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Sheet Metal Design Guidelines - SMLease Design

To develop better quality parts at reduced cost, some of the common sheet metal design guidelines like: minimum distance between holes, cutouts, slots, distance between holes, cutouts, slots to part edge and bends, multiple bends in same direction, minimum bend radius need to be followed.

You can use this guide to make your sheet metal parts manufacturable. You can Contact Us for Sheet Metal Design & Manufacturing Support.

 


Minimum inside radius for Sheet Metal Bend:

Minimum bend radii requirements depends on applications and material.When the radius is less than recommended, this can cause material flow problems in soft material and fracturing in hard material which can result in Localized necking or fracture.

It is most economical to use a single bend radius throughout the design, but if necessary, you can utilize multiple radii.

It is recommended that minimum inner bend radius should be at least 1 times material thickness but in worst conditions for CRCA we can consider minimum radius as 0.65 times of thickness.


Minimum Bend/Flange Length

It is recommended that Minimum flange Bend length need to be maintained to avoid cracks and easy manufacturing.

Minimum flange Bend length = 3X Sheet Thickness + Bend Radius.

 


Minimum Hole Diameter

The diameter of the hole in sheet metal part should not be very small, for manufacture small holes, small sizes punches are required, which may leads to break during the operation.

It is recommended that the minimum diameter of the hole should be equal to sheet thickness but for more harder materials it should be 2 times of sheet thickness.

 


Minimum Hole/Slot Distance from Bend Edge

Minimum distance must be maintained between hole edge to bend edge to avoid metal distorsion, deformation and fracturing.

It is recommended that the minimum distance between hole edge and bend should be two times the sheet thickness plus bend radius


Minimum Centre to Centre Distance Between Two Holes

Minimum centre to centre distance between two holes must be maintained to avoid metal distorsion, deformation and fracturing.

It is recommended that minimum centre to centre distance between two holes must be should be sum of hole radius plus two times the sheet thickness.

 


Effect Of Grain Direction On Sheet Metal Bend 

Bending perpendicular to rolling direction is easier than bending parallel to rolling direction. Bending parallel to rolling direction can often lead to cracks in hard materials.

 

Bend Relief

When a bend is made near the edge of the sheet it results in tearing of metal. To avoid tearing bend relief is provided.

 

 


Extrude Hole Size & Position Recommendation

Making Extruding hole in sheetmetal requires extreme pressure & generates lot of friction and heat. If extruded hole is too close to the part edge, it can lead to deformation or tearing of the metal. so minimum distance between extruded hole to edge need to be maintained:

Minimum Distance From Extruded Hole To part Edge = 3 X T + D/2

Minimum distance between two extruded holes in sheet metal designs need to be maintained. If extruded holes are too close it can lead to metal deformation.

Minimum Distance Between Two Extruded Holes =  (5 + Hole Dia + 2 X T)

Minimum distance between extruded hole to bend need to be maintained to avoid metal deformation and fracturing.

Minimum Distance between Extruded Hole and Sheet Metal bend = 3 X T + R + D/2


Round Emboss Design Recommendation

Making Emboss in sheetmetal requires extreme pressure & generates lot of friction and heat. If emboss is too close to the part edge, it can lead to deformation of the metal. So minimum distance between emboss to edge need to be maintained:

Minimum Distance From Emboss To part Edge = 3 X T + D/2

Minimum distance between two emboss in sheet metal designs need to be maintained. If emboss are too close it can lead to metal deformation.

Minimum Distance Between Two Emboss =  (5 + D)

Minimum distance between Emboss to Bend need to be maintained to avoid metal deformation and fracturing.

Minimum Distance between Emboss and Sheet Metal bend = 3 X T + R + D/2


Louver Feature Design Recommendation

 

Minimum distance between two knockout tools in sheet metal designs need to be maintained. If they are too close it can lead to metal deformation.

Minimum Distance Between Two lowers on Shorter Edge (P1) =  5 mm

Minimum Distance Between Two lowers on Longer Edge (P2) =  8 mm


Round Knockout Design Recommendation

 

Minimum distance between two knockout tools in sheet metal designs need to be maintained. If they are too close it can lead to metal deformation.

Minimum Distance Between Two knockout (P1) =  (5 + D) mm


You can Contact Us for Sheet Metal Design & Manufacturing Support.


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