METAL BENDING

GROUP 7- MIB
METAL BENDING

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1
FABRICATION
TERMINOLOGIES
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TERMINOLOGIES

Flat - portion of a part

that is not included in
the bend. It is equal to
the base measurement
minus setback.
Leg - the longer part of
a formed angle
Flange -the shorter part
of a formed angle

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TERMINOLOGIES

Sheet Metal Grain

- small lines that run in
one direction through the
material distinguishes
the grain direction
Bend Radius
- the arc formed when
sheet metal is bent.

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TERMINOLOGIES

Neutral Axis
-line along the bend
44.53%
which neither shrinks nor
From the stretches, but retains its
inside bend original dimension
Mold line
- extension of the flat
side of a part beyond the
radius.

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TERMINOLOGIES

Mold point
- the point of intersection
of the mold lines.
Bend Tangent Line
- designate the location
where the sheet metal
begins to form around the
bend radius.

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TERMINOLOGIES

Setback
- distance between the
mold line and the bend
tangent line inside the bend
area
Bend Allowance
- the amount of material
to be bent

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2
BEND
CALCULATIONS
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BEND CALCULATIONS

2π(R+𝟏𝟐T)
Bend Allowance:
4
FOR 90°
BEND
Setback: radius + thickness

ϴ
Bend Allowance: 2π (R+KT)
360

OTHER THAN Setback: K(radius + thickness)

90° BEND
takes into account when
K-Factor: K= tan (ϴ/2)
the metal is bent to an
angle ± 90 degrees
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BEND ALLOWANCE
OTHER THAN 90° BEND
GIVEN:
GIVEN: 45° bend
90° bend Radius: ¼ inch
Radius: ¼ inch Thickness: 0.051 inch
Thickness: 0.051 inch
SOLUTION:
SOLUTION:
2π(R+𝟏𝟐T) ϴ
Bend Allowance = Bend Allowance = 2π (R+KT)
4 360
K = tan (45/2) = 0.4142
(2 × 3.1416)(0.250 + 1/2(0.051))
=
4 45
BA = 2π (0.250 + (0.4142 x 0.051))
360
6.2832(0.250 + 0.0255)
=
4 BA = 0.2129”
6.2832(0.2755)
=
4

= 0.4327” FOR 90° BEND

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BEND ALLOWANCE

According on Jeppesen:
π(2𝑅+𝑇)
Bend Allowance = 360
𝑥 𝑛 ; where n= bend degree

GIVEN: SOLUTION:
90° bend
π(2𝑅+𝑇)
Radius: ¼ inch BA = 𝑥𝑛
360
Thickness: 0.051 inch
3.1416((2𝑥0.250)+0.051)
BA = 𝑥 90
360

BA = 0.4327”
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BEND ALLOWANCE

According on Jeppesen:
π(2𝑅+𝑇)
Bend Allowance = 360
𝑥 𝑛 ; where n= bend degree

GIVEN: SOLUTION:
45° bend
π(2𝑅+𝑇)
Radius: ¼ inch BA = 𝑥𝑛
360
Thickness: 0.051 inch
3.1416((2𝑥0.250)+0.051)
BA = 𝑥 45
360

BA = 0.2164”
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SETBACK
OTHER THAN 90° BEND

GIVEN: Radius = ¼ = 0.250”

Thickness =0.064”
Angle = 135°
GIVEN:
Radius = ¼ = 0.250”
SOLUTION:
Thickness =0.064”
K = tan (ϴ/2) = tan (45/2) =0.414
SOLUTION:
Setback =R+T
Setback = K(R + T)
= 0.250 + 0.064
= 0.414(0.250+0.064)
= 0.314”
= 0.130”

FOR 90° BEND

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3
COMPUTATION FOR
LAYOUTS
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 Pattern drawn on flat metal to determine
locations of:

sight bend cutting

lines tangent location
line

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 FOR U – SHAPED BEND

 determine the bending

radius (either through chart or given already)

 find the
Setback value = (bend radius + metal thickness)

 determine Flats = mold line – setback

 determine bend tangent line = mold line (end of the

metal) – setback value

 determine sight line = (1 radius from the 1st bend

tangent line)

 determine bend allowance to mark the 2nd bend 17

tangent line
 FOR U – SHAPED BEND
(for the 2nd bent)

