Sheet Metal

DRAFTING MANUAL
Section K18.0
Page 1
January 2000
SHEET METAL PRACTICE
Tolerances Thickness 1, 2
1.0 GENERAL
This section contains specific information related to the
documentation and specification practices for sheet metal. The
practices defined herein are limited to those of a general nature
since local practice is affected so heavily by sheet metal
equipment availability such as bending brakes, presses,
numerical controlled machines, and forming dies and punches.
2.0 REFERENCE DOCUMENTS
Width
Over
12.00
20.00
40.00
48.00
1
This section is based on a series of books, The Profitable Way

Specifying and Purchasing Handbooks, prepared by Jack
Blair, GEs Manager of Materials Utilization Programs,
Corporate Purchasing Planning and Development, Bridgeport, Connecticut. These General Electric books are no longer
available; however, the information felt most useful to drafting
designers has been included here.
3.0 DEFINITIONS
Sheet Metal - Normally viewed as that material up to 0.250inch thick for nonferrous materials and up to 0.1875 for most
ferrous materials.
To incl
20.00
40.00
48.00
60.00
Thickness
0.0971
0.1799
0.2299
0.0710
0.0972
0.1800
Tolerance, inch, plus or minus
0.006
0.007
0.007
0.007
0.007
0.008
0.007
0.008
0.009
0.007
0.008
Tolerance on width is always plus, and varies from 1/8

inch to 3/8 inch for 0 inch to 80 inches wide.
Tolerance on length is always plus and varies from 1/8
inch to 3/4 inch for 15 inches to 120 inches long.
4.1.2 - Other carbon steel as described in 4.1.1 is available with

a mill edge. Tolerance on width is +7/16 to +1 1/2 thru 60
inches wide. Mill Edge is the normal edge produced in hot
rolling and does not conform to any definite contour. It is
known to the industry as natural round and is the lowest cost
edge. Due to its inherent poor edge, one inch over the finish
width must be allowed to eliminate the possibility of defects
extending into the finished product. CUT EDGE is a slit or
sheared edge which may be sharp and contain some burrs.
4.0 TYPICAL SHEET METAL MATERIALS

4.1 Carbon Steel
4.1.1 - Hot rolled, commercial quality, low carbon, pickled and
oiled steel sheet with cut edges. This material is the common,
everyday variety of hot rolled low carbon steel sheet. The
carbon content is limited to 0.12 % maximum to facilitate
fabrication by welding. It closely corresponds to UNS G10100.
The cost of is equivalent to hot rolled strip and approximately
23 % less than cold rolled sheet. It is readily welded, punched,
sheared, machined and formed, and is recommended for low
stress mechanical applications. Typical properties are:
Mechanical Properties
Tensile strength, ksi ...................................................... 45
Yield strength, ksi (0.2 offset) ...................................... 30
Elongation % in 2 inch ................................................. 30
Bend test Flat on itself in any direction.
4.1.3 - Cold rolled, low carbon STEEL SHEET, commercial

quality, commercial flatness, oiled. Standard practice of
inspection requires that one side only need be suitable for the
purpose for which the cold rolled sheet is intended. It is
suitable for exposed parts requiring a good surface. These
sheets are produced with a dull surface texture suitable for the
application of paints, enamels, or lacquers. This material is not
recommended for plating. The maximum carbon content is
0.12 % which is satisfactory for welding processes. Typical
properties are:
Mechanical Properties:
Yield strength, ksi ........................................
Elongation, % in 2 inches .............................
Rockwell Hardness, HRB, max ....................
3237
25
50
Tolerances - Thickness:
48 inch wide sheets, 0.036 inch thick .............
54 inch wide sheets, 0.060 inch thick .............
0.003
0.005
Tolerance - Width:
30 inches to 48 inches wide .................................... 3/16
Over 48 inches to 60 inch sheets .............................. 1/4
Tolerance - Length: (Sheets over 12 inches wide)
96 inches to 120 inches long .................................... 3/4
GENIUM PUBLISHING
*Supersedes issue of July 1985
Section K18.0
Page 2
January 2000
DRAFTING MANUAL
4.1.4 - Commercial, cold rolled, low carbon steel strip with

