The basics of applying bend functions

Calculating bend allowance, outside setback, and bend deductions By Steve Benson November 9, 2012 Why calculate values such as bend allowance, outside setback, and bend deductions? Because sometimes you will need to work your way around a bend on a print, and you may not have all the information you need to complete a flat pattern.

Figure 1 The bend allowance calculation always uses the complementary angle. When a sheet metal part is bent, it physically gets bigger. The final formed dimensions will be greater than the sum total of the outside dimensions of the part as shown on the printunless some allowance for the bend is taken into account. Many will say material grows or stretches as it is bent in a press brake. Technically, the metal does neither, but instead elongates. It does this because the neutral axis shifts closer to the inside surface of the material. The neutral axis is an area within the bend where the material goes through no physical change during forming. On the outside of the neutral axis the material is expanding; on the inside of the neutral axis the material is compressing. Along the neutral axis, nothing is changingno expansion, no compression. As the neutral axis shifts toward the inside surface of the material, more material is being expanded on the outside than is being compressed on the inside. This is the root cause of springback. Bend Allowance (BA) BA = [(0.017453 Inside radius) + (0.0078 Material thickness)] Bend angle, which is always complementary The length of the neutral axis is calculated as a bend allowance, taken at 50 percent of the material thickness. In Machinerys Handbook, the K-factor for mild cold-rolled steel with 60,000-PSI tensile strength is 0.446 inch. This K-factor is applied as an average value for most bend allowance calculations. There are other values for stainless and aluminum, but in most cases, 0.446 in. works across most material types. If you multiply the material thickness by the K-factor (0.446), you get the location of the relocated neutral axis: for example, 0.062 0.446 = 0.027 in. This means that the

neutral axis moves from the center of the material to a location 0.027 in. from the inside bend radiuss surface. Again, the neutral axis goes through no physical change structurally or dimensionally. It simply moves toward the inside surface, causing the elongation. Note the two factors shown in the bend allowance formula: 0.017453 and 0.0078. The first factor is used to work your way around a circle or parts of a circle, and the second value applies the K-factor average to the first factor. The 0.017453 is the quotient of /180. The 0.0078 value comes from (/180) 0.446. Note that for the bend allowance, the bend angle is always measured as complementary (see Figure 1). Outside Setback (OSSB) OSSB = [Tangent (Degree of bend angle / 2)] (Inside bend radius + Material thickness)

Figure 2 The outside setback (OSSB) is a dimensional value that begins at the tangent of the radius and the flat of the leg, measuring to the apex of the bend. The outside setback is a dimensional value that begins at the tangent of the radius and the flat of the leg, measuring to the apex of the bend (see Figure 2). At 90 degrees, it does not matter if you use the included or complementary angle; you still end up with 45 degrees, and you get the same OSSB answer. For underbent angles (click here for Figure 3), it is common practice to use the complementary angle. For overbent (acute bend) angles, either the included or complementary angles may be used. The choice is yours, but it does affect how you apply the data to the flat pattern. Bend Deduction (BD) BD = (Outside setback 2) Bend allowance A bend deduction (BD) is the value subtracted from the flat blank for each bend in the part, and there may be more than one. Bend deductions differ depending on the part itself, different bend angles, and/or inside radii. Note that when overbending and

making the OSSB calculation using the included bend angle, you may calculate a negative value for the bend deduction. You will need to take the negative value into account when calculating the flat blank, as discussed in the next section.

