
"A", Fieure 7.
= HLD
= .75
A = .75
- (T + R)
(.032 + .125)
.157
t~eent
line -4.
Find diUlnsicm "B", '.Ihieh is the bend allo",ance for a 90 bend, '.lith .032 lI'.aterial
on a l/il" radius.
BA
= .OO2i.3
...
Setback
= K (T + R)
= 1.732 (.032 + .125)
= 1.732 x
= .2719
.157
= 2.32ll
0:'
2 21/6/."
AERO
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PAGE .3-25
The other tIlo holes in the flange are located in the same lIay.
subtrsct the setback,
di~nsion
1.5 - .;271Q
= 1.2281 = 1
15/64"
Measure this distance from BTL, -7, and scribe line -11. To locate the center of
thB t~ ho:es on this line, usa either a square or pair of dividers. Measure
distance from ono hole to the edge of metal and scribe line -l~. Scribe line -13,
t88 re~u~'Ed distance. Drill transfer punch holes on center, mark template for
hole sizes and scribe tru~ di~tAr.
REF_
REF.
-/
-~'"
4-
2_l
I
-5
'"'":::.Q
I-
6-
~ -9
\.;
NO1
'll
~p,eILLi
c"v -15
III
#0.2
2 HOLe::.
L
-13
ORILL#IOJ
1-
-i
FIGURE-9~
-/
\,
-/1
,;
-, I-c!
'"
:::,
I-
<
....
rr
-10
Cl
-d
-7
'"!::!
___ -1+
.~.'~.
-f
!ff
----1I
-,/2
--L
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PAGE 3-26
iii! (rY'P)
9
1----/. 3
2--
1-----2~
\I
\I
II
II
II
II
II
~-4:~ 8~~1=.========~
iii
I
I
I
FIGURE-7
"f DR-ILL
- Z HOLJ!!:J
FIGURE-6
,1-----------------~2~------------~1
-r-
,~!
.--f--
-.3
-2
-4
-7
-G
-5
-ll
--
I
,
l-o'-l9
32
~.3Z2" \ ..
221
(;.4-
~~
'4
115
2 C4-
AERO
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PAGE 3-27
331
330
Drill transfer punch holes, mark = I . / S , and designate as No. 1 bend. A.ft.er the
first bend is l!!Brle the metal is ra leaeed and moved in the brake (tovard the operator) until the ooc:ond reference line ia in position. This line, -15, should be
lOOarured liB" !'rom BTL -7. I t if! scribed, marked \lith the degree of bend and
arrel./B and designated 8.S No.2 bend.
This completel'l the layout. 'rhe template l!lhould nol./ be labeled, caref'ully cut and
fil&d to exact eize. It is then ready for nee in producing the pa.rta required.
Problem 4:
Layout a template for a part having a bend not parallel to the edge.
Procedure :
Some sheetmetal parts have bends lIhich are not parallel to the edge or benda 'Jbich
are not parallel to each other. An example of such a part ie the COIIllIlOn wing rib.
Tha reinforcing clip shovn in Figure 10 bas a bend not parallel to the &dga. 'l'he
layout procedure for this olip requires that a I!!9ld liM be located on the pattern.
All other layout lines are made either parallel or perpendicular to thiB lIlOld line.
In Figure 11 the I!!9ld line paslO8s through I!!9ld pointe at I" and 2" from the reference end.
SGcru"e
II
Scribe line ...2, the second lIide, perpendicular to the reference end and 2 l/B" to
the right of line -1. Locate a point on thie line at MID 1".
IIi th .... IIharp scriber dray the mId line, line -3, connecting the t'olO mold points.
locate bend tangent line -4 by lD9asuring back T
distance from the mold line. Scribe this line.
+R
or 5/32"
D.II II
perpendicular
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r:f=:i
PAGE 3-28
-.;;
<ge -t}-.q
e",
o .:>:
-"
.1.R
Ci
Gc
T
zl..
.:5
"Y"""-v;>-
.03Z.-lf--
FIGURE-IO
,: /-v,
C
""r<-<Ve-
....,.
-/
REF.
END
FIGURE-II
NOIJ, locate the points for a line draIJD at -@A wich Yill intereed linea -1 and
~.
From theae points scribe linea -7 and -8, the aides of the flange, making them
perpendicular to the iBA Una. (-bEA ia the center of tile bend.)
'!'he end of tile flange, line -6, Yill be parallel to bend tangent line, -5, and
be located at 3/4" - (T + R) or 19/32" from it. Measure and scribe line -6.
Locate tile bre..ke reference line in the u8118.1 manIlBr by measuring (into tile bend)
one radius from the bend tangent line wich ia to be put =der the brake. This
line has been left off for clarity in Figure 11.
US" of the "J" .Chart
..
..:..;.:;".
All bends in sheetrnetal can be laid out by the use of bend allolJanc<3, as ~iBcussed
thus far .A second method for maJdng layouts of bends employing a eomewat different principle may also be U!led. This requires a "J" Chart.
'!'he "J" Chart method is lees accurate tilan the bend alloIJance method, as so:ntJ
Also, tile reference lines for
locating metal in a cornice brake wen making open and closed angle bende cannot
be determined Yitilout finding bend tangent linea using the "K" Ch-'irt end the rend
allcvance me thoe!. The" J" Chart method does, hovever, enable a mechanic to \!!B.ke