round edges. Standard practice of inspection requires that one
side only be suitable for the purpose for which this class of
cold rolled steel is intended. The maximum carbon content is
0.12 % which is satisfactory for welding processes. Typical
properties are:
Rockwell hardness test, HRB (Target Aim To), max ... 65
Bend test Flat upon itself in any direction.
Tolerances - Thickness:
3/4 inch wide ........................................................ 0.002
4.2 ALUMINUM
4.2.1 Strengths - It is generally known that aluminum sheet
which is suitable for forming is not as strong as low carbon
steel sheet. The strength of a sheet metal enclosure is a very
difficult thing to calculate. For most applications the minimum
thickness of sheet material is specified. This thickness generally exceeds the necessary minimum for strength requirements
by a considerable margin. For this reason, and the fact that
calculations are complex, few people attempt to measure
strength or rigidity.
Tolerance - Width:
3/4 inch wide, 0.105 thick .................................... 0.015
The behavior of aluminum in an enclosure can be understood

by comparing strength and modulus of elasticity with low
carbon steel.
Tolerance - Camber:
3/4 inch wide, 1/2 inch in any 8 feet.
Table 1 gives an approximation between aluminum and low

carbon steel from the standpoint of strength and rigidity.
4.1.5 - Hot rolled, low carbon, commercial quality, as rolled,

not oiled steel with mill edge. Mill edge is the normal edge
produced in hot rolling and does not form to any definite
contour. Maximum carbon content is 0.12 %. Typical properties are:
In order to make interpretation easier, beams, posts and sheets

were selected as representative members. In actual practice, the
side of an enclosure with a flange is a combination of post and
sheet members.
Tensile strength, ksi ...................................................... 45
Elongation in 2 inches .................................... Varies with
the thickness. For 0.105 thick it is 1632.5 %
Rockwell hardness, HRB ............................................. 50
Bend test Flat on itself in any direction.
The strength of a given material is the ability of that material to

resist stress (force per area such a pounds-per-square-inch) and
strain (the elongation or stretching sometimes denoted as inchper-inch). Designs not exceeding the elastic limit (the straightline portion of the stress-strain curve) will return to their
original size and shape upon removal of the load. The elastic
limit ration is denoted by the Modulus-of-Elasticity formula:
Tolerances - Thickness: (For 0.105 thick)

0 to 3.50 wide ....................................................... 0.006
3.51 to 6.00 ........................................................... 0.008
6.01 to 12.00 ......................................................... 0.009
Thickness is measured by 3/8 inch in from edge of strip 1
inch or wider; and at any place on the strip when narrower
than 1 inch.
Tolerance - Width:
Up to 2 inches wide .................................................... 1/32
Over 2 inches to 5 inches wide ................................... 3/64
Over 5 inches to 10 inches wide ................................. 1/16
Over 10 inches to 12 inches wide ............................... 3/32
Tolerance - Length: (For 5 to 10 feet long)
Up to 3 inches wide ........................................ +3/8, 0 inch
Over 3 inches to 6 inches wide ....................... +1/2, 0 inch
Over 6 inches to 12 inches wide ..................... +3/4, 0 inch
Camber of Edgewise Curvature (Depth of Arc) in any 8 Feet
For material wider than 1 1/2 inch = 1/4 inch.
For material 1 1/2 inch wide and narrower = 1/2 inch.
GENIUM PUBLISHING
E=
(stress)
(strain)
(Continued on the next page.)
DRAFTING MANUAL
Section K18.0
Page 3
January 2000
TABLE 1
Strength of Aluminum
(In relation to low carbon steel of same thickness)
Type member
Strength
Deflection
Stiffness or rigidity
Beam (acting as a horizontal