Development of the Flat-blank Layout

There are two basic ways to lay out a flat blank, and which to use will depend on the information that you are given to work with. For the first method, you need to know the leg dimensions. A leg is any flat area of a part, whether it is between bend radii or between an edge and a bend radius. For the second method, you need to know the dimension from the edge (formed or cut) to the apex of the bend, or the intersection created by both planes that run parallel to the outside surfaces of the formed material. 1. Flat blank = First leg dimension + Second leg dimension + Bend allowance 2. Flat blank = Dimension to apex + Dimension to apex Bend deduction There is another way to look at the second option. As mentioned earlier, if you use the included angle for the OSSB, the bend deduction may be a negative value. As you may know, subtracting a negative value requires you to add: for example, 10 (-5) = 15. If you are working the formula on your calculator, it will automatically make the proper calculations. If you are working the formula through line by line, you will need to keep track of the answers sign and whether it is positive or negative. The following examples walk you through the flat-blank development methods. They apply bend functions to a simple, single-bend part, bent past 90 degrees complementary, to show how the complementary or included angles are applied in the OSSB and ultimately to a layout. The part in Figure 4 is bent to 160 degrees complementary. It has a material thickness of 0.250 in. and an inside bend radius of 0.250 in. The legs are each 1.000 in., and the dimension to the apex (between the part edge and bend apex) is 3.836 in. Note that in the formulas below, Ir represents the inside bend radius and Mt represents the material thickness. For all methods, we calculate the bend allowance the same way: Bend Allowance (BA) BA = [(0.017453 Ir) + (0.0078 Mt)] Degree of bend angle complementary BA = [(0.017453 0.25) + (0.0078 0.25)] 160 BA = [0.00436325 + 0.00195] 160 BA = 0.00631325 160 BA = 1.010 From here, we perform different calculations, depending on the flat-blank development used. Using the first method, we develop the flat blank by adding the two legs of the bend and the bend allowance. Flat-blank Calculation Calculated flat-blank length = Leg + Leg + BA

Calculated flat-blank length = 1.000 + 1.000 + 1.010 Calculated flat-blank length = 3.010 The second flat-blank-development example adds the two dimensions (from edge to the apex), and subtracts a bend deduction. In this case, the calculations use a complementary angle for the OSSB, and the dimensions are called from the edge to the apexagain, as specified in Figure 4.

Figure 4 This 0.250-in.-thick part is bent to 160 degrees complementary with an inside bend radius of 0.250 in. The drawing specifies that the dimension from the edge to the apex is 3.836 in. Outside Setback (OSSB) OSSB = [Tangent (complementary bend angle/2)] (Mt + Ir) OSSB = [Tangent (160/2)] (0.25 + 0 .25) OSSB = [Tangent 80] 0.5 OSSB = 5.671 0.5 OSSB = 2.836 Bend Deduction BD = (OSSB 2) BA BD = (2.836 2) 1.010 BD = 5.672 1.010 BD = 4.662 Flat-blank Calculation Calculated flat blank = Dimension to apex + Dimension to apex Bend deduction Calculated flat blank = 3.836 + 3.836 4.662 Calculated Flat-blank Length = 3.010 In this final example, the flat-blank calculation adds the dimensions and then subtracts the negative bend deduction (again, you add when subtracting a negative number). In this case, we are using the included angle for the OSSB, and the dimensions are still called from the edge to the apex. Outside Setback (OSSB) OSSB = [Tangent (Degree of bend angle included/2)] (Mt + Ir),/i> OSSB = [Tangent (20/2)] (0.25 + 0.25) OSSB = [Tangent 10] 0.5 OSSB = 0.176 0.5 OSSB = 0.088

Bend Deduction (BD) BD = (OSSB 2) BA BD = (0.088 2) 1.010 BD = 0.176 1.010 BD = -0.834 Flat-blank Calculation Calculated flat blank = Dimension to apex + Dimension to apex Bend deduction Calculated flat blank = 1.088 + 1.088 (-0.834) Calculated flat-blank length = 3.010 You can see that regardless of method, the same answer is achieved. Be sure you are calculating these values based on the actual radius you are attaining in the physical part. There are many extenuating circumstances you may need to consider. Just a few are the forming method (air forming, bottoming, or coining), the type of bend (sharp, radius, or profound radius bends), the tooling you are using, and the multibreakage of the workpiece during large-radius bending. Also, the farther past 90 degrees you go, the smaller the inside radius will physically become. You can calculate for most of these, and this is something well be sure to tackle in future articles.

Getting the Part Right the First Time

There are lots of different paths to find your way around a bend, by using either the included or complementary angles. We can easily calculate these values; it is the application of the results that counts. However, once you know how and where the information is applied in a given situation, the flat-pattern layout is easy. So why calculate all these values? Because sometimes you will need to work your way around a bend on a print, and you may not have all the information you need to complete a flat pattern. At least now you can calculate all the different parts of the bend, apply them correctly, and get it right the first time.

