![]() ![]() The female radius on the forming section should be ground to 1x metal thickness larger than the inside bend radius and ground back to a 20-degree angle from the midpoint of the tangents of the radius (this is a relief angle, and its accuracy is not critical).The radius that the metal is bent over should be machined to product specifications.The following are the initial guidelines: This design is based on the premise that metal-when bent around a small inside bend radius-will thin as much as 25 percent at the midpoint between the tangents of the radius. In addition, it can be adjusted easily to decrease or increase the severity of impact by shimming or grinding the forming section. This design allows the metal to be coined or impacted on the one area of the bend that is most advantageous. ![]() However, keep in mind that this design works best for bends that have an inside bend radius that is equal to or less than 1x metal thickness. To achieve a 90-degree bend, you must overbend the material past the desired bend angle and allow it to return to the desired shape with the springback.įigure 1 shows perhaps one of the simplest die designs that can achieve a 90-degree bend. ![]() Whatever method you choose, you must be able to adjust the tool easily in response to variables discussed in Part I of this series. There are several good ways to design a tool to achieve a 90-degree bend. This article is Part II of a two-part article on die design for bending. ![]()
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