member)
40 to 67 %
3 steel
1/3 of steel
Post (vertical member acting

in tension or compression)
40 to 67 %
40 to 67 %
3 steel
1/3 of steel
Sheet (acting as plain surfaces

for mounting components
or as side of an enclosure)
All aluminum alloys have a modulus of elasticity of approximately 10 106. This is another way of saying that all aluminum acts alike so far as the stress and strain are concerned.
A strong material will permit a larger deflection without failing
than will a weaker one. If the application of the part you are
designing will permit considerable deflection, then a stronger
material will offer something. For example, if you were
designing a steel fishing rod you would want a strong material
which will permit large deflection.
It has been suggested that industry in general over-designs in
so far as many steel enclosures are concerned. Where more
deflection than that of steel is permitted, use material close to
the thickness of steel. Instead of 0.105 inch thick steel for floor
mounted enclosures, use 0.125 inch thick aluminum providing
the internal suspended load does not exceed 1200 pounds.
Larger loads can be handled by placing heavy components like
transformers, motor-generator sets in the bottom of the
enclosure. In general, increasing the thickness of the material
will increase the strength and rigidity in direct proportion.
Reinforcements and proper placement of components may be
more economical than increasing material thickness.
4.2.2 Corrosion Properties - Aluminum and aluminum alloy
materials will resist the outdoor exposure conditions encountered in the United States without developing structurally
serious corrosion, provided certain undesirable conditions do
not exist. Contact of parts made with aluminum-base alloys
with those of most dissimilar metals (except zinc and cadmium) in moist locations is likely to lead to serious galvanic
corrosion of the aluminum alloy. Similarly extended contact of
aluminum alloy parts with wet porous materials, such as paper,
felt, cloth, hair, cork, etc. should be avoided, or special
precautions should be taken to prevent corrosion.
Chemical Corrosion The aluminum base alloys resist

hydrogen sulfide and most other sulphur compounds, ammonia
and ammonium hydroxide, most organic chemicals, acetic acid,
concentrated nitric acid and hydrogen peroxide. They are
attacked by caustic alkalis, many alkaline salts, hydrochloric
and hydrofluoric acids and solutions containing chlorides and
heavy metal compounds.
Atmospheric Corrosion All tempers of aluminum alloys are
highly resistant to corrosion in most environments.
Manufacturing Properties Most aluminum alloys can be bent
90 degrees with a suitable radius without cracking. Soft
(annealed) aluminum can be bent 180 degrees and flattened,
providing special precautions are observed in the factory.
Although it is possible to soft solder aluminum, it is not
recommended. The joint will be instable due to galvanic
corrosion between the solder and the aluminum.
Brazing Can be gas or electrically brazed.
Anodic treatment may be satisfactorily applied to this alloy
without darkening its surface to improve its corrosion resistance. No forming should be done after anodizing due to the
hard brittle surface resulting from the anodize coating.
Tolerances: (98 inch wide sheets)
0.064 thick, inch .................................................... 0.004
0.091 thick, inch .................................................... 0.004
0.128 thick, inch .................................................... 0.005
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 4
January 2000
4.2.3 Aluminum alloy UNS A95052, flat sheet. Typically

either soft (annealed) or 1/4 hard (strain hardened).
This material has the highest strength of any non-heat treatable
aluminum alloy. It has a mill finish and is purchased with one
side protected by a layer of adhesive paper.
Chemical Composition % (ASTM)
Magnesium ..............................................
Chromium ................................................
Iron, max .................................................
Silicon, max .............................................
Manganese, max ......................................
Copper, max ............................................
Zinc, max .................................................
Other elements, each, max ......................
Other elements, total, max .......................
Aluminum ................................................
2.22.8
0.150.35
0.40
0.25
0.10
0.10
0.10
0.05
0.15
Remainder
Temper Tensile strength, ksi

Soft
25 min31 max
1/4 Hard 31 min38 max
Elongation % in 2 inch,
minimum
Thickness
Thickness
0.0510.113 0.1140.161
19
20
7
9
Shearing strength, ksi .....................

