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H. Greffin 08.09.2003 S. Meyer 10.09.2003 2 H. Greffin 19.03.2004 R. Hoppe

CO 084 Bending Information

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 Table of contents Johann A. Krause

1 Bending................................................................................................................... 5

1.1 General information ......................................................................................... 5

1.1.1 Contact personnel in Production ........................................................ 5
1.1.2 Tolerances......................................................................................... 5
1.1.3 Selection of the bending tool.............................................................. 5
1.1.4 Convenience during bending ............................................................. 6
1.2 Production aids................................................................................................ 6
1.2.1 Bending round and angular workpieces ............................................. 6
1.2.2 Alignment aids ................................................................................... 7
1.2.3 Rolling ............................................................................................... 8
1.3 Examples for the design of bending parts........................................................ 9
1.3.1 Where the minimum distance xmin is not observed ............................. 9
1.3.2 Deformations ................................................................................... 11
1.3.3 Free cuts.......................................................................................... 12
1.3.4 Double tools..................................................................................... 14
1.3.5 Bending of oil pans .......................................................................... 17
1.4 Stiffening sheet-metal parts ........................................................................... 19
1.4.1 Stiffening using folds........................................................................ 19
1.5 When bending is unsuitable........................................................................... 20
1.5.1 Bending + Welding ?........................................................................ 20

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 Bending Information Johann A. Krause

1 Bending

1.1 General information

This document supplements the specific information relating to our machines listed in "CO
004 Cold bending".

1.1.1 Contact personnel in Production

Contact personnel are employees in the PR-B department.

1.1.2 Tolerances

After production, the dimensions of a bent part are checked in the sheet-metal workshop with
the aid of DIN ISO 2768.
Even the thickness of the sheet metal panels is subject to tolerances (DIN EN 10131 for
sheet up to 3 mm inclusively, DIN EN 10111 for sheet >3 mm up to 12 mm). However, the
compensation value v refers only to the nominal size of the sheet thickness. Consequently,
the full effect of tolerances is reflected in the developed length.
For this reason, it should be noted that dimensions unimportant to the design are subject to a
correspondingly wide tolerance (e.g. in the case of a leg length of 100 1 mm, instead of the
free size tolerance of 100 0.3 mm). In the case of small dimensions, the free size
tolerances are very small and, in the case of complex parts, cannot be maintained
absolutely.

1.1.3 Selection of the bending tool

Even the selection of the correct bending tool is not a simple matter. In the document "CO
004 Cold bending (in Chapters 3.2.2 Compensation values v, general and 3.4.1 Folded edge
lengths Lmax on works bending machines)" there are, in fact, several tools listed for each
sheet thickness. On this, the sheet-metal workshop provides the following notes:
In the case of short bend lengths, a small bottom die (lower number 10, 12, 20, 38 and 90)
should be selected.
In the case of large bend lengths, a correspondingly large bottom die should be selected.
This combination is a result of the required bending force. Since a greater force is required
when bending a longer edge, the bottom die must also be capable of withstanding more
force.
In cases of uncertainty, consult the sheet-metal workshop. The principle applies, that the
largest possible bending radius should be chosen.

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Johann A. Krause Bending

1.1.4 Convenience during bending

The following principle always applies in the design of bending parts: as light and as small as
possible. The maximum width to be produced is 3000 mm. The maximum leg length which
can be produced with automatically controlled limit stops is 2500 mm.
Whenever possible, coverings should have a leg length not exceeding 1000 mm. Owing to
the usually small sheet thickness the coverings easily sag during handling.

1.2 Production aids

1.2.1 Bending round and angular workpieces

In the design of bending parts without straight stop edges, observe that a flat projection is
provided as a production aid. This flat projection is removed after bending.

Example:

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 Bending Information Johann A. Krause

1.2.2 Alignment aids

To hold the form of a bending part stable during use without welding, a method can be
employed which uses a lug and notch. By this means, the orientation of the edges to each
other is also determined. The notch must be at least 1 mm wider that the lug.

Since the leg is over-bent during bending in order to achieve, for example, a 90 angle, the
notch must also be deeper than the lug sheet thickness; i.e. in the case of 4 mm sheet, the
notch must be 5 mm deep. Information on other dimensions/sheet thicknesses can be
obtained from the sheet-metal workshop, since this procedure has until now only been used
for 4 mm sheet.

