Bending – Details, Work Load
Determination, Springback Estimation,
Numerical Problems
1. Introduction to Bending
Bending is a fundamental sheet/plate forming process that applies a moment to plastically
deform a workpiece about an axis, changing its angle and curvature while largely preserving
thickness. In press-brake bending, a punch forces the sheet into a V, U, or custom die.
Typical modes include air bending, bottoming, and coining. Key design quantities are the
bend radius (Ri), die opening (V), bend allowance (BA), and the K-factor.
2. Bending Mechanics and Modes
During bending, the outer fibers are in tension while the inner fibers are in compression; a
neutral axis exhibits zero longitudinal strain. If the applied moment exceeds the elastic
limit, plastic deformation results in a permanent angle after unloading. Common modes: (i)
Air bending (punch does not fully seat the material in the die), offering flexibility; (ii)
Bottoming (material is forced to conform to die angle at moderate pressure); and (iii)
Coining (very high pressure to imprint the punch radius, minimizing springback).
3. Bend Allowance (BA), Bend Deduction (BD) and K-Factor
Because material stretches in the bend region, the flat layout differs from simple geometry.
Bend Allowance (BA) approximates the arc length of the neutral axis, while Bend Deduction
(BD) accounts for the difference between the extents of the two legs and the flat blank size.
A common approximation uses the K-factor (ratio of the neutral axis distance from the
inner surface to thickness). For a bend of angle θ (radians), inside radius Ri, and thickness t,
the bend allowance can be written as:
BA ≈ (Ri + K·t) · θ
Typical K-factor ranges: 0.30–0.50 for air bending of steels; bottoming/coining tends to
reduce K.
4. Determination of Work Load (Press Tonnage)
Press-brake tonnage for V-die air bending is often estimated by a widely used rule-of-
thumb:
F (kN) ≈ k · L(mm) · t(mm)² / V(mm)
where k is a material/process constant (≈1.2–1.5 for mild steel; use ≈1.33 as a typical
value), L is bend length, t is thickness, and V is die opening. This captures the trends: higher
thickness and length require more force, while a larger die opening reduces force.
Bottoming and coining require substantially higher forces.
Figure 1: Estimated bending force vs. die opening for t=3 mm, L=1 m (rule-of-thumb).
Practical selection of die opening for air bending often follows V ≈ 6t–12t (commonly ≈8t
for mild steel), balancing edge marking, force, and radius control. Typical inside radius for
air bending of mild steel is roughly Ri ≈ V/6 to V/8; bottoming forces Ri closer to the die
radius.
5. Springback: Concept and Estimation
Springback is the elastic recovery that reduces the bend angle and increases the bend radius
after unloading. It increases with higher strength-to-stiffness ratio (σy/E), larger inside
radii relative to thickness (Ri/t), and lower plastic strain (air bending). Coining and
bottoming reduce springback.
A practical estimation for a 90° air bend uses a simple proportional trend:
Δθ (degrees) ≈ C · (σy/E) · (Ri/t) · 90,
with C ≈ 1 as a first approximation.
This conveys that springback grows with material strength (σy), decreases with stiffness
(E), and increases with Ri/t. Exact springback depends on tooling, strain-hardening,
anisotropy, and must be calibrated empirically for precision work.
Figure 2: Trend of springback angle vs. Ri/t for a typical σy/E (illustrative).
Figure 2: Trend of springback angle vs. Ri/t for a typical σy/E (illustrative).
6. Numerical Problems
Problem 1 – Press Tonnage (Air Bending)
A 1.2 m long mild steel sheet (t = 4 mm) is air-bent in a V-die with V = 32 mm. Estimate the
bending force using k = 1.33.
Solution:
F ≈ k · L · t² / V = 1.33 × 1200 × 4² / 32 = 1.33 × 1200 × 16 / 32 ≈ 1.33 × 600 ≈ 798 kN.
Problem 2 – Springback Estimate (90° Bend)
A 90° air bend on a 2 mm sheet has inside radius Ri ≈ 2 mm and material with σy/E ≈ 0.002
(typical mild steel). Estimate the springback angle Δθ.
Solution:
Δθ ≈ (σy/E) · (Ri/t) · 90 = 0.002 × (2/2) × 90 = 0.18°. The final part would open by ~0.18°,
so one might overbend slightly (e.g., target 90.2°) to compensate.
Problem 3 – Bend Allowance and Flat Length
A bracket requires a 90° bend, t = 3 mm, Ri = 3 mm, leg lengths after bending are 40 mm and
30 mm. Assume K = 0.40. Find bend allowance (BA) and flat length (FL).
Solution:
For θ = 90° = π/2 rad,
BA ≈ (Ri + K·t)·θ = (3 + 0.4×3) × (π/2) = (3 + 1.2) × 1.5708 ≈ 6.597 mm.
Flat Length FL ≈ 40 + 30 − Bend Deduction.
For a quick estimate with one bend, use
FL ≈ 40 + 30 − (2·(Ri + t) − BA) ≈ 70 − (2·(3 + 3) − 6.597) ≈ 70 − (12 − 6.597) ≈ 64.60 mm.
7. Useful Tables
Table 1 – Typical Material/Process Parameters (Indicative)
Parameter Mild Steel (indicative) Notes
Young’s Modulus E ≈ 200 GPa Use for springback trends
Yield Strength σy ≈ 200–300 MPa Higher σy → more
springback
σy/E ≈ 0.001–0.002 Controls elastic recovery
scale
Typical V opening ≈ 6t–12t Common rule-of-thumb: ≈
8t
Table 2 – Comparison of Air Bending, Bottoming, and Coining
Mode Force Level Springback Pros/Cons
Air Bending Low–Moderate Higher Flexible angles; least
tonnage;angle
sensitiveto variation
Bottoming Moderate–High Low Good repeatability;
needs accurate tools
Coining Very High Very Low Max precision; high
tonnage; tool wear
8. Summary
Bending design and process planning revolve around accurate workload estimation, reliable
flat pattern development, and managing springback. Rule-of-thumb tonnage formulas help
size presses and dies, while K-factor methods guide flat layouts. Springback is inherent and
must be compensated via overbending, tooling selection, or coining/bottoming when
needed.