More Than One Way to Skin a Cat

Press brake technicians can use various formulas to calculate bend functions. For instance, in this article we have used the following for outside setback: OSSB = [Tangent (degree of bend angle/2)] (Material thickness + Inside radius). However, some may use another formula: OSSB = (Material thickness + Inside radius) / [Tangent (degree of bend angle/2)]. So which is right? Both are. If you use the complementary bend angle in the first equation and the included angle in the second equation, you get the same answer. Consider a part with a 120-degree complementary bend angle, a material thickness of 0.062 in., and an inside radius of 0.062 in. The bend allowance (BA) is calculated at 0.187, and the leg lengths are 1.000 in. To obtain the dimension to apex, add the OSSB to the leg. As you can see, both OSSB formulas produce the same result and lead you to the same bend deduction for calculating the flat blank.

First OSSB Formula OSSB = [Tangent (degree of bend angle complementary/2)] (Material thickness + Inside radius) OSSB = [Tangent (120/2)] (0.062 + 0.062) OSSB = [Tangent (60)] 0.124 OSSB = 1.732 0.124 OSSB = 0.214 Second OSSB Formula OSSB = (Material thickness + Inside radius) / [Tangent (degree of bend angle included/2)] OSSB = (0.062 + 0.062)/[Tangent (60/2)] OSSB = 0.124/[Tangent (30)] OSSB = 0.124/0.577 OSSB = 0.214 Bend Deduction (BD) BD = (OSSB 2) BA BD = (0.214 2) 0.187 BD = 0.428 0.187 BD = 0.241 in. Flat-blank Calculation Calculated flat-blank length = Dimension to apex + Dimension to apex Bend deduction Calculated flat-blank length = (OSSB + Leg) + (OSSB + Leg) Bend deduction Calculated flat-blank length = (0.214 + 1.000) + (0.214 + 1.000) 0.241 Calculated flat-blank length = 1.214 + 1.214 0.241 Calculated flat-blank length = 2.187 in.

For overbent angles (see Figure 3), the original formulaOSSB = [Tangent (degree of bend angle complementary/2)] (Material thickness + Inside radius)also may be written using the included degree of bend angle. But again, when you get a negative bend deduction value, you need to take that into account when calculating the flat blank. Working with an included bend angle of 60 degrees, a material thickness of 0.062 in., an inside bend radius of 0.062 in., and a bend allowance (BA) of 0.187 in., you get a negative bend deduction. That means you subtract the negative BD (again, the same as adding) when doing the flat-blank calculation. As you can see, the same calculated flat-blank dimension results: Outside Setback (using included angle) OSSB = [Tangent (degree of included bend angle/2)] (Material thickness + Inside radius) OSSB = [Tangent (60/2)] (0.062 + 0.062) OSSB = [Tangent (30)] 0.124

OSSB = 0.577 0.124 OSSB = 0.071 Bend Deduction (BD) BD = (OSSB 2) BA BD = (0.071 2) 0.187 BD = 0.142 0.187 BD = -0.045 Flat-Blank Calculation Calculated flat-blank length = Dimension to apex + Dimension to apex Bend deduction Calculated flat-blank length = (Leg + OSSB) + (Leg + OSSB) BD Calculated flat-blank length = (1.000 + 0.071) + (1.000 + 0.071) (-0.045) Calculated flat-blank length = 1.071 + 1.071 (-0.045) Calculated flat-blank length = 2.187 in.

Why should you care about inside bend radii?

By Steve Benson January 29, 2004 Operators, designers, and engineers, why should you care about the inside bend radius if the customer doesn't? Because, ultimately, just how easy or difficult it is to produce a part depends on decisions made during the design stage. Misunderstanding terminology, process capabilities, or production methods can lead to mistakes that can make production more difficult. The most common mistake is incorrectly calculating and achieving the correct minimum inside bend radius. A minimum bend radius is a function of the material and has little or nothing to do with the press brake punch tip. A minimum bend radius for one material thickness is not the same for another material thickness. In cold-rolled mild steel, the minimum bend radius is 63 percent of the material thickness. For example, a

Photo courtesy of TRUMPF Inc.

piece of 12-gauge (0.104-in., 2.64-mm) material turns sharp at 0.065 in. (1.66 mm), making any punch radius less than that value, by definition, a sharp bend, such as 0.062 in. (1/16 in., 1.58 mm), 0.032 in. (1/32 in., 0.82 mm), or 0.015 in. (1/64 in., 0.38 mm). Radius bends occur between the 63 percent threshold and a bend radius no greater than 10 times that of the material thickness. Can a press brake operator achieve the desired bend radius on-the-fly? Well, maybe, maybe not. I suppose that depends on the operator's skill level.

