SHEET METAL DEVELOPED

LENGTH CALCULATIONS

OMKAR PRAVIN PIMPALE

 SHEET METAL DEVELOPED LENGTH
CALCULATIONS

• Developed length is the Flat length in Sheet Metal obtained after unfolding.
• Flat length is required to create the Blank size & its calculations for the
required Sheet Metal component.
• Consider a Sheet Metal component:

Here,
OS – Outside Setback
Setback: It is the distance from the mold line to the bend line.

𝐴
OS = tan⁡ × (𝑇 + 𝑅)
2
Here,
A = Bend angle in degrees
T = Sheet thickness
R= Inner Bend Radius

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE

As,

𝐵𝐸𝑁𝐷⁡𝐴𝐿𝐿𝑂𝑊𝐴𝑁𝐶𝐸(𝐵𝐴) + 𝐵𝐸𝑁𝐷⁡𝐷𝐸𝐷𝑈𝐶𝑇𝐼𝑂𝑁(𝐵𝐷) = 2 × Outside⁡Setback

𝐴
∴ ⁡𝐵𝐴 + 𝐵𝐷 = 2 × tan⁡ × (𝑇 + 𝑅)
2

As we know,

Π
𝐵𝐴 = 𝐴 × × (𝑅 + 𝐾𝑇)
180
Where,
K = K-factor
If,
1
𝑅 < 𝑇⁡⁡⁡⁡⁡,⁡⁡⁡⁡⁡𝐾 =
4
1
𝑇 ≤ 𝑅 ≤ 2𝑇⁡⁡⁡,⁡⁡⁡⁡⁡⁡𝐾 = ⁡⁡⁡⁡⁡
3
1
𝑅 > 2𝑇⁡⁡⁡⁡,⁡⁡⁡⁡⁡𝐾 =
2

So, we can calculate BD from the above equations,

𝐴
𝐵𝐷 = [2 × 𝑡𝑎𝑛 × (𝑇 + 𝑅)] − 𝐵𝐴
2

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE

 DEVELOPED LENGTH CALCULATIONS

Case 1: -

SHEET⁡METAL⁡FLAT⁡LENGHT
= LENGTH⁡A1 + LENGTH⁡B1 + BEND⁡ALLOWANCE(BA)

Here,
A1 = 20mm B1 = 30mm A = 90°
1
∵ 𝑅 = 𝑇 = 2𝑚𝑚⁡⁡⁡⁡,⁡⁡⁡⁡⁡𝐾 =
3

Π
𝐵𝐴 = 𝐴 × × (𝑅 + 𝐾𝑇)
180
𝜋 1
∴ 𝐵𝐴 = 90° × (2 + ( × 2))
180 3

𝐁𝐀 = 𝟒. 𝟏𝟖𝟖𝟖⁡𝐦𝐦

SHEET⁡METAL⁡FLAT⁡LENGHT = 20 + 30 + 4.1888 = 54.1888 mm

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE

Case 2: -

SHEET⁡METAL⁡FLAT⁡LENGHT
= LENGTH⁡A2 + LENGTH⁡B2 + BEND⁡DEDUCTION(BD)

Here,
A2 = 24mm B2 = 34mm A = 90°
1
∵ 𝑅 = 𝑇 = 2𝑚𝑚⁡⁡⁡⁡,⁡⁡⁡⁡⁡𝐾 =
3

𝐴
𝐵𝐷 = [2 × 𝑡𝑎𝑛 × (𝑇 + 𝑅)] − 𝐵𝐴
2
90°
∴ 𝐵𝐷 = [2 × tan ( ) (2 + 2)] − 4.1888
2
𝑩𝑫 = 𝟑. 𝟖𝟏𝟏𝟐⁡𝒎𝒎

SHEET⁡METAL⁡FLAT⁡LENGHT = 24 + 34 − 3.8112 = 54.1888 mm

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE

Verifying the above calculations using CAD Software:

o Component dimensions in Folded view:

Fig.1
o Component dimensions in Unfolded view:

Fig.2

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE

Taking the reference of Fig.2 we can see, the Sheet Metal Flat length = 54.163 mm
which is approximately equal to the value that we obtained from the above
calculations i.e., 54.1888 mm.

-Omkar Pravin Pimpale

(Bachelor of Engineering in Mechanical)

SHEET METAL DEVELOPED LENGTH CALCULATIONS OMKAR PRAVIN PIMPALE