SHEET METAL WORKING TABLE OF CONTENTS CONTENTS 1 GENERAL, ‘BONOING RaDe CORROSION-RESISTANT STEEL sERYLLUM COPPER ALUMINUM 2 ALUMINUM ALLOYS MAGNESIUM ALLOYS CARBON STEEL COMMERCIAL BRASS ENO RELEF CUTOUTS NoTeHNG (FEN CORNERS ane WELDED coRNERS avons RIQBING AND STFFENNG {THN SHEET METAL ‘ROSS aRACES LOCATION OF HOLES HOLE PUNCHING SSTANDARO PUNCHES eacNG SPUN stapes SECTION 2 Page 1 of 17 PAGE NO, 3 5 6 7 ° * a ° 0 10 2 2 2 134 15 6 7SHEET METAL WORKING ‘SHEET METAL WORKING GENERAL ‘he advantages of using sheet metal in the design of equipment ere obvious. It Is Widely used because strong, light-weight parts can be made quickly ena checpy. Je a method of fabriction, sheet mete, working Includes; bending, drawing, Blanking, piercing, trmming, shearing, Folin, ribbing, sploning and sVvetching BENDING The direction of grain wil affect th formabiity of nerd mete's but does not c’ffect softer metals apprecibly. When the onl of bend ls af right angles to the rection of the grin, a smaller bend Fads can be used without fracturing the metal EEINITONS Bend Redus.— The redius formed when bending sheet metal Wold Line.~ The intersection of extension Ties of two external surfaces of o bend This is the point where the intersection would occur if the perts were produced without bend resus, Bend Relist The removal of material to provide clearance for the intersection of Bend radi when forming a. comer. Dimension bends to mold fines. When the surfeces being dimensioned are parallel of Seuare, the mold ines are the sume as the extension lines.” When the surfaces cre at an angle to each other, aimension te the mold line. When engular cimensions cre required, inceate the angle from the potion of © 80" bene SECTION 2 Page 2 of 17 rk » Generals, overall dimensions ave preferred. However inside dimensions ore permisedle i the port has specisl dimension or tolerence requirements, Lt i Overall DinsnsioningSHEET METAL WORKING BENDING RADI When prevsion bends ore requir tolerance may grees for thin metale (012 to -060 inch) and. one degree for thicker metals (.060 to .154 inch) portculey Tor boxes, frames, chassis and onguler SECTION 2 Page 3 of 17 In the tables which follow, the minimum Send ell for various metals ie supplied If the aetual raat ie not given, @ factor is used in determining minimum insice red Mere o factor is used, the cadius for Because of auch aliferences, technica! ‘gives thckneas of mela oblaiied menuals wil very ae to the minimum Setmullpiag the thickness by ine bend red to whieh vers metaie may be facer “A-zere-focior indicates Ina Bent without domege lo the port ‘ine bend may be shar, CCORROSION=RESISTANT STEEL INMUM INSIDE BEND. RADI FACTORS. FOR 90° COLD BEND PARALLEL TO ROLLING DIRECTION (GRAIN) 304, 36, 347, 0 e000 o-os 304, 316, 347, 0 ow 00s | 0-05 BERYLUUM COPPER: ASTM B194, a2—C~533 IMUM INSIDE. BEND RADI FACTORS. FOR 90" COLD BEND. ‘far Seek™_| rong recon [rng recton rng erecton va fs te 0040 : 1s 2 va | 2 | waoe 2 2s 3ET METAL WORKING SECTION 2 Page 4 of 17 ALUMINUM AND ALUMINUM ALLOYS: MINIMUM INSIDE BEND RADII FACTORS FOR 90" COLD BEND Ito cod tanger Topas Diese Tat FR upton ome [00s | eos | one | aie | oase ioe | Sar | She she | Sf sosi-0 ° ° o fos-1 Jos-1 soo—14 » |is-2 fas-2 2 2-3 ‘ sosa-nss | ts zs-s fos-3 | s-4 | ans | soSHEET METAL WORKING WAGNESIUM. ALLOYS ASTM 890, Alley FSi, Alloy AZSIA, CO-M-44 MINIMUM INSDE END RADI SECTION 2 Page $ of 17 a, ines od i ioe been 500" F [Room temp | 3251 F [Roo temp ore 0.08 0.09 0.09 019 0.020 006 0.08 0.09 19 0.025 0.06 013 ons 025 0.032 0.08 038 016 032 0.040 0.09 039 o19 ose 0.081 009 028 025 ose 0.064 016 032 032 062 oor ons 038 038 082 0.081 ans oe aa oe ost org oat as 1.00 x02 028. 