Endurance limit, ksi .......................
Proportional limit, ksi ....................
Rockwell hardness, typical,
HRH; HRE ................................
Brinell hardness, typical, HB .........
Electrical Properties
Conductivity, % of copper standard
Permeability ...................................
Soft
18
16
1/4 Hard
20
17
8
85; 50
47
60
35
1
Thermal Properties
Conductivity of copper, %, average
Coefficient of expansion, per
degree F (68212 F), 106 .....
Melting range (degree F), approximate
41
13.2
11251200
General Properties
Modulus of elasticity, 106, psi ....
Weight, lb/in3 .................................
Specific gravity ..............................
10
0.97
2.68
4.3 STAINLESS STEEL

4.3.1 General High-chromium corrosion-resisting steels are
popularly known as stainless steels, although no perfectly
stainless metal has yet been discovered. The improved corrosion resistance of this class of steels is caused by the formation
of a protective film due to the presence of chromium. This film
is formed by air, but frequently it is artificially accelerated by a
passivating dip into diluted nitric acid. This dip removes the
free iron at the surface of the part and forms the protective
film. If the film is broken in service, it will usually heal if
oxygen is present.
All stainless steels are resistant to nitric acid, as well as the
weak acids, but are attacked by the strong non-oxidizing acids,
hydrochloric and sulphuric, of all concentrations. Chloride
solutions will also break down the protective film and cause
corrosion. The resistance to attack by alkalies and organic
substances is very good.
In conjunction with the formation of the protective film, it
should be mentioned that the finish is important to corrosion
resistance. The better the finish, the greater the resistance to
corrosion.
Stainless steels of all types are subject to local failure by
intergranular corrosion if improperly heat treated. The improper treatment consists of heating the solution-quenched
specimen within a critical range from 752 F to 1652 F (400
C to 900 C), even for only a few minutes. It is believed that
chromium carbides are precipitated on the grain boundaries by
this treatment. These carbides rob the adjacent metal crystals of
their chromium and thus remove their resistance to corrosion.
Consequently, the chromium-impoverished metal along the
grain boundaries is readily attacked by strong corrosive agents.
They can be restored to the original condition by reheating to
1900 to 2000 F and quenching in water so as to re-absorb the
carbides and retain them in solution.
There are two distinct groups of stainless steels magnetic and
non-magnetic. If a non-magnetic stainless steel is required,
each specification will have to be examined to determine if the
stainless steel has this quality.
The advantages of stainless steel products lie principally in
corrosion resisting, non-magnetic and aesthetic properties.
There is no advantage of strength as compared to common low
carbon steel. Although the tensile strength of stainless steel is
greater than low carbon steel, the additional strength is due to
cold working as it is being stretched. A comparison of the yield
strengths reveals one to be about equal to the other.
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 5
January 2000
Stainless steel is more difficult to machine or punch than low

carbon steel. This is not because it is initially harder but
because of cold working ahead of the tool.
Tolerances - Width (inch)

(46 inch sheets) = +0.06, 0
(48 inch sheets) = +0.13, 0
4.3.2 A UNS S30403 type chromium-nickel, austenitic steel

sheet commonly known as stainless steel - (dull finish). Due to
its low carbon content, excessive precipitation of the chromium
carbides when held at 752 F to 1652 F (400 C to 900 C) for
short periods is considerably reduced. Prolonged exposure at
this temperature would result in excessive carbide precipitation. Therefore, this material is not recommended for continuous service at elevated temperatures in corrosive atmospheres.
However, it can be welded, brazed, or soldered without
detrimental consequences because these processes subject the
material to the critical range of heat for only a few minutes.
Tolerance - Length
(96 inch long sheets) = +0.25, 0
Structures or assemblies utilizing this grade of stainless steel

must not be subjected to stress relief treatments since such
treatments result in harmful carbide precipitation, and therefor
render the material susceptible to intergranular corrosion.
Tolerance - Flatness (For 46 inch and 48 inch wide sheets)