Bending Basics
Before we continue, a discussion of bending principles is in order. First, we must establish a common language about forming methods, bend types, and their subsequent mathematical effects. During any forming process, material elongation occurs. Elongation is a bit of a misnomer, because the material actually changes shape, which may or may not include elongation. The part of the material that normally would square into the corner must go somewhere else as a result of the radius effect. This elongation commonly is called a bend deduction (BD) or K factormathematically equivalent terms. How many times have you referred to a bend deduction or K factor chart to find a bend deduction value only to discover later that it wasn't correct for the finished part? What happened? Was the chart wrong? Was the problem operator error? Was engineering asking for something that couldn't be done in practice? Any or all of these factors could have caused the error.

Chart Confusion
Let's look at examples from five BD charts. Sixteen-gauge cold-rolled steel (0.059 in., 1.50 mm) with a 1/32-in. (0.032-in., 0.83- mm) inside bend radius has the following values:

1/32-in. radius in 0.060-in. material Chart #1 N/A Chart #2 0.063 Chart #3 0.083 Chart #4 0.097 Chart #5 0.102 1/16-in. radius in 0.060-in. material Chart #1 0.106 Chart #2 0.108 Chart #3 0.110 Chart #4 0.132 Chart #5 0.136

The difference between the high and the low values for one 1/32-in. single bend radius is 0.039 in. Multiplying 1/32 times three bends gives 0.117 in. The difference between the high and low values for one 1/16-in. bend radius is 0.030 0.090 for three bends. Are the charts wrong? No. Every value from every chart is valid for an achieved radius under a given set of circumstances. The problem lies in the fact that the radius called for rarely, if ever, matches the achieved radius. Most test samples confirm the descrepancy.

Correct Bend Deduction

Empirical-formula charts do not take into account all the variables. They just assume a 1/32-in. (0.83-mm) radius in 14-ga. material, rather than the natural minimum radius of the material of 0.046 in. (1.18 mm), 63 percent of the material thickness. This changes the value of the calculations. If the 0.032-in. (0.83-mm) value is used in the calculations, the resulting BD will be incorrect, because 0.046 in. (1.18 mm)the achievable radiusproduces an incorrect bend deduction value, which, in turn, makes the corresponding flat blank layout incorrect. BD or K factor is developed in the following manner: BD = (2 x OSSB) - BA OSSB = [Tangent (0.5 x <)] x (Rp + Mt) BA = [(0.017453 x Rp) + (0.0078 x Mt)] x <</div> Where: BD = Bend deduction OSSB = Outside setback BA = Bend Allowance Rp = Punch tip radius (can be interchanged with inside radius) Mt = Material thickness < = Degree of bend angle These formulas are valid, but they do not take into account whether the bend to be produced is a sharp or radius bend.

Options
Picture a sheet of 0.100-in.-thick material (2.54 mm). By multiplying the material thickness by 0.63 (63 percent), the natural minimum radius can be determinedin this case, 0.063 in. (1.57 mm). Within the 63 percent range of this particular material, press brake tool radii of 0.062 in. (1.57 mm), 0.032 in. (0.83 mm), and 0.015 in. (0.41 mm) are valid sharp-bend tools. No matter how far into the sharp range you go, it is the natural radius that will be produced, not the 1/16-in., 1/32-in., or 1/64-in. punch tip radius. The only thing that will change throughout the range is the severity of the ditch at the bottom of the bend.

Any of the punches listed could produce the part. Why? Because, for example, if the part required a 1/16-in. radius in 0.100-in.-thick material, the bend, by definition, would be a sharp bend. An experienced operator or setup person could use any tool radius equal to or less than the 63 percent sharp-bend threshold to achieve the desired bend. This has the effect of tripling the tooling options. As an operator, you might find that the perfect gooseneck punch is available only with a 1/32-in.-radius tip. Not a problem, since a sharp bend is a sharp bend, regardless of the tip used to achieve it.