• determine 2nd flat = mold line – (2 x setback

value)

• mark the 3rd bend tangent line

• add sight line from 3rd bend tangent line

• mark the 4th bend tangent line by

determining the bend allowance

• the remaining piece serves as the 3rd flat

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 FOR U – SHAPED BEND

• locate where the metal needs to be cut

• use sight lines when using a bending brake

• cut from 4th bend tangent line

• cut on squaring shear

• deburr edges before bending the metal

• note – sight lines are marked off from bend

tangent line that will be placed under the nose
of the brake at a distance equal to radius
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EXAMPLE:

Form 2024-T3 aluminum that is 0.32 inch thick

into a 4 inch long by 2 inch deep and 2 inch wide U-
shape channel.

Given: @ 90° ; Setback = R + MT

MT = 0.032” = 0.125 + 0.032
R = 1/8” = 0.157 inch

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Flat A
= mold line – setback
= 2 – 0.157
= 1.843 inch

Bent Tangent Line

= mold line – setback
= 2 – 0.157
= 1.843 inch

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 Bent Allowance
π(2𝑅+𝑇)
= 𝑥 90
360
π(2(0.125)+0.032)
= 𝑥 90
360
= 0.2214822821 inch
(used to mark 2nd BTL)

Sight Line = R from BTL

Bent Tangent Line 2

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2nd Flat
= mold line – setback
= 2 – (2x0.157)
= 1.686 inch

Bent Tangent Line 3

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 Bent Allowance
= 0.2214822821 inch

Bent Tangent Line 3

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 FLAT C

CUTTING LINE

Sight Line
= R from BTL 4

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 FORMING BENDS

• begin by verifying that the proper size radius

blocks are installed in the upper jaw.
• adjust the nose of the blocks
• open the jaws of the brake and slip the metal
in place
• Clamp the jaws of the brake and raise the leaf
to the desired angle
Note: When making more than one bend,
consider the possibility of the upper jaw of the
brake interfering with flats that have already
been made 26
FORMING BENDS
(if the bend cannot be completely
formed because of interference)

When it is not possible to complete a bend

in a brake, blocks of wood and a mallet are
used to finish the bend.
• clamp the metal in a vise between a
hardwood block
• bump the metal down over the radius
block by using a mallet and a piece of
hardwood
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 FOLDING A BOX

Most common sheet metal parts that a

technician is required to fabricate is a four
walled box.

The flat pattern layout for a box is similar to a

U-channel except that relief holes must be
drilled at the inner bend tangent lines

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FOLDING A BOX

Determining setback

All of the bends used in this box are 90 degrees, so the setback
will be the sum of the bend radius and the metal thickness, or:

Setback = Bend Radius + Metal Thickness

= .156 inch + .051 inch
= .207 inch

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FOLDING A BOX

Find the length of the flats for the sides

The mold line lengths for the sides are all 1 inch, so the flats of
the sides will be this amount less one setback:

Side = 1.00 inch - .21 inch

= .79 inch

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FOLDING A BOX

Find the length of the flat for the bottom

The mold line length for the bottom is 4 inches, and since there is
a setback dimension at each end of this, the flat for the bottom will be:

Bottom = 4.00 inches - .42 inches x2

= 3.58 inches

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FOLDING A BOX

Find the bend allowance

Use the chart and follow the 5/32 inch bend radius column down
to the .051 inch thickness line.

For a 90 degree bend, .280 inch of material is needed.

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FOLDING A BOX

Find the length of the developed width for the material

Since the box is to be square, a square piece of metal equal to

the sum of the three flats and two bend allowances is needed. For this
example, the developed width is found as follows:

Developed Width = .79 inch + .28 inch + 3.58 inches + .28 inch + .79 inch
= 5.72 inches.

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FOLDING A BOX

Lay out the box

- Cut a square 5.72 inches on each side

- remove all of the burrs
- mark the bend tangent lines in from the edges, equal to the flat
dimensions for the walls of the box, or at .79 inch
- make a second line inside each at a distance equal to the bend radius,
or at .28 inch.

