Sheet Metal Design Guidelines

Issue XVIII, March 2016

A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS 2

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A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS 3

 In this issue, we cover design guidelines that can help optimize features such as embosses, lip
and extruded form in a sheet metal forming process. Embossing is a sheet metal forming process
for producing raised or sunken designs or relief in sheet material by passing sheet between rolls
of the desired pattern or by using matched male and female roller dies.

Read the guidebook for specific guidelines such as Countersink Hole Distance to Form, Emboss
to Edge Distance, Emboss to Bend Distance, Emboss Spacing, Closed Hem Parameters and
Extruded Form Spacing.

We are continuously working towards enhancing our DFM knowledgebase and adding guidelines
for next-generation processes such as additive manufacturing and tubing as well strengthening
the
. existing ones.

We hope you are finding the DFM Guidebook informative and worthy of your continued
interest. We will be covering newer manufacturing issues in our future issues and look forward
to your continued support.

If you have any feedback or questions on DFM guidebook, please write to us at

info@dfmpro.com

Rahul Rajadhyaksha
Senior Product Manager
Geometric Limited

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 Contents
Countersink Hole Distance to Form ........................................................................ 6
Emboss to Edge Distance ........................................................................................ 7
Emboss to Bend Distance........................................................................................ 8
Emboss Spacing ....................................................................................................... 9
Closed Hem Parameters ....................................................................................... 10
Extruded Form Spacing ......................................................................................... 11

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 Countersink Hole Distance to Form

A certain minimum distance needs to be maintained between countersink hole and form to
prevent distortion of holes during manufacturing.

It is recommended that the minimum distance (D) between the major diameter of a countersink
and a form should be four times the material thickness.

Where,
t= Sheet metal thickness
D= Minimum distance between countersink hole distance to form

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 Emboss to Edge Distance
Emboss is a part of forming process in sheet metal design. While designing, minimum distance
should be maintained between emboss and edge of the sheet to avoid shear and deforming. To
avoid such issues designer has to maintain sufficient gap between Emboss and part edge.
It is recommended that the minimum recommended distance between major diameters of
emboss and the edge should be four times the material thickness plus the base radius of emboss.

Where,
t= Sheet Metal thickness
D= Distance from major diameter of emboss to edge of part

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 Emboss to Bend Distance

Minimum distance should be ensured between Emboss to bend in order to avoid shearing and
deformation. To avoid such issues designer has to maintain sufficient gap between Emboss and
bend.

It is recommended that minimum recommended distance between the Emboss to bend should be
greater than or equal to five times the material thickness.

Where,
t= Sheet Metal thickness
D= Minimum distance between emboss to bend

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 Emboss Spacing

It is recommended that minimum distance between embosses should be maintained to avoid

formability issues like without necking, shearing or cracking.

Where,
D= Distance between embosses
t= Thickness

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 Closed Hem Parameters

For bending operation, there should be sufficient contact between sheet and tool. Insufficient
contact may cause the sheet to shear or result in improper bending. Hence, sufficient contact
area (H) should be maintained.

It is recommended that return flange length to the sheet metal thickness should be greater than
or equal to four times the material thickness.

Where,
t= Sheet Metal thickness
H= Return flange length

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 Extruded Form Spacing

A certain minimum distance should be maintained between two extruded forms to avoid fracture,
care needs to be taken when placing formed features close to each other. If a station does not
clear a form already placed in a part, the form will get flattened out.

The minimum recommended distance between the forms should be greater than or equal to
eight times the material thickness.

Where,
D= Minimum distance extruded form features
t= Sheet metal thickness

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