Caveat
Of course, as everyone knows, there is no free lunch. The sharper the punch radius is in relationship to the material thickness, the greater the effect on angular error, and concurrently, dimensional error. In other words, any variances in material thickness, hardness, and grain direction exponentially increase with each decrease in punch radius. By understanding and addressing what is happening at the point of bending, you can avoid many forming problems, including those associated with flat blank layouts (CAD or not) and the effects of a sharp bend on the finished part. By doing so, you'll have a healthier bottom line.

Using benchmarking for bend deductions

By Steve Benson May 30, 2002 Benchmarking is a very good idea for your operation ... just make sure your benchmarks are your own. Benchmarking is using measurement or evaluation to judge similar processes, parts, charts, and methods. The term benchmark is believed to come from medieval timesmore specifically, form the stonemasons who built the great cathedrals of Europe. Before that time local craftsmen built every piece of furniture and cut every piece of stone to size by judging length, width, and height by eye. This meant there were no standards by which to judge components for length, width, and height relative to any other part. In other words, everything was eyeballed. At some point someone came up with the idea of placing a mark or gouge into a workbench to indicate the length or width of a part. By comparing each leg of

furniture or block of stone against the benchmark, the builder could be assured that each subsequent piece was pretty much the same size as the previous one.

Modern Version Bend Deduction Charts

A benchmark, then, is a measurement that can be used as a reference for other measurements or data sets. In the modern sheet metal shop, bend deduction charts are a good example of benchmarking. A bend deduction chart created in a shop where bending methods, bend types, and tooling are agreed upon by all becomes a valid benchmark. Ideally, modern benchmarks would serve the same universal purpose as the notch in the bench did for our ancient brothers. A test run of the material being formed would validate the bend deduction values at any time. However, when inappropriate benchmarks are used, problems arise. For instance, benchmarks can be rendered invalid when they're used in a different shop where tooling or forming methods differ from the benchmarks' source. Figure 1 and Figure 2 show two different bend deduction (BD) charts for the same material thickness and bend radii. Notice how different the bend deduction values are, even though both are correct for the shop in which they were created. One shows a bend deduction of 0.106 for a 1/32-in. inside radius for 16-gauge cold-rolled steel; the other chart shows it is 0.136. These are perfect examples of how another shop's benchmark may or may not be correct for you. If you try to apply someone else's benchmark to your process, chances are it won't match the marks on your workbench, leaving you with one leg that is too long.

Mathematics: Establishing a Common Benchmark

As long as you use the same forming methods and tooling that were used to create the original data set, validating the original numbers should be easy. If everyone used the following formulas and processes to create of their bend deduction charts, they could establish a common benchmark. To set a standard benchmark for your bend deduction charts, you must take an accurate measurement of the inside radius, either by meeting part specifications or by planning for what is going to be done. This radius measurement can be taken on the tip of the punch radius in bottom bending or coining. It also can be taken as a percentage of the V-die opening in air forming using these percentages20 percent for 304 stainless steel, 15 percent for cold-rolled steel, 15 percent for H32 5052 aluminum, and 12 percent for hot-rolled pickled in oil. Simply multiply the V-die opening by 0.20, 0.15, or 0.12 to find the value for the inside radius.

Once a value for the inside radius is set, simply plug it into the following formulas to establish a proper benchmark in your bend deduction charts for a given material thickness and inside radius. Bend Allowance (BA) BA = [(.017453 x Rp) + (.0078 x Mt)] x ^ Outside Setback (OSSB) OSSB = [tangent (^/2)] x (Mt + Rp) Bend Deduction (BD) BD = (2 x OSSB) - BA Where: ^ = Complementary angle of bend Mt = Material thickness Rp = Radius of the punch (coining and bottom bending) or inside radius (air forming) As long as the inside radius of the bend can be measured with a radius gauge, also a benchmark, the benchmark supplied by mathematics can be yours to apply in your shop and in any other shop that measures and calculates these values.

The Key
The key to valid benchmarking is understanding how the benchmark relates to the tasks, tools, and methods employed in your particular environment. Benchmarking the tasks that you generally perform rather than using a benchmark someone else has created will steer you in the right direction, unless they also are using mathematically derived benchmarks. Then you're OK.

