Bend Testing

3.6.Bending
It is the ability of the material to resist cracking during bending.
 = Mr/J
Where:-  = the bending stress M =bending moment;
r =the max distance from the beam's neutral axis. J = moment of
inertia
*The bend radius R is defined as the radius of curvature on the
concave, or inside, surface of the bend. To estimate the change in
length produced by bending, the neutral axis is usually taken at a
distance of 0.45 times the sheet thickness from the inside surface of
the bend. When metal is bent, its final length is increased over its
original length in the blank because the metal thickness is decreased.
As the bend radius becomes smaller, the decrease in thickness
increases. The initial or developed length of the center line of the
bent section is called the bend allowance B. If it is assumed that the
neutral axis has a radius of curvature equal to R + 0.45T, the bend
allowance can be determined from the following equation.
B = ( R + 0.45T ) 2 / 360
  = angle of bend in degree,
The bend allowance is useful for determining the length of the blank
required for making a bend.
For a given bending operation the bend radius cannot be made
smaller than a certain value, or the metal will crack on outer tensile
surface. The minimum bend radius is usually expressed in multiples
of the sheet thickness. Thus a 3T bend radius where T is the sheet
thickness indicates that the metal can be bent without cracking
through a radius equal to three times the sheet thickness.
* The strain to produce fracture in bending is a reverse function of
the width-thickness ratio b/T.
* In bending sheet with high b/T ratio the cracks will occur near
the center of the sheet when the ductility is exhausted. However, if
the edges of the sheet are rough, edge cracking will occur.
E  1/b/T
K-factor
K-factor is a ratio of location of the neutral line to the
material thickness as defined by t/T where t = location of
the neutral line and T = material thickness. The K-Factor
formulation does not take the forming stresses into account
but is simply a geometric calculation of the location of the
neutral line after the forces are applied and is thus the roll-
up of all the unknown (error) factors for a given setup. The
K-factor depends on many factors including the
material, the type of bending operation (coining,
bottoming, air-bending, etc.) the tools, etc. and is typically
between 0.3 to 0.5.
In sheet metal design, the K-factor is used to calculate
how much sheet metal one needs to leave for the bend in
order to achieve particular final dimensions, especially for
between the straight sides next the bend. Use the known
k-factor and the known inner bending radius to
calculate the bending radius of the neutral line. Then
use the neutral bending radius to calculate the arc
length of the neutral line ("circumference of circle"
multiplied by the "bend angle as fraction of 360 deg").
The arc length of the neutral line is the length of the
sheet metal you have to leave for the bend!
 The BA can be calculated using the following formula:[7]

BA = bend allowance
BD = bend deduction
R = inside bend radius
K = K-Factor, which is t / T
T = material thickness
t = distance from inside face to
the neutral line
A = bend angle in degrees (the
angle through which the material
is bent)
Note that when dimensions "C" are specified,
dimension B = C - R - T
The outside set back (OSSB) is the length
from the tangent point of the radius to the
apex of the outside of the bend. The bend
deduction (BD) is twice the outside setback
minus the bend allowance. BD is calculated
using the following formula:

The above formula works only for

right angles. For bend angles 90
degrees or greater the following
formula works, where A is the angle
in radians (=degrees*π/180)
 (c)2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning ™ is a trademark used herein under license.

(a) The bend test often used for measuring the strength
of brittle materials, and (b) the deflection δ obtained by
bending
Flexural Strength
• Schematic for a
3-point bending
test.
• Able to
measure the
stress-strain
behavior and
flexural
strength of
brittle ceramics.
• Flexural
strength
(modulus of
rupture or bend
strength) is the
stress at
fracture.
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