Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

BENDING GUIDELINES 1#
SCOPE

NUMBER: PAGE: 1 of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

The majority of applications at ATS require the use of sheet metal components. This document will outline: the preferred materials to use in welded and non welded components the materials stoc ed by ATS common design errors bend radiuses proper dimensioning

PRE(ERRED MATERIALS TO USE IN )ELDED AND NON )ELDED COMPONENTS -!" #a. $s the minimum thic ness preferred by the fabrication department when ma ing welded sheet metal components. Thinner material will distort when welded. This material is stoc ed by Systems. % &'S is preferred over C'S. C'S will fracture when bent onto itself at room temperature. %"("! T" Aluminum can not be used) it will fracture when bent. Specify *((*%&!+ Aluminum.

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MATERIALS STOC$ED BY ATS %Standard stoc sheet si,e for steel is +-. / !0(.) Aluminum is available in slightly different si,es. See 1ig ! for a list of stoc thic nesses. Contact purchasing if a larger sheet is required. %Stainless steel is stoc ed with a 02 finish. $f a 3+ finish is required it must be specified on the print. (+, 1# Stoc- ./eet .+0e.# Dimension s 00#A !-#A !"#A !+#A !0#A !!#A :.

4aterial *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel

Decimal $nch (.(*!* (.(8(( (.("08 (.(9-! (.!(7+ (.!08( (.08((

5bs6Sq. $n. (.((7 (.(!+ (.(!(.(00 (.(*! (.(*8 (.(9(

4aterial A%8"7 &' ;<= A%8"7 &' ;<= A%8"7 &' ;<= A%8"7 &' ;<=

Dimension s !"#A !+#A !0#A !(#A

Decimal $nch (.(87(.(9+9 (.!(+" (.!*+8

5bs6Sq. 1t 0.8(( *.!08 +.*98 8."08

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

A%8"7 &' ;<= 9#A (.!97* 9.8(( A%8"7 &' ;<= !6+ (.08 !(.0!( Aluminum sheets are not stoc ed in the standard +-. / !0(.) See 1ig 0 for a list of available stoc si,es. (+, # Stoc- &'%1+2%1 ./eet .+0e.# Bidth / 5ength "( / !0( +- / 7" +- / !0( Decima l $nch (.("* (.!08 (.08(

4aterial *((*%&!+ Aluminum *((*%&!+ Aluminum *((*%&!+ Aluminum

Thic ness !+#A !6-D !6+D

5bs6Sq. $n. (.((" (.(!0 (.(08

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COMMON DESIGN ERRORS

3#1

BENDS THAT CANNOT BE MANU(ACTURED This profile cannot be achieved with the equipment available at ATS. Sheet metal bending is done in a press) where the part to be bent is placed on a C shaped die) and a punch lowers to form the part. $f more than one bend is to be put into the part the designer must ensure that it is possible to set up the part in the press such that it will not interfere with the press when it is bent. 1or eEample if dimension 2 is longer than dimension A the part may hit the side of the press before the bend is complete. See F1igure *G for punch guidelines.

(+, *# Bre&- 4re.. .c/e1&t+c typically for leEan !6!" %!6-

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: * of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

$t is not possible to ma e three consecutive bends in the same direction to form a tube. $f this type of configuration is needed) it must be made from two pieces. Belding two H5. shaped pieces together is the most desirable method) it is easy to weld and clean up. A less desirable method is to weld two H>. shaped pieces together to form the same profile. This method is difficult to weld without distortion since the seam has a tendency to sin during welding) causing a slight bow in the welded surface.

4=ST D?S$'A25?

>@D?S$'A25?

>@D?S$'A25?

Easy to ben d two L sha p e s and weld toget h e r .

Final ben d cann o t be prod u c e d with the equi p m e n t

Surfac e when makin g difficult

will bow weld e d it mor e to blend

A Covers made of sheet metal generally have to be made from two pieces. $n this eEample the width of the part is less than the height ma ing it impossible to create the channel with the available machinery. Tab A cannot be formed as it is too narrow to fit any tools inside. 2elow Ffigure +.G is an eEample of how the part should be split so that it could easily be manufactured.

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: 3 of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

(+, 3# P&rt 1&5e fro1 t6o 4+ece.

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PRODUCING ROUNDED EDGES A hemmed edge 6 safety edge cannot be made on any material thic er then !+ #a. $f the material is thic er then !+ gage) add a note to remove sharp edges or use eEtruded >% channel that is available through Spaenaur. A common mista e is to create the safety edge too close to an eEisting bend. A safety edge must be a minimum of - times the material thic ness away from an eEisting bend.

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HOLES, CUTOUTS AND SLOTS

=ften a part will be detailed without ta ing into consideration how the part will be produced. $n this eEample) the slot is too close to the bend. The slot must be machined after the bends have been formed so that the slot does not become deformed. The same applies for holes6cutouts that are too close to a bend. $f a slot or hole is needed in a part its edge must be at least " times the material thic ness away from the bend line. Bhen a part requires additional machining after forming the flat pattern cannot show these features Ffigure 8.G) because the flat pattern drawing file is sent to the supplier where all the features would be cut prior to forming.