Bend deduction charts

Where can I get one? By Steve Benson July 26, 2001

Quite often I am asked, "Where can I get a bend deduction chart that works, one with valid numbers?" That's a good question. In reviewing a couple dozen bend deduction charts from a variety of sources, I couldn't find any that agreed with another, with the exception of a single number here and there. For the most part, they varied widely. Figure 1 shows data from five of those charts selected at random. The total error, or amount of difference between the top and the bottom entries, was 0.039 in. for the 1/32-in. radius and 0.030 in. for the 1/16-in. radius. Assuming that you have a generous tolerance over one bend, the error in bend deduction can be spread out, and a Figure 1 good part still can be produced. However, if tight tolerancing or if multiple bends are involved, the difference between the top and bottom values can make a good part a bad one quickly. For example, a part with three bends could have as much error as 0.117 in. (2.97 mm). This leads to the question, Which chart is correct? The answer is, All of them! They all are correct for the environment in which they were created. In other words, each chart creator must have said something like, "This is the value of a 1/32-in. (0.81mm) bend radius by virtue of the punch tip's radii." Using this criteria, the creator approximated the punch radius rather than measured the inside radius. Some charts actually measured the resulting inside radius and found the correct bend deduction. Either way, the charts worked for each of them but may not have worked when applied to another shop's set of circumstances.

Past vs. Present

In the past, it wasn't as important to know precisely what the resulting inside radius was. Everything was coined or bottom-bent, which meant that resulting in the punch tip's radius always was achieved. Bends that were coined or bottom-bent almost always were made with a sharp punch tip. A sharp bend is one whose radius is less than 63 percent of the material thickness and is a requirement of coining and usually a feature of bottom bending. This fact alone made the older charts reasonably accurate. Today air forming is the standard and the inside radius is no longer achieved by the punch tips radius. Instead, the inside radius is achieved as a percentage of the V-die opening. Bend deductions (BD), the amount of change in the material between the flat and the formed material, are developed from mathematical formulas. These calculations are, as they always have been, based on the measurable inside radius and the associated geometry of the bend.

The inside radius is measured with radius gauges. Radius gauges come in common forms of measurement: fractional, decimal, and metric gauges are available through a number of manufacturers. Figure 2 shows an inside radius being measured. When a radius gauge rests squarely in the center of the bend, there should be no rocking motion, which occurs when the radius predicted is larger Figure 2 than the actual inside bend radius. You should not be able to see light underneath the gauge, which happens when the actual bend radius is smaller than the predicted inside radius. Regardless of the forming methodair forming, bottom bending, or coiningor the tools used, the inside radius establishes the basis for the bend deduction. Once the inside radius is established, the following formulas can be used to calculate the true BD/(K-factor): BA = [(0.017453 x Rp) + (0.0078 x Mt)] x <</dd> OSSB = [tangent (0.5 x <) x (Mt + Rp)] BD = (OSSB x 2) - BA Where: < = Degree of bend angle Rp = Punch radius or inside radius Mt = Material thickness You also should note the two major camps of formulas. In Camp No. 1 are bend deductions, bend allowances, and outside setbacks. These are mathematically the same as the formulas in Camp No. 2: K factors (BD), X factors (OSSB), and bend allowances (BA). The K and X factors were developed at Lockheed Corp. in the 1950s. One item of note: The K factor found in the "Machinists Handbook" (Industrial Press Inc., New York) it is the equivalent of the bend allowance and serves the same function. The numerical value of the inside radius must not be calculated with an inside radius value of 63 percent or less of the material thickness. This is because the natural minimum inside radius that can be made in the material is no less than that. Coining and bottom bending reproduce the punch radius (because of the tonnages involved) and therefore the true punch radius value can be used in the calculations. A sharp bend in air forming creates only a small ditch in the center of the bend, and the Figure 3

actual and measurable radii still are floated out as a percentage of the V die, a percentage that also changes by material type. Figure 3 shows this principle in action. If the air-formed part has to be bent as a sharp bend, it is necessary to calculate the BD using the value from 63 percent of material thickness value. Simply multiply the material thickness by 0.63 instead of the actual punch radius. How to: Material thickness (Mt) x 0.63 Example: 0.074 x 0.63 = 0.046 (1.87mm) 0.046 then is the value used in the calculation. Based on this examplein which the minimum radius is 0.046if 1/32 in. (.032) were used in the calculations, the bend deductions then, obviously, would be incorrect.

