Fabrication Formulas

Formulas

Bend Allowance (BA)

The amount of added to the sum of the two leg lengths to obtain the flat pattern length.

$BA = {\dfrac{\pi}{180} \cdot B< \cdot (IR + K \cdot MT)}$

Bend Deduction (BD)

The amount removed from the sum of the two flange lengths to obtain a flat pattern.

$BD = {2*(\tan \left( \dfrac{B<}{2}\right) \cdot (IR + MT))-{\dfrac{\pi}{180} \cdot B< \cdot (IR + K \cdot MT)}}$

Material Thickness (MT)

The gauge of the material in decimal form.

Bend Angle (B<)

The inside angle between the two legs or flanges of a bend.

K-Factor (K)

The ratio of the position of the Neutral Axis to the Material Thickness.

$K={\dfrac{180 \cdot BA}{\pi \cdot B< \cdot MT}-\dfrac{IR}{MT}}$

Y-Factor (Y)

A constant based off of the K-Factor used by Pro-Engineer in place of a K-Factor.

The final formed inside radius after spring back has occurred.

The final formed outside radius after spring back has occurred.

Outside Setback (OSSB)

Distance between the outside tangent points and the apex of the outside mold lines.

$OSSB = {\tan \left( \dfrac{B<}{2}\right) \cdot (IR + MT)}$

Inside Setback (ISSB)

Distance between the inside tangent points and the apex of the inside mold lines.

$ISSB = {\tan \left( \dfrac{B<}{2}\right) \cdot IR }$

Outside Mold Line (OML)

A line that runs parallel to the outside of the workpiece.

Inside Mold Line (IML)

A line that runs parallel to the inside of the workpiece.

Outside Offset (OSOS)

The measurement from the surface of the outside radius to the apex of the outside mold lines.  When calculating the outside offset use the included bend angle.

$OSOS={\dfrac{IR+MT}{\tan{\left( \dfrac{B<}{2} \right)}}-(IR+MT)}$

Inside Offset (ISOS)

Distance between the inside mold lines and the bend line.

$ISOS={\sin\left(\dfrac{B<}{2}\right) \cdot \left(\sqrt{2 \cdot ISSB^2}-IR \right)}$

Inside Through the Material (ISTM)

The distance between the outside and inside mold lines.

$ISTM={\tan{\left(\dfrac{B<}{2}\right)} \cdot MT}$

Inside Shift (ISS)

Distance between the outside mold lines and the bend line.

$ISS={ISTM-ISOS}$

Bend Line Shift (BLS)

The distance from the Outside Mold Line to the original bend line on the flat pattern.  This is used to calculate the back stop location when working off of a flat pattern.