Example from: K.0N213.091.04.00

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Johann A. Krause Bending

1.2.3 Rolling

In the case of rolling parts, if there are notches on the external edges, these should be
connected with web plates. This is required so that the rolling process can achieve better
results. Without web plates, there is a possibility that the material will twist at the notches.

The width of the web plates is dependent on the geometry of the part; therefore consultation
with the PR-B department is required.

Example from: K.00634.366.01.00

Rolling direction

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 Bending Information Johann A. Krause

1.3 Examples for the design of bending parts

1.3.1 Where the minimum distance xmin is not observed

The distance xmin (see CO 004 Cold bending) should always be maintained if conditions
allow.
If the distance xmin cannot be maintained, i.e. the minimum distance between the bending
edge and openings/holes is not observed, it is possible to introduce a laser cut or free cut in
the course of the bending line. All free cuts must be drawn as real geometry in order to avoid
problems with the laser cutting.
In this way, no bending will take place along the length of this cut. The edge of the cut
remains free of any deformation. Unwanted deformation of the openings can be avoided in
this way.
The width of the laser cut is dependent on the sheet thickness.

Sheet Width of cut

thickness

4 mm 1 mm
10 mm 2 mm
12 mm 4 mm

Since this procedure is still quite new, however, in all cases advice should be sought from
the PR department.

Example from: K.00633.772.05.00 Laser cut

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Johann A. Krause Bending

A second alternative is to remove a section of material behind the opening. For this, the cut-
out must be designed in a way that it encloses at least the bend radius.

Example from: K.00638.147.01.00

DEVELPOED VIEW

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 Bending Information Johann A. Krause

1.3.2 Deformations

During the bending of thicker sheets ( 4 mm), the bent edges are deformed outwards.
These deformations can be compensated by the introduction of free cuts in the form of
circular arcs.
It is vital that this type of free cut is introduced where edges are decisive in determining the
orientation of a part. The depth of the free cut must be at least 2 mm, and depends on the
sheet thickness. The width should be chosen so that it encloses the bend radius.

Example from: K.00633.772.05.00

Free cut

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Johann A. Krause Bending

1.3.3 Free cuts

In the bending of ears, it is advantageous to incorporate a free cut into the bending part. All
free cuts must be drawn as real geometry in order to avoid problems with the laser cutting.
In the case of sheet thicknesses less that 6 mm, the width of the free cut must be at least 1
mm. In the case of sheet thicknesses 6 mm and greater, the width of the free cut must be at
least 2 mm. The free cuts must be made at right angles to the bend line.
In this way, the sheet cannot tear in the area of the bend and the bend radius will run out
cleanly. The length of this free cut should be equal to at least double the sheet thickness, or
it should be chosen so that the bend radius run-out can be fully achieved.
It is equally possible to position a free hole or stress-relieving hole at the end of a free cut.
The diameter of such a hole must be at least equal to the sheet thickness.

Example from: K.00870.210.01.00

Free cut

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 Bending Information Johann A. Krause

Example from: K.00870.220.01.00

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 Johann A. Krause Bending

1.3.4 Double tools

In the sheet-metal workshop special tools (5/50 for 2 mm sheet and 6/60 for 3 mm sheet) are
available for bending the channel in the FR conveyor coverings in which the stop pin runs.
These tools are formed in such a way that they have per bending edge the same
compensation values as the simple tool. The 5/50 tool is formed like the 1/12 tool and the
6/60 tool is formed like the 1/20 tool.
It follows from this that the compensation value of a double tool is 2 x the compensation
value of a simple tool ist. A stroke of the bending bench with the double tool therefore
corresponds to a double bending edge.
(see CO 004 Kaltbiegen).
The developed length can be calculated as usually from the single leg lengths minus
compensation value. Note that the depth is not variable.
It is 2 mm when the sheet is 17 mm and 3 mm when the sheet is 19 mm. If a channel has to
be produced, the inner distance between the double bending edges has to be at least 34
mm, this applies to both sheet thicknesses.
Depth

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 Bending Information Johann A. Krause

Besides the tool data, the drawings should also give the external deviations of the channel.
Example from: K.00634.299.01.00

If the double tools are also used for bending parts with multiple bending edges, the
developed length L is calculated as shown in the following example:

Example from: K.00655.300.01.00 Material sheet steel; t=2 mm

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Johann A. Krause Bending

Formula symbols used:

