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Bending guidelines

Table of contents

Version 1.1 26/06/2018

General

  • The maximum sheet thickness for steel and aluminum is 6 mm.
  • The maximum sheet thickness for stainless steel is 5 mm.
  • The maximum weight is 40 kg.
  • The maximum dimensions are 2980 x 1200 mm.
  • These sizes are all compared to an angle of 90°. For a sharp bend, use wider dimensions for the groove.

Tolerances

Tolerances are always symmetrical relative to the nominal dimension.

  • Angle precision: ± 0.5˚.
  • Leg length (per setting): ± 0.2 mm.
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Internal radius

The internal radius is determined by the tools in conjunction with the material properties.

Sophia® will adjust the radii drawn in order to retain the shape of the final product. At the minimum, draw an internal radius of 0.5* sheet thickness in order to prevent problems with corners.

For reference, these internal radii can be used for an angle of 90 degrees.

Material thicknessSteelStainless steelAluminum
1 mm1.401.581.27
1.5 mm1.872.201.65
2 mm2.483.002.16
2.5 mm3.824.613.20
3 mm3.704.553.30
4 mm3.375.673.92
5 mm4.537.655.03
6 mm4.53-5.29

ATTENTION: these sizes are all compared to an angle of 90°. For a sharp bend, use wider dimensions for the groove.


Minimum leg length

This is the minimum overlay of the sheet on the mold that is necessary to perform the bending. The minimum leg length (b) is determined by the sheet thickness.

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Steel and aluminum

All types

Thickness Groove width (w) Leg length (b)
1 mm 8 mm 6.3 mm
1.5 mm 10 mm 7.6 mm
2 mm 12 mm 9.2 mm
3 mm 16 mm 11.7 mm
4 mm 24 mm 17.7 mm
5 mm 30 mm 21.7 mm
6 mm 40 mm 29.7 mm

Stainless steel

All types

ThicknessGroove width (w)Leg length (b)
0.8 mm 8 mm6.3 mm
1 mm 10 mm7.6 mm
1.5 mm 12 mm9.2 mm
2 mm 16 mm11.7 mm
3 mm 24 mm17.7 mm
4 mm 30 mm21.7 mm
5 mm 40 mm29.7 mm

High-strength steel

S355 rolled blue and CorTen A

ThicknessGroove width (w)Leg length (b)
1.5 mm 12 mm9.2 mm
2 mm 16 mm11.7 mm
3 mm 24 mm17.7 mm
4 mm 30 mm21.7 mm
5 mm 40 mm29.7 mm
6 mm 40 mm29.7 mm

ATTENTION: these sizes are all compared to an angle of 90°. For a sharp bend, use wider dimensions for the groove.


Minimum X-measurement for Z-bending

In order to prevent collision with the tools during a “Z-bend”, it is necessary to take into account the minimum X-measurement shown in the table.

Please note: If the setting is sharper than 90 degrees, then the minimum leg length of a V-groove must be kept wider.

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Steel and aluminum, Z-bend

All types

Sheet thickness Minimum X-measurement Groove width
0.8 mm 8 mm 8 mm
1 mm 8 mm 8 mm
1.5 mm 11 mm 10 mm
2 mm 14 mm 12 mm
2.5 mm 19 mm 16 mm
3 mm 19 mm 16 mm
4 mm 26.5 mm 24 mm
5 mm 33 mm 30 mm
6 mm 40 mm 40 mm

Stainless steel, Z-bend

All types

Sheet thicknessMinimum X-measurementGroove width
0.8 mm 8 mm8 mm
1 mm 8 mm8 mm
1.5 mm 11 mm10 mm
2 mm 14 mm12 mm
2.5 mm 19 mm16 mm
3 mm 24.5 mm20 mm
4 mm 26.5 mm24 mm
5 mm 40 mm40 mm
6 mm  N/A

High-strength steel, Z-bend

S355 rolled blue and CorTen A, Z-bend

Sheet thickness Minimum X-measurement Groove width
1.5 mm 14 mm 12 mm
2 mm 19 mm 16 mm
3 mm 26.5 mm 24 mm
4 mm 33 mm 30 mm
5 mm 40 mm 40 mm
6 mm 40 mm 40 mm

ATTENTION:these sizes are all compared to an angle of 90°. For a sharp bend, use wider dimensions for the groove.


