There should be at least %50 contact between the fastener and the surface of the countersink. For V embossments the maximum depth is equal to 3 times material thickness. In the mean-time, you can use the tables below as a guide to determine maximum box/channel depth based on channel width and flange height. Only the truly critical dimensions should be highlighted as such. See the picture below. When possible the notch should be equal to a multiple of the punch’s length in order to prevent nibbling from occurring. Bend Allowance is the length of the arc formed by the "neutral axis" of a bend. Bend radius is smaller if a more narrow v-gap is used, at the expense of higher tonnage requirements to perform the bend, increased risk of stress cracks on the bend surface, and surface marking where the punch and die makes contact with the part. Like Bend Deductions, Bend Allowance and Outside Setback can help you manually modify a flat pattern to obtain the correct finished part size. Knowing the orientation of the part from your hanging holes make sure the part can be easily cleaned after plating. Welding by hand should be restricted to gauges thicker than 20 gauge. Between two parallel ribs, minimum distance is 10 times material thickness plus the radius of the ribs. What is Bend Allowance and Outside Setback? There will always be a radius on the bend, as shown below: The bend radius depends on material properties and the size of the V-die gap used to bend the part. Avoid large sheet metal parts with small bent flanges. In addition to hanging holes design drainage holes. Wire material should always be the same as the material being welded. For open hems, the bend will lose its roundness when the inside diameter is greater than the material thickness. You can use this data to manually modify your flat-pattern if you need to do so. In a part produced using air bending, the metal is placed between a punch and a V-die as shown below: As the press brake forces the punch and the die together, the metal folds where the punch makes contact with the part. If you use CAD software to model your bent part and create your flat pattern for manufacturing, you'll usually tell it the k-factor so that it knows how to unfold your part to create the flat pattern. The "bend stackup" on our press brake looks like the following: Depending on the geometry of your bent part, it could collide with the punch or V-die, die holder, brake, punch holder, or ram during the bend. The minumum flange length is based on the die used to bend. The minimum depth of a lance should be twice the material thickness and at least .125”, If the lance if formed with standard tooling be sure that the length of the bend is dividable by a standard set of. 45° gussets shouldn’t be designed to be more than 4 times material thickness on their flat edge. Somewhere in the middle, the material does neither: the length of that region is the bend allowance length. For holes, the distance between the gusset and the hole’s edge should be at least 8 times material thickness. Because Sheet Metal parts are manufactured from a single sheet of metal the part must maintain a uniform wall thickness. In a bent sheet-metal part, minimum flange length is the minimum distance from where the punch contacts the metal, to the edge of the part. - 3 - Embosses and Offsets – Emboss and offset dimensions should be to the same side of the material unless the overall height is critical. Welded joints should be designed with as tight of tolerances as possible to remove the need for a welder to add wire. If the V-die loses contact with the part, it will not bend properly, if at all. This is negated if the blank is being cut by a. This also benefits man leaf and panel benders which can only bend one direction per setup. Hems are used to create folds in sheet metal in order to stiffen edges and create an edge safe to touch. Specialized tooling cen be very expensive. If the bend angle is not 90 degrees, it is the distance from the start of the bend radius, to the tangent point of the outside radius. Because the parts are going to be hung from hooks and dipped it is beneficial to design hanging holes into your part rather than leaving the decision to the plater. This prevents bulging along the edge. Bends Always consult a tooling profile chart when developing your part. Maximum box depth (or channel depth) is the deepest channel we can create in a part without causing a collision with the brake or tooling during the bend. What is Bend Allowance and Outside Setback? 6. These should be used as general guidelines, and may not cover all cases. A hole should be at least three times material thickness away from the edge of the dimple. Minimum Flange Width: While specifying flange widths in your drawing, please ensure that the width of the flange does not go below four times the thickness of the sheet metal. When you design your part in CAD, you can configure both the bend radius and k-factor to match our manufacturing processes, so that your finished part is as close as possible to the size you intend. A hole should be at least the radius of the curl plus material thickness from the curl feature. But again, sheet metal CAD is the, Channel width and max flange heights in the table below are measured from the. Recommended Minimum distance between two hole centers in sheet metal design should be equal to sum of hole radius plus two times the sheet thickness. The part itself only touches the punch on the bend line, and the v-die on the edges. Maximum flange heights for the above materials are given below: contains design rules for each bending material that we offer. Sheet Metal Fabrication Resources, Blog and Discussion Forum. Minor change in sheet thickness can cause variations in part. Recommended Distance = Radius of Hole1 + Radius of Hole2 + Sheet Thickness. The diameter of a dimple should be no more than 6 times the material thickness. 1) Use common metal materials to reduce material specifications and control as much as possible within the company’s material manual; 2) In the same product, reduce the variety of materials and sheet thickness specifications … But if the finished size of your part is important, we highly recommend that you use CAD software so that you are certain that your flat pattern and bend locations produce the part that you need. The thickness of sheet metal varies from sheet to sheet. When designing parts for laser cutting one should not make holes smaller than the thickness of the material. Between two extruded holes, distance should be at least 6 times material thickness. From a bend, lances should be at least 3 times material thickness plus bend radius, however the actual minimum is often much greater than this and driven by the tooling profile. Spot welding should be used for joining equally thick co-planar surfaces. It will compensate for that when unfolding your part, so that the finished part is as close as possible to your design. Design For Manufacturability – Sheet Metal Guidelines Bends For the ease of manufacturing, multiple bends on the same plane should occur in the same direction.

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