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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:
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.
The actual measurable inside radius (Ir) is equal to .370 instead of a .393 radius.
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Excessive SpringBack
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.
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.
account the Punch Radius (Rp) and the Material Thickness (Mt).
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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:
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.
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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