The rise in the demand for custom-made products has resulted in research that proved sheet metal to be a versatile material that can be transformed into different forms. The transformation occurs by employing simple sheet forming processes such as metal bending to shape the sheet metal into the desired forms needed for various production purposes. Many processes are involved in making this happen, and knowing how to bend sheet metal comes with proper knowledge. This article will explore the importance of sheet metal bending in fabrication processes and how to bend sheet metal. It also includes some useful bending tips that can help guide bending steel plates.
Sheet Metal Bending
Sheet metal bending is an effective way of making products with different shapes for different processes. It guarantees simplicity and is an efficient way of forming new products. Here, you will learn about sheet metal bending, its importance, and the methods needed for the process. Sheet metal bending is an operation that uses force to change a sheet’s shape. This is done to achieve a manufacturing process’s desired form or shape. The external force used alters only the external features of the sheet. However, parameters of one type of sheet metal, such as length and thickness, remain the same. The malleability of the sheet metal further allows it to undergo various shaping processes.
Application of Bent Sheet Metal
Sheet metal bending is one of the essential procedures in the metal processing industry. For example, it is an important phase in automotive companies since they work with different shapes to get the perfect automobile part that works with the given design. The process can be at an industrial level, ideal for creating big engine parts. Nevertheless, it can also be used to make little parts to replace worn-out engine parts. While many processes are involved in the operation, all sheet metal bending methods consider standard techniques to ensure precision across its production.
Sheet Metal Bending Methods
Sheet metal bending methods are similar in that their end goal is to transform sheet metal structures to the desired forms. However, they differ in operation. Knowing how to bend sheet metal comes with understanding that factors such as the thickness of the material, size of the bend, sheet metal bend radius, and intended purpose to determine the methods.
V-bending
This is the most common sheet bending method used for most bending projects. It employs an instrument known as the punch and v-die to bend sheet metals at desired angles. The bending punch presses the sheet metal placed over the V-die during the process. The angle formed by the sheet metal depends on the punch’s pressure point. This makes this method easy and efficient as it can be employed for bending steel plates without altering their position. There are many sub-categories of the v-bending method as well.
Sheet Metal Bending Allowance
Bend allowance is a manufacturing term that refers to the allocation given to accommodate sheet metal’s stretch and bending tolerance. When sheet metal is bent from its original flat shape, its physical dimensions are also altered. The force to bend the material causes the material to compress and stretch inside and outside. This deformation causes a change in the sheet metal’s overall length due to the exerted force of compression and stretching on the bend. However, the length calculated from the bend’s thickness between the inner compressed surface and the exterior under tension remains the same. This is indicated by a line called the ‘neutral axis.’ Bend allowance considers the thickness of the sheet metal, the bend angle, the method employed, and the K-factor (a constant used in sheet metal bending calculation that estimates the amount of stretch of the material.) It measures the compression ratio on the inside line of a bend to the tension on the outside. While the sheet metal’s inner surface contracts, the exterior expands. Therefore, the K factor remains constant. The K-factor (usually between 0.25 to 0.5 max) serves as a control figure in sheet metal bending calculation. It aids the determination of the exact materials required before trimming portions of the sheet metal and is also useful in the sheet metal bend radius chart.
Tips for Bending Steel plates
Bending steel plates can seem complex. However, with some tips, it can be easy. Below are some tips that can help you with the process.
Watch Out for Spring Back
The material must be bent beyond its required angle when bending sheet metal. This is because sheet metal possesses a high bending ability that allows it to spring back to its original position. Hence, an allocation must be made for such occurrence by bending the material slightly above the desired position.
Is the sheet metal malleable enough?
Bending into a sharp corner would crack the sheet metal. Therefore, you should avoid this as much as possible. Considering the sheet metal gauge would be best, as not every material would be malleable enough to withstand bends into sharp corners.
Always Use a Space Break
Always use a space break where applicable as it provides support and guarantees cleaner sheet metal bending and continuous pattern across bent sheets.
Do Not Forget The Process Position Holes
Process position holes should be created on bending parts to guarantee the sheet metal’s precise positioning in the die. This would eliminate the sheet metal moving during the bending process and ensure precise results across multiple sheet metals.
Bend Allowance
Accounting for bend allowance is important in knowing how to bend sheet metal. This would guarantee more precise numbers ensuring accuracy in finished products.
Conclusion
The demand for custom-built products may never diminish, and custom metallic products require the knowledge of sheet metal bending. Therefore, this article introduced sheet metal, its importance, and what you need to know about how to bend sheet metal to the right shape you want. Understanding sheet metal bending is easy with this article; now you have the basic knowledge and all you need to know about sheet metal bending. Keep this article handy, so you can refer to it anytime you want.