NOTE: Since the bends intersect in the corners, the metal will tend to crack if
relief holes are not drilled.

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FOLDING A BOX

Lay out the box

NOTE: Since the bends intersect in the corners, the metal will tend to crack if
relief holes are not drilled.
A good rule of thumb for relief holes is:

- to use a diameter of twice the bend radius with the holes centered at the
intersection of the inner bend tangent lines.

- The sight line and the ends of each of the sides will be tangent to these holes.

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FOLDING A BOX

Cut the material

- Drill the relief holes and then use a deburring tool to smooth the edges
of the holes

- Then cut out the material at each of the corners

- smooth all the edges and corner cuts using a fine toothed file.

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FOLDING A BOX

Bend the box

- Use a box, or pan bakes, to bend the sides.

- Once two opposite sides of the box are bent, position the upper jaw of
the brake to fit between the formed sides

- When using a conventional leaf brake, form two opposite sides on the
brake and then bend the remaining sides over a forming block.

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4
COMPOUND CURVES
AND CONTOURS
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COMPOUND CURVES

- design that can considerably stiffen sheet metal without any increase
in its weight

- shapes that allow a part to be used for aerodynamic streamlining

- When a compound curve is formed, metal must be displaced, and the

shrinking and stretching take place in more than one plane.

- can be fabricated by a number of different methods including hand or

machine forming.

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COMPOUND CURVES

HAND FORMING SIMPLE FORMING

considerable experience patterns can be used

is necessary to make to fabricate contours
some of the more and curves.
complex parts that have
unique shapes.

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HAND FORMING
Bulb angle stringer
- used in semimonocoque structures because
of the resistance of the metal to distortion

- To form a convex curve in a stringer of this

type, the metal on the flat with the bulb
angle must be stretched. This can be
accomplished by bumping the metal with a
mallet against a round hardwood block

- It is more likely required to form a bulb

angle into a convex curve than into a
concave shape. To do this:
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Bulb angle stringer the edge of flat
A must be
shrunk.

use a V-block made

of wood, and
hammer on the edge
of the flat

Move the angle back and

forth over the V-block as
the metal is hit so it will
shrink uniformly over the
entire bend.

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Compound Curved Channel
To form a compound curved channel
- begin by making a cutting the hardwood forming block
to the exact shape and size of the inside of the desired
channel dimension.

- round the edges with a radius that is greater than the

minimum radius allowed for the material

- Taper the edges of the block back about three degrees

to allow for spring-back

- Once the first block is made, cut a second block of the

proper size and shape

- Drill three holes through both pieces to be used for

bolts or other devices
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Compound Curved Channel
- Consider the bend allowance when laying out the
material

- Drill the tooling holes in the metal to match those in

the forming blocks

- put the metal between the blocks, securing them

with the proper size pins or bolts

- clamp the assembly in a vise with the concave side

up

- Strike the metal with a plastic mallet as near the When forming a compound curve, the metal should
be backed up with a hardwood forming bar for better
bend tangent line as possible control of the bend.

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Compound Curved Channel
- Once the flats have been formed, turn the
assembly over and form the convex side

- Back up the material with the tapered block and

strike the metal near the bend (time start at the
center and work outward toward each end)

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Bumping

- for streamline covering due to its

protrusion in air stream

- made of fiberglass reinforcement resins

or aluminum alloy

- can be used in covering aircraft

bellcranks

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Bumping

- process of deep parts, can cause work – hardening, this

can be solved by annealing in a furnace
Annealing process:
- use welding torch to coat with thin layer of carbon with
rich acetylene flame
- carefully heat the metal to remove carbon using soft
neutral flame
- after cooling, begin bumping process

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 Flanging lightening holes

- flanging edges to increase

rigidity
- uses male and female flanging
dies stiffens edges of lightning
hole
- forms metal smoothly and
uniformly without work-
hardening

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Joggling

- one end of the piece is bent up to clear the other then bent back
to be parallel to the original piece

- can be fabricated by soft hammer against a block of wood or

hydraulic press with joggle dies

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Joggling

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