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: 7 of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

(+, 7# (e&t%re. 1&c/+2e5 &fter for1+2,, re1o8e5 fro1 f'&t 4&tter2

3#3

EDGE LENGTH

As a general rule there should be - times the material thic ness between the bend line and the edge of the part) any less then that and the sheet metal will not properly engage the die. This also applies for cutouts in the part. 1igure " shows an eEample of a part without enough material through the entire length of the bend. To remedy this) either remove the material up to the bend line or eEtend the material - times the material thic ness past the bend line.

(+, "# C%t too c'o.e to t/e e5,e

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: " of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

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BEND RADIUSES %The bend radius should) if possible) be ept the same for all radiuses in the part to minimi,e setup changes. %1or most materials) the ideal minimum inner radius should be at least ! material thic ness) See figure - for a more detailed loo at available internal radiuses. 2end radiuses larger then those specified should not be used. They can be produced by the fab shop but require more time to setup and produce as they must be punched multiple times by the press. %2end radiuses are dependant on two factors: !. Thic ness of material. 0. Type of material. %#age numbers do not represent the same thic ness for all materials. 1igure 9 shows the different gage numbers and the thic ness of the material in inches. (+, 9# G&,e T/+c-2e.. :refere2ce +2 +2c/e.; S Stai n l e ss A l u m i n u m .!$$ .!%' .%"! .%#! .%)& .%(! .%&' .%'(

!% !! !' !$ !) '% ''

ga ga ga ga ga ga ga ga

.! " .!&$ .!'% .!%( .% ( .%)% .%&) .%&%

.!## .!$! .!'( .!%" .% # .%)& .%&# .%&!

(+, <# I2ter2&' Be25 R&5+%.e. 4aterial Dimension Decimal 2ottom Die 2end 'adius

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

*(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel *(+%Stainless Steel s 00#A !-#A !"#A !+#A !0#A F$nch I mmG (.(*!* I (.-( (.(8(( I !.09 (.("08 I !.87 (.(9-! I !.7(.!(7+ I 0.9-

NUMBER: PAGE: 9 of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY: FmmG " !0 !" !0 !" !0 !" !0 !" 0( !" 0( 08 *8 8( FmmG .7* !.89 !.7 !.7 0.8+ !.7( 0.8+ !.7 0.8+ *.0 0.8+ *.0 *.7 8."0 -.(-

*(+%Stainless Steel

!!#A

(.!08( I *.!-

*(+%Stainless Steel

:.

(.08(( I ".*8

4aterial A%8"7 &' ;<= A%8"7 &' ;<= A%8"7 &' ;<=

Dimension s !"#A !+#A !0#A

Decimal F$nch I mmG (.(87- I !.80 (.(9+9 I !.7( (.!(+" I 0.""

A%8"7 &' ;<=

!(#A

(.!*+8 I *.+0

A%8"7 &' ;<= A%8"7 &' ;<=

9#A !6+D

(.!97* I +.88 (.08 I ".*8

2ottom Die FmmG !0 !" !0 !" !0 !" 0( !" 0( 08 *8 8(

2end 'adius FmmG !.7 0.8+ !.7 0.8+ !.7 0.8+ *.0 0.8+ *.0 *.7 8."0 -.(+

4aterial *((*%&!+ Aluminum *((*%&!+ Aluminum *((*%&!+ Aluminum

Dimension s !+#A !6-D !6+D

Decimal F$nch I mmG (.("* I !."( (.!08 I *.!(.08( I ".*8

2ottom Die FmmG !0 !" !0 !" *8 8(

2end 'adius FmmG !.7 0.8+ !.7 0.8+ @one @one

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PROPER DIMENSIONING

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: < of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

%A flat pattern view must be included with the drawing showing the bend lines and any features that need to be put in the part prior to bending. 1eatures that need to be add after the bends are formed must be removed from the view. %Dimension to the outside of the bends as illustrated belowJ this dimension is utili,ed by the fab shop in the manufacturing process of the part. %$f the inside dimension is important Fshroud fitting over an assemblyG and must be maintained then dimension to the inside but add a dimension to the outside using parenthesis. This ensures adequate communication between design and fab as to what the design department is requesting. %Standard bend radiuses should be used. See the above section for a list of standard bend radiuses. %2end radiuses should be dimensioned to the inside of the bend. %Sheet metal components should only be dimensioned to maEimum of one decimal place if designed in metric and two decimal places if in imperial. %Dimension to the outside of the part whenever possible. %2end angles should be rounded to the nearest degree. %$f multiple pieces of stainless steel pieces are to be used close to each other it is important to specify the grain direction on the flat pattern. %Bith Stainless steel the polished surface must be indicated on the print.

S+14'e S/eet Met&' E=&14'e )+t/o%t I2ter2&' (e&t%re.

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.

Automation Tooling Systems Cambridge Advanced Systems Division

MECHANICAL DESIGN STANDARDS

NUMBER: PAGE: 9 of 9 ISSUE DATE: October 19, !!" REVISION: PREPARED BY: S# $%b&'& APPROVED BY:

S+14'e S/eet 1et&' E=&14'e )+t/ I2ter2&' (e&t%re. C%t Pr+or to Be25+2,

ATS PROPRIETARY: T&$S D=C>4?@T $S T&? ;'=;?'TA =1 ATS. $T $S C=@1$D?@T$A5 $@ @AT>'? A@D 4>ST @=T 2? T'A@S4$TT?D T= ;A'T$?S =>TS$D? =1 ATS B$T&=>T S?@$=' 4A@A#?4?@T A;;'=CA5.