Calculating Inside Radius Based on V-die Opening

Depending on the material type, the inside radius based on the V die opening is calculated with the following percentages:

20 percent - 304 stainless steel 15 percent - Cold-rolled steel 15 percent - 5052 H32 Aluminum 12 percent - Hot rolled steel

The tensile strength of the material type should allow you to make educated guesses about the relative percentages for other materials. You can predict the inside radius simply by multiplying the V-die opening (width) by the standard percentage rating listed for that material type and then use it in the calculations. 0.472 x 0.15 = 0.070 11.98 x 15 percent = 1.77 mm

Conclusion
Charts are OK if you can create your own or find one that fits your operation's methods and tooling. However, it is much more accurate to calculate the BD based on the actual achieved inside radius rather than guessing, especially when you are air forming.

Gauging difficult parts at the press brake

It's easier than you might think By Steve Benson March 27, 2003 Gone are the days when engineers and draftsmen slaved for hours over drafting boards with a pencil and slide rule in hand (does anyone remember slide rules?). Today we've moved beyond slide rules and even beyond hand-held calculators to personal computers and mainframes to do much, if not all, of our design work. CAD and CAM software has made this possible. Even with the advancements in computer design systems, parts layout still can still be a very difficult process, particularly when ease of forming is a major concern. But when is ease of forming not an issue at some time in almost every shop?

The Question
The majority of parts being manufactured are pretty straightforward--a square-corner notch here, a compound flange there. However, many times radius bends, features, or radius edges are required that can make parts extremely difficult to produce. For example, how would you develop a flat blank for a part that literally has no flat or square edges from which the press brake operator can gauge? And, just to make it Figure 1 interesting, let's say that the part has no uniform hole or feature patterns from which to pin gauge. The question then arises: Can this part be designed, manufactured, and still formed easily at the press brake? Sure, this type of project could be done with elaborate side gauging, fixturing, or specialized tooling, but at what cost? Perhaps the $8,000, $10,000, or $20,000 for a custom tool, or perhaps running up huge labor bills while some press brake operator spends hours trying to solve the riddle just to produce a part like the one shown in Figure 1.

An Answer
Believe it or not, even without a single straight edge or usable hole pattern, the part still can be formed easily. A square or straight edge for gauging can be accomplished by laser stitching, which is, in effect, adding extra material to the part.

Laser Stitching
Laser stitching usually is accomplished using a standard 2laser to produce all of the compound radii and angles a complex part might have. Of course, this does not mean that stitching can't be done on a turret press, but punching radius edges on a turret press produces an edge that won't look quite as nice as a laser-stitched edge.

Figure 2

The part in Figure 1 has no straight edge from which to square or gauge easily. Now look at the flat blank for the same part with additional material laser-stitched to the workpiece (see Figure 2). Notice the way in which the extra material has been stitched onto the radius edges. This extra material then is used to gauge the part. To make the process even easier for setup personnel--not to mention general press brake operations--the additional material should be a standard size, for example, exactly 1 or 2 inches, a nice round number. This allows the setup person or operator simply to add an inch or two to the desired finished part dimension of the workpiece and to write that value to the controller. Once the forming process is completed, the extra stitched-on material (tab) is broken off by hand and discarded (see Figure 3).

Figure 3

Deburring
The size of the stitched tab, or hanger, varies depending on material type and thickness. Type and thickness combined with the shape of the tab will determine if extra deburring or edge dressing is necessary to complete the part satisfactorily (See Figure 4). The time required to add and remove the tab is minimal when compared to the time, effort, and costs incurred by attempting to produce the same part on a press brake minus the stitched-on additions. In fact, it is quite possible that the part might be too difficult to form on a standard press brake without first adding the laser stitched material.

Figure 4

Worth the Effort

By adding laser stitching to your bag of tricks, what once might have seemed an impossible workpiece or unprofitable venture can become a reasonably easy and profitable item to produce. Simply add the dimension of the actual workpiece (regardless of flange dimension) and the extra flange extension value from the part edge to the square or straight edge of the extension to set up the press brake. Doing so validates the following quote: "The impossible will take only a moment longer." Just a moment longer than the average part would take!