050 oso 1.00 0128 025. oss oss 128 0186 038 075 07s 163 0.188 038 1.00 1.00 1.88 0.250 050 125 1.25 250SHEET METAL WORKING CARBON STEEL AS ROLLED OR ANNEALED: ‘COMMERCIAL QUALITY (Ca) OR DRAWING QUALITY (90) 'MINIMOW INSIDE BEND RADII FOR 30" COLD SEND Sheet thickness Mosimum bend reeus, inches 9.008 oor ors 9.020 0.025 0.030 0.035 042 0.080 0.062 0078 0.093 0.108 0125 0.156 0188 0.250 ° ° ° 16 we we ws 16 3/2 Vs 5/32 sie 32 “ 5/6 ss wn SECTION 2 Page § of 17ET METAL WORKING SECTION 2 Page 7 of 17 (COMMERCIAL BRASS: SAE 70C, ASTM B36, Aloy 8 INMUM INSIDE. BEND RADII FACTORS. FoR 90" COLD BEND Temper | nirbws | tices Papendedar to] aL 45" fe far Sar _[ioks acon [ry ‘Satin a hard | 0 te 2 |e aosor ° ° ° sistas| 3 Jose te oosn| 0 ° oss 4 | eos0 ° ° os 4 | couse ° oss 1 4 | cece oss ars 1 8 | co ° 5 4 swing | 5 | conse as 5 ® sire preg] 16 [05 2 q 8ET METAL WORKING SECTION 2 Page 8 of 17 PHOSPHOR BRONZE: SAE 77A, ASTI 8103, Alloy A WINMUM INSIDE BEND RADI FACTORS FOR 90" COLD BEND, Bas] Set FATE temper | sorters | shtiruee Paperianar w] AS tod Ser [roe recton [rng aren ated | 0 te2 [te corm ° ° ° Vibes | 2 powos we ozo] avs oe) ove ters 4 | cots 1s soon | 8 | cease 12sSHEET METAL WORKING END RELIEF cUTOUTS. To prevent interference whenever sheet metel bends intersect one another, material must be removed from the intersection {The moterial removed should be ot least 05 inch behind the int tend tines. Usual, @ Felef cutout is @ radius. 03 MN y i ‘BEND LUNES: NoToHNG Notches nd slots oe mede in the fat Blank in order to avoid tearing of eracking the meta. It Is usualy adequete it the Width ond’ depth of relists are twice the thickness of the stock, =| wore nor crimcaL (No: rust an SE ‘BEND UNE SECTION 2 Page 9 of 17 ‘OPEN CORNERS Use open corer construction wherever posabie to oveid the eddltiond! cost of welding & Beno RADIUS 330 01A Mn Lanois Generally, the rules governing the punching of holes in metal apply equaly to loncing 1X minimum dlatance of et least 1/4 inch should be alowed between @ bend and the tge of the opening. + 25 MNSHEET METAL WORKING SECTION 2 Page 10 of 17 WELDED coaNeRs iter knotches are put In the fat blank and the edges have been rall formed, the G29 con be filed with o formed knuckle Winch is welded in place ond the comers De not show comer bend relief on © sround oF fies smooth welded corner, However, the bend relief Gsiineation must be shows 99 al Unwelded corners. ‘A contoured oF finished weld should not be called for unless specifealy required By engineering > kuexLE 7 IGATENNG Holes Ughtening holes are cutoute in sheet metal parte usully for the purpose of feduzing weigh They may be pin round holes oF of other shapes ene are dimensioned in the some manner ot other cutouts, ‘A comer shape should be drown af it eppears efter weldng ond indicated by the appropriate welding symbol In order to avoid stresses which might cause tearing or fatigue cracking of the Sontoured metal, such holes should have inside radi in the comers of openings. ANUGKLES [ here rounded comers are nesdes, «4. tops and bottoms of easinets, the use of drawn ball corer or kruekle should be considered ISHEET METAL WORKING SHEARING ‘Shearing is the method employed for cutting off large oF small places of motel from strip or plate stock "As in punching holes, burrs are formed ond must be Femoved by machining operations such os gending, reaming or Mili. Barrel fumbling fs used for daburing small ports. ANA “wo DRAWING The common materials for the drawing process include steel, eluminum, magnesium fond brass, To ecnleve 0 successtu raw of © eyindrieal shape, the ductility of the material hes to be considered. Also portent is the size of the comer redi nd the ratio of height to siameter Rectangular shapes can alse be drawn However, to prevent fractures et the comers, the shape of the blonk end the esign of the aie must be carefully oneldered.""The raclus of comers” should be not lees than si times the stock thickness: nor under 3/8 ine, SECTION 2 Page 11 of 17 Hou DOWN PAD The accurecy ond rigidly of @ bend can be inerecsed by means of corrugation, Fabing and stifening flanges. Geneccly, foe ere double the stock thicknese in height end equal fo the stock thickness in inside radius (section A-A) Sometimes it is desirable to reinforce @ hole by forming a rib eround the hole (Gection 8-8). calal FL tk | | ‘ Ae SECTION CA scone 6-8 blog con hee reduce ne ‘age-snd weight of < park.SHEET METAL WORKING JN SHEET ETA In thin sheet metal, lapping ond spot Welding of comers is preferee to outing Gnd welding of comers for 9 stronger end more inexpensive sit ‘GROSS BRACES Supports and cross braces should be tapered to moke cesembly eosier ond to reduce weight. However, the flange taper should not be to the metal face The toper should be parti, as shown. TWCE METAL THICKNESS SECTION 2 Page 12 of 17 LOCATION OF HOLES Never locate « hole too close to 2 bend or en edge. The edge of the