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Sheet metal bending is a fundamental skill that can be utilized with or without a metal brake, delivering simple and complex parts for a range of industrial and commercial applications without tooling. Sheet metal bending brakes are unnecessary in creating high-quality bends, but they improve efficiency, allowing for increased sheet metal bending over a shorter period.
What is Sheet Metal Bending?
When learning how to bend sheet metal, it is essential to remember that the overall goal is to apply enough force to change the shape of the metal without compromising its integrity. The applied force causes the metal to deform along a straight axis, resulting in a permanent angular bend. Factors such as material thickness, bend radius, and bend angle play a significant role in accurately determining how to bend the sheet metal.Which Sheet Metal Materials are Easiest to Bend?
Nearly all materials can be bent to some degree. However, some are more malleable than others and are used as the more traditional option for sheet metal applications. Some of the best metal options for sheet metal bending include:- 6061 Aluminum
- 5052 Aluminum
- Cold Rolled Steel
- Hot Rolled Steel
- 304 Stainless Steel
- 316 Stainless Steel
- Copper
- Brass
Sheet Metal Bending with a Metal Brake
Sheet metal bending can be achieved by a brake press that utilizes a pair of dies to bend a piece of metal to your predetermined specifications accurately. Sheet metal bending brake presses utilize tonnage and width to provide the parameters for the maximum amount of force it can exert when fabricating a part. The two processes for achieving metal brake sheet metal bending include:Air Bending
Air bending is the most common machine brake bending method available. This process utilizes a brake press that combines a v-shaped bottom tool (die) with a rounded point top punching tool (punch) to form a piece of sheet metal. Air bending works by pressing the material partway into a die with a V-shaped groove, providing greater flexibility in bend angles and part designs.Air Bending Advantages
Advantages of air sheet metal bending include:- Reduced tooling costs
- Quick setup
- Compatible with various materials
- Can handle thick and thin materials
- Energy efficient
Bottom Bending
The bottom bending sheet metal forming process utilizes a punch and a die to make accurate bends that conform to the shape of the die. Unlike air bending, bottom bending forces the sheet to contact the punch and the bottom of the die cavity. This creates a highly accurate bend with minimal springback and a sharper internal radius.Bottom Bending Advantages
- Highly accurate
- Minimal springback
- Repeatable
- Strong, consistent bends
- Sharper bend angles
- Increased control over material flow
Sheet Metal Bending without a Metal Brake
Even though machine use is the preferred method for bending sheet metal, it can still be accomplished without a brake using standard tools. Examples of sheet metal bending without a metal brake include:- Hammer & Vice - This method works best for small bends in light-gauge sheet metal.
- Wood Blocks & Clamps - Wood blocks and clamps provide a more controlled bending method for longer bends or larger pieces.
- Bending Pliers or Seamers - For small projects, seamers or bending pliers offer increased control.
IMS is Your Locally Trusted Metal Supply Company
With seven locations serving California, Arizona, Nevada, and Northern Mexico, IMS is a full-service metal supplier that understands your needs. Our inventory of metal products includes a broad range of metal shapes and an extensive selection of alloys. At IMS, we offer the following advantages:- Same-day will-call pick-up
- Next-day local delivery
- Excellent high-volume discount pricing
- Custom cut-to-size metal production
- ISO 9001 certified
- Support of Just-In-Time manufacturing processes
- No minimum purchases
