MACHINE TECHNOLOGY205

READING AND USING ENGINEERING DRA WINGS

BLANK DEVELOPMENT

For Formed Sheet Metal Parts

There are many systems employed by a variety of

industries (aircraft, electronics, architectural, automotive, etc.)
to account for "what happens in a sheet metal part when bending
it from its flat blank state to Its final bent-upform:
"Setbacks ", "Bend Allowances " and "K Factors " are somewhat
different approaches to arrive at a proper flat blank size
and insure that features are correctly located
on given part side after bending.

The system illustrated here is one developed by staff of a former precision

manufacturer in Berkeley, CA. It has proven over many decades, when doing
"coin" bending*, to produce extremely accurate and reliable results .

* Please Note: The following formulas for right-angle bends assume a bending
process called "coin" (or. " bottom") bending ... as opposed to "air" bending.

da baruch
 DIMENSIONING WITH NON-90 DEGREE BENDS

1.000
Extension Line Dimensioning
1.000

1.000 1.000

0.881
Tangential Dimensioning

0.881
Illustrated here is the development of a blank for parts having a standard 90 deg. bend.
Shown is a common dimensioning method and calculation of a Setback (bend deduction) *

SB = Setback: The amount to be subtracted from the sum of the outside

dimensions of the two legs of the bent part; the object is to determine the correct
length of the flat blank in preparation for bending. The formula for this is
SB= .43r + 1.372t

r = The radius on the inside curve of the bend.

t = The thickness of the sheet or plate

2.000

0.125
I
2.000

Developing the flat blank length for the above drawn part:
Calculate the Setback and then subtract it from the sum of two
outside dimensions as follows -

Where r=.125 and t=.125,

SB = .43 (.125) + 1.372 (.125)

.0538 + .1715
.225

Then 2.000
+2.000

4.000
- .225

3.775 This is the length of the flat blank.

3.775
I 0.125
 In example #2 of flat blank development, everything is the same as
example #1 except the metal thickness ("t" now = .062) :

EXAMPLE 2 EXAMPLE 3

90 90C
2.000 2.000
R0.125 R0.032

I 0.062 I 0.062
2.000 2.000

EXAMPLE #2

SB = .43 (.125) + 1.372 (.062)

.0538 + .0851

.139

Then 2.000
+2.000

4.000
- .139

= 3.861 This is the length of the flat blank.

EXAMPLE #3

SB = .43 (.032) + 1.372 (.062)

.014 + .0851

.099

Then 2.000
+2.000

4.000
- .099

3.901 This is the length of the flat blank.

NON-90 DEG. SETBACKS - EXTENSION LINE DIMENSIONING

SB = 2 (r + t) tan (a/2) - 271 (r + .4t) a/360

a = Angle of bend, specifically the angle of deflection - in other words,

the amount of bend away from the 180 o starting point. (To find the
deflected angles in these examples, subtract the included angles
shown from 180 o) .

r = The radius on the inside curve of the bend,

t = The thickness of the sheet or plate

120C

R0.062
0.125
I
2.000

NON-90 DEG, SETBACKS - TANGENT LINE DIMENSIONING

0.125

SB = 2 (r +1) - (r + .4t) A / 57.3

Calculate: 1.863 + 1.863-SB

 NAME

CALCULATE FLAT BLANK LENGTHS WITH THE FORMULA

SB = ,43r + 1,372-t
I 1,125

T
1.500
0,100
r- RO,063
2,000
J
J_ 0.500 / TYP

2,500 2,000

0,090

r
1,500 R0.093
0,125

T"
1,000
|- 0,625

\0
\0 " ^
\

"* 17D
2,500

0,090 0,100
2,000
1.125 R0.125 RO.063
-^

-3.250- -2,000-

,090 0,625

1,125 /-R0.125 X2 p O,125 1.000

_L
0,750 X2

8 Blank Devel.
dab - 5 4 B013
 Calculate the flat-blank location of the center of the hole
grid in the X & Y axes fron the indicated reference edges:

X= Y=

1,500

Reference
6,000 Edges for Flat
Blank

R0.125
3,050 TYP

0,100 J
o O
2,550
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Blank Devel.
dab - 5 4 E013