hole should Be no closer to the inside of the bend of edge ofa plate then 1 1/2 times the metal thickness. If sven o hole i Feaucee, it may be necessery to put the hole in after the bend has been made + 11/2 T(MIN) i o sake 2c When @ punch ond a dle are used for putting holes in sheet stock, the sides Of the hole ore not perfectly perpen must be punched undersized ond reamed ‘the desired dimension PUNCH - stock CO oeSHEET METAL WORKING SECTION 2 Page 13 of 17 In addition, hole punching is employed in small lot or mass production processes, Meny factors need to be considered Ineluding material properties, hole size ond location, stock thickness end the clearence between the punch ond ele ‘Aso, punched holes need not be only ound. Standard punches come in @ variety of sizes and shopes as shown in the tbslations Below ROUND SE See eee, rape a he ent Shea Shee coeont Le Se ee Fee tir 35/16 tho 3/8" Site ed ie 1a erent bea Co progress i732 progress mh 1/3E" 2. A stondars 7 se fea he PRR MWe SQUARE SIZE [J \% 78 5/32, 3/16 7/32. 4/4 32. 8/16 3/2. 3/8 3/32. 7/18 S732, 2 7/32. 96 19/32. 5/8 af. 1/6 25/32. 3/4 25/32. 13/18 2727178 29/32. 19/6 1-9/6, 1-5/8 1/16 1-8/8, 113/16 7/8, 115/18, 2 CCORNER_ROUNDING RADUS 1% 36 af we sf a 1SHEET METAL WORKING SECTION 2 Page 14 of 17 (Standerd Punches continued) "ot SHAPE DOUBLE “D" SHAPE Sz a8 <-> 313281 11 se ee i ae onc vn 405 359 rT 30 see M40 410 T 760.640 le sos 473 - 1380 00 590 kemoue RECEPTACLE / SE _ J-e-| x8 oe} | L [aa ma ane vue | 4 we re one | fy imam] t| 1 s/s she anf 11/6 ELECTRICAL OUTLET KNOCKOUT NoTCHING CONDUIT SIZE DU sze ae he 7 12 78 0 1-7/6" Y a or toe seSHEET METAL WORKING SECTION 2 Page 15 of 17 GUSSEIING ‘The wockest parts of eny usualy to be found et it fre employed to spreed concentrated at jpints over lerge areas, They are an inexpensive method for strengthening on entire structure, Inereesing Fighlty end making the structure less Susceptible fo Bending forces, ture ore ints, Guseets Meny methods ore avalabe for affing © gqusset to 3 frome. The most common of these techniques ore shown below RBS There are many forms of ribs but however atteched, ther primary function Te te stectively increase the strength and Filly of @ structure A va Flot Cieulor Pane! Ribbed Agcinst Sending or WarpingSHEET METAL WORKING ‘BRACING The riglty of e structure ond its bility te resist bending, torsional and bucking stresses con be enormously improved by forreet braving, Usually, the Toad exeryng copacty of a structure is also improved by bracing without significantly inereesing weight 000 6000 SECTION 2 Page 16 of 17 Inadequote bracing can couse excessive deflection ond even result in senstily te smal vibrational forces, ce shown below Poor Subject to buckling fend side movernent | coco This beacing wil prevent side rovernent coo Braces ore Tightwsight ond prove strengthSHEET METAL WORKING ‘SPUN SHAPES. The process of spinning Ie limited to symmetrical shopes that are circular in crose section ond notmal to the xls of rotation This method eon be used to form most soft and duetle metels, and orderly it i used to manufacture items such os cocking utensils, light reflectors and Yerious other conical shapes. The forming tool in the spinning process usually mace of wood or herd metal ‘ond the tool Is pressed against the blonk causing the metal to flow over the form. Because a straight-sided cinder is very dificult to apin, It should be formed, if possible, by © drawing operation \ ae However, conical and dome shaped ports ‘as shown in the folowing ustrations ore ‘easy #0 spin and offer many advantages over other types of production Spun parte are generally considered to be moderately low is cost becouse very little finishing 3 required. A simple trimming ‘operation ond cleaning is all that is requires. SECTION 2 Page 17 of 17 CONE SPINNING ‘As shown below, in cone spinning, the ‘chuck meets the mete’ ot smaller angles than in the cose of spinning < simple eyinder whieh allows for better central in forming the metal The hemispherical shape Ie more feu to spin because the angle of deformation becomes progressively more acute The greatest single advantage of spinning ‘over other methods le the very low cost ‘of getting into production, The rin disadvantage is the fact that shapes are limited to round, symmetrical forms.