Maximum bend angle

Due to the rebound of the material, the sheet must always be bent a bit farther than the angle indicated. The tools have a maximum angle of 30˚, which allows for bends of up to 37˚ when you take the rebound into account.

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Steel and aluminum

All types

DikteBuighoek
to 4 mm 37°
5 mm 67°
6 mm 85°

Stainless steel

All types

DikteBuighoek
to 3 mm 37°
4 mm 67°
5 mm 85°

High-strength steel

S355 rolled blue and CorTen A

DikteBuighoek
to 3 mm 37°
4 to 5 mm 67°
6 mm85°

ATTENTION:these sizes are all compared to an angle of 90°. For a sharp bend, use wider dimensions for the groove.

If the protruding section is longer than 58 mm, then the corner to be bent cannot be smaller than 70˚ due to collision on the lower beam of the bending machine. If the protruding section is not longer than 58 mm, then the maximum angle is 37˚.

Kantbank 1
Kantbank 1

Minimum distance from hole to bending line

A distinction is made between slots and round holes. The minimum distance of Ymin can be determined by the formulas below.

Minimum distance for round holes

Ymin. = Rj + 2S

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Minimum distance for rounded slots

L < 25: Ymin. = Rj + 3S
L ≥ 25: Ymin. = Rj + 4S

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If the hole still has to be closer to the bend line, a cut can be made to the bend line.

Conditions for the cutting line:

  • Length = minimum length of hole (A)
  • Width = 0.8 x sheet thickness (B)

 

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Collision with tools/machine

The ability to manipulate the material is largely dependent on the tools used. In order to create U-shapes, 247TailorSteel uses special D-tools. In order to prevent the tools from being overworked, the D10 tools are used to bend U-shapes of up to 5 mm for steel and up to 4 mm for stainless steel. The R10 tools are used to bend U-shapes of up to 6 mm for steel and up to 5 mm for stainless steel. However, there is a limit to the feasible width/height ratio of the U shape. See the figures below to determine what the feasible width/height ratio is.

Front view of stamp

Front view of stamp

Side view of stamp J-10

Side view of stamp J-10

Side view of stamp D-10

Side view of stamp D-10

For products as shown in the image, the flange cannot be longer than 32 mm. This is related to the extension (35 mm) of the “horn stamps” that are used to make these types of products.

Illustratie 3

Box-shaped products

In order to prevent collision with the machine, the maximum height for box-shaped products is 230 mm.

Illustratie 8

Large/Conical radii

Large or conical radii must be delivered in segments.

Products with this kind of radius are bent in steps, during which the distance between the bends must satisfy the rules for “minimum leg length”.

If a radius is bent conically using multiple consecutive settings, then the bend lines that meet at a “point” can not be drawn as overlapping.

Illustratie 4
Illustratie 7 (3)
Illustratie 7 (3)

Minimum bend width

Our narrowest tools are 20 mm. For bends such as those in the image below, this must be taken into account. This is why there must be enough room present for the mold in order to perform the bend.

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In order to bend settings (into corners) such as those shown below, a cut must be made like the one displayed with the red lines.

This cut must be at least the same width as the side to be set.

Illustratie 2
Illustratie 2

Minimum space between 2 settings

The sides to be set (corners) cannot be drawn completely against each other due to our tolerances. We recommend leaving at least 0.5 mm of space between them.

Illustratie 14

Illustratie 14

Always take into account a minimum of 0.5 mm of space between the side to be set and the side that will remain flat.

Illustratie 10 (5)

Hemming

247TailorSteel does not do hemming.

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Changelog

DateChange TypeDescription
13/11/2018
  • Update
Updated bending information
26/06/2018
  • Update
Updated bending information
20/09/2017
  • Publish
Page published