Bending Sheet Metal Into A Box

When the sheet metal bend is parallel to the direction of the fiber of the metal material cracks are likely to occur at the bend of the sheet metal and the bending strength is low and it is easy to break as shown in the following figure.

Bending sheet metal into a box. Lower the clamping bar handle down to clamp your metal into place. Box bending can be rather tricky with sheet metal because of the geometry of a press brake. Not everything requires a brake. When bending a 2 sided box with only a bottom front and back it is possible to remove a section of the holder and let the punch for a bridge.

You can find your bend allowance with the following formula. This is caused by the tension between the material s expansion on the outside of the radius and the compression on the inside see figure 4. One way that i often work with sheet metal for automotive panels is to sandwich 2 4 s in a vise with the workpiece in the middle then work the metal with a rubber mallet. A flat version of your box.

When bending with large returns there are a few tricks outside of just tooling selection. Use your bending leaf handles to slowly fold your sides and tabs to 90 degrees. Use the corner notcher to cut out any right angles. There are lots of other ways to bend sheet metal especially if it s a smaller piece.

π 180 x b x ir k x mt bend allowance ba where b is the angle complementary to your desired bend angle 1 to 180 degrees mt is the thickness of the material ir is the inside radius and k is the k factor. Springback is defined as a material s natural tendency to return to its unbent position. Besides the usual springback considerations for a normal bend the width of the ram needs to be taken into account with deep box forming to find the true minimum. Slide your metal piece underneath the teeth and line your marked line up with the edge of the teeth.

Return your bending leaf to neutral position and lift up your teeth to remove your bent metal. I have a graph paper drawing in the pics below but its not for this box 2 trace your template on to your piece of sheet metal as pictured i suggest 20 22 gauge steel 3 cut your piece into the same shape as template.