Lg1 = Developed length for bends formed with the double tool
Lg2 = Developed length for bends formed with the 90 angle
Lges = Total developed length
tBlech = Sheet thickness
ADW = Compensation value for double tools
A90 = Compensation value for 90 angle
X = Total leg length for bends formed with the double tool
Y = Total leg length for bends formed with the 90 angle

Input parameters:
tBlech = 2 mm
ADW = - 16 mm
A90 = -4 mm
X = 166 + 17 + 81 17 + 100
Y = 37.5 + 33 + 70 + 37.5

1. Calculation of the developed length Lg1 for bends formed with the double tool
Lg1 = X + ADW
Lg1 = (166 + 17 + 81 17 + 100) + (- 16)
Lg1 = 381 - 16
Lg1 = 365

2. Calculation of the developed length Lg2 for the remaining bends

Lg2 = Y + 4 x A90
Lg2 = (37.5 + 33 + 70 + 37.5) + [4 x (-4)]
Lg2 = 178 12 2
Lg2 = 164

3. Addition of the two lengths Lg1 and Lg2 for the total developed length Lg
Lges = Lg1 + Lg2
Lges = 365 + 162
Lges = 527

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 Bending Information Johann A. Krause

1.3.5 Bending of oil pans

In order to simplify the bending and welding procedures it is necessary to design the
disruptions in a way that the grips do not lie on each other after bending. Thus it is possible
to chose the edge-sequence arbitrarily. Furthermore the weld metal deposits in the gap
between the grips. So an optimal tightness is guaranteed.

Example: Material: steel sheet ST1203; t = 2 mm height of pan h = 30 mm

sheets thickness tolerance 0.13

The empirical formula for the size of the disruption is:

height of pan h - thickness of sheet t = Size of disruption

It applies for the example:

30 mm 2 mm = 28 mm

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Johann A. Krause Bending

The size of the disruption must anyway be tolerated positive. The tolerance should be at
least identical with the upper dimension of the sheets thickness tolerance. Please see for
sheet t 3 mm DIN EN 10131 and for sheet t > 3 mm 12 mm DIN EN 10111. An upper
tolerance of 0,5 mm may not be exceeded.

When considering the formula stated above theoretically, the edge of the relief is in fact
situated within the bend radius but in practice this method has proved itself.

In no way the oil pan should be welded where bending would be possible. Because of the
mostly very thin thickness of the sheet t = 2 - 3 mm and the size of the oil pan it is not
possible to avoid a warpage of the part when being welded.

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 Bending Information Johann A. Krause

1.4 Stiffening sheet-metal parts

1.4.1 Stiffening using folds

Besides the known stiffening method using welding ribs, it is also possible to incorporate a
180 fold into the sheet-metal parts. The following procedure is used:
In the first stage a bending angle >90 is produced.
In a second stage this is pressed together to form an angle of 180.
Incorporating folds into a bending part is very costly; therefore it should only be used on
external edges where conditions allow. If the incorporation of folds into a bending part is
required, however, always consult the sheet-metal workshop.

Until now, this method has only been used with sheet thicknesses of 1.5 mm. Here, a
compensation value of 1 mm can be anticipated. If it becomes necessary to make folds in
other sheet thicknesses, the sheet-metal workshop should be consulted so that the
appropriate compensation value can be determined.

Example:

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Johann A. Krause Bending

1.5 When bending is unsuitable

At some designs it seems to be favourable to chose the bending as manufacturing method,
but sometimes it is for reasons of economy reasonable to think about an alternative
manufacturing method. An important aspect is to minimize the number of the necessary
manufacturing technologies

1.5.1 Bending + Welding ?

The following example shows the manufacture of a box. In the "old" Version 3, an "L" is bent
(part a) and the remaining three sides should be lasered and welded.

Example from K.00652.662.01.00 - Version 3

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 Bending Information Johann A. Krause

In this simple design, for example, it is more cost-effective to weld the box together from five
pieces. This method dispenses with the bending operation.

Example from K.00652.662.01.00 - Version 4

It is not possible to manufacture a box made of an entire bend part as the height of the box is
340 mm (the maximal height of the box when being bent is 90 mm see. CO 004).

Boxes with a height 90 should be designed as an entire bend part unless the edges do not
need to be additionally welded.

+ Keep the number of the necessary manufacturing technologies as small as

possible !

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