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Profound radius bends

Large Radius Bending, also known as R Bending or Profound Radius Bending, is the process of creating a bend with
a large radius to material thickness relationship.

When the inside radius becomes 8 to 10 times the material thickness or

greater, it is characterized as a Profound radius bends. The two significant
factors which characterize large radius bending are the multi-breakage and
the increased amount of Springback found in large radius bends.

Multi-breakage occurs in large radius operations, more common in softer

sheet metal and less commonly in materials with higher tensile strengths.

Multi-breakage is less likely to occur in a thin sheet of 304-stainless steel and

more likely in a softer sheet of H-series Aluminum. This occurs as the
workpiece begins to bend and the sheet material begins to separate from the
punch tip.
Figure 1
The workpiece actually bends ahead of the punch and ultimately attains
somewhat of a polygonal shape that worsens with angle, figure 2.

Besides the polygonal shape, the material springs back after the bend is
completed, so does the final radius. The final radius will be slightly smaller
than the punch tip.

This Final radius (Fr) can be calculated from the Punch Radius (Rp) and
the Material thickness (Mt) using the following formula:

Fr = Rp – (Rp x ((Rp x .15 + .030) – Mt))

Multi-breakage and Radius

Not only does the formula cover all ranges of material thickness and bend Figure 2
radius, it is also a bit more accurate. So follow along as we go through a
sample problem.

Remember, always work from the inner most parentheses out.

Material thickness = .031

Punch radius = .393 ( A standard metric radius.)
Actual Ir = .393 – ( .393 * (( .393 * .15 + .03) – .031))
Actual Ir = .393 – ( .393 * (( .088 ) – .031))
Actual Ir = .393 – ( .393 * ( .0579))
Actual Ir = .393 – ( .0227 )
Actual Ir = .370

The actual measurable inside radius (Ir) is equal to .370 instead of a .393 radius.

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Excessive SpringBack

In Chart 1 you see the relationship between Springback,

material thickness and bend radius. Note that a 60-mm
radius in .8-mm material can develop 30° of springback in
mild cold rolled steel.

It is difficult for design engineers to predict springback

because so many variables can affect it, such as material
properties, tool geometry and sheet thickness. As a rule,
however, the larger the punch radius, the greater the
springback, and the greater the bend angle, the greater the
springback.
Chart 1
The Die Shape

Large dies used for these types of bends often need to bend past the V-shape at 90°. Punches and dies, unless
customized, are designed at 90°. This standard 90° V-opening die could not help to compensate for Springback.

Bottom bending and coining of profound radius bends is not possible using a
standard V-die because the punch cannot penetrate the die space far enough
to compensate for the excess springback of the large radius bend but
instead, coins at the two points of contact between the punch, material and
the die faces, so Springback is not eliminated, figure 3.

Because of the need to compensate for Springback modern large V-opening

dies have a relieved area which allows for a radius punch to push deeper
into the die space, figure 4.

It should also be noted that this relieved die could also decrease die angles
from 90° to as little as 73°, included.
Figure 3

Changing the die angle to a lesser angle has the effect of compensating for
springback, but at the same time increasing the multi-breakage
effect. These dies do not eliminate multi-breakage in the workpiece,
they actually make the effect worse.

The addition of a urethane pad at the base of a relieved die will

eliminate the multi-breakage phenomenon and allow for a correct
and consistent bend radius by forcing the material against the punch
radius. In the image below you can see how a relieved type die
allows for greater over-bending of the workpiece.

Die width Selection

Calculating the proper die opening for a large radius bending is a

little different than the formula for finding the optimal die open
previously discussed. You will use a simple formula which takes into Figure 4

account the Punch Radius (Rp) and the Material Thickness (Mt).

For a standard v-opening with no relief you will use:

Standard V-die = (Rp + Mt) x 2.5

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For the relieved die, because it does require as much of an opening as the standard V-die, we use the formula below:

Relieved V-die = (Rp + Mt) x 2.2.

Specialty Dies and Methods

Both of these phenomena can be prevented by using

specialized dies which push the workpiece against the punch
during the bend, ensuring that the final radius is equal to the
punch radius.

One common die type which can correct these issues is the
Rolla-V type of die which uses a spring loaded half circle. These Figure 5
rotating set of pads hold the workpiece static while they move
around the sheet material and punch face, figure 5.

As the punch pushes down through the metal, the Rolla-V’s roll while
providing pressure against the punch tip. This ensures even forming around a
radius and allows for easy over-bending to compensate for springback, which
can be significant in a large radius bend.

There is a video showing many of the virtues of the Rolla-V’s in the custom
tool chapter. While not for everything, they are capable of producing many
bends impossible in other punch and die systems. Figure 5 is a good
example.

A spring loaded bottom push-back set at the center of the die applies upwards
pressure throughout the bend, pushing the workpiece against the bottom of
Figure 6
the punch, preventing the multi-breakage phenomenon from occurring. A
strong spring loaded bar can also create a nice radius at the cost of added
tonnge, figure 6.

If a spring loaded die or a urethane pad is unavailable, a simple piece of high

pressure water hose or like material will work.

Note that Rolla-V and urethane backup pads force the material around the
radius of the punch. Therefore, the punch radius is the radius used in the
bend deduction calculations.

Figure 7

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