0.036 thick
= 0.75 in. variation from flat
0.062 to 0.172 thick inclus. = 0.50 in. variation from flat
5.0 BENDING ALLOWANCES
5.1 CARBON STEEL
The following formulas and Table 2 recommend bend radius
data for carbon steel.
(Continued on page 6.)
The material is lightly cold rolled and has a dull surface. It has
full finish, No. 2D. It can be used for deep drawn articles
which are polished subsequent to fabrication. Typical properties are:
Tensile strength, ksi ........................................
Yield strength, ksi (2 % offset) ......................
Elongation, % in 2 inches ...............................
Rockwell hardness, HRB ...............................
75
28
50
70
Magnetic Properties
Permeability at H = 200 oersteds: at room temperature
(25 C maximum) 2.00.
Tolerances Thickness (inch)
0.032 thick ......................................................
0.062 thick ......................................................
0.094 thick ......................................................
0.125 thick ......................................................
0.172 thick ......................................................
0.004
0.006
0.008
0.010
0.014
Chemical Composition % (Ladle Analysis)

Carbon, max ...................................................
Manganese, max .............................................
Phosphorus, max ............................................
0.03
2.00
0.040
Chemical Composition % continued

Sulphur, max ..................................................
0.030
Silicon, max ....................................................
1.00
Chromium ....................................................... 18.0020.00
Nickel ............................................................. 8.0012.00
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 6
January 2000
TABLE 2
Values of K (bending allowance for 90 bends on vee dies)
Metal
Thickness
0.010
0.015
0.019
0.025
0.030
0.036
0.044
0.060
0.062
0.090
0.094
0.105
0.120
0.125
0.180
0.188
0.250
0.313
0.375
0.500
1/16
(0.06)
0.019
0.016
0.013
0.009
0.007
0.002
+0.002
+0.012
+0.014
+0.031
+0.035
+0.042
+0.050
+0.054
+0.088
+0.006
+0.009
+0.012
+0.016
+0.019
+0.018
+0.022
+0.031
+0.031
+0.130
Inside Corner Radius

3/16
1/4
1/2
(0.19)
(0.25)
(0.50)
0.075
0.101
0.208
0.065
0.090
0.205
0.065
0.088
0.202
0.060
0.085
0.198
0.057
0.082
0.195
0.055
0.080
0.191
0.053
0.078
0.186
0.043
0.070
0.176
0.043
0.068
0.175
0.024
0.051
0.157
0.023
0.051
0.155
0.015
0.042
0.148
0.005
0.032
0.139
0.004
0.031
0.135
+0.037
+0.006
0.101
+0.042
+0.008
0.096
+0.085
+0.053
0.057
+0.115
+0.089
0.018
+0.155
+0.128
+0.022
+0.234
+0.207
+0.100
1/8
(0.13)
0.049
0.041
0.039
0.035
0.032
0.031
0.026
0.016
0.017
+0.003
+0.003
+0.012
+0.022
+0.028
+0.060
+0.070
+0.107
3/4
(0.75)
0.316
0.313
0.310
0.306
0.302
0.298
0.293
0.283
0.283
0.264
0.263
0.255
0.245
0.243
0.207
0.204
0.163
0.126
0.085
0.006
1 inch
(1.00)
0.423
0.420
0.417
0.413
0.410
0.406
0.401
0.391
0.390
0.372
0.370
0.363
0.353
0.350
0.315
0.311
0.271
0.233
0.193
0.114
1 1/4
(1.25)
0.530
0.527
0.524
0.520
0.515
0.511
0.506
0.496
0.497
0.477
0.477
0.468
0.458
0.457
0.420
0.428
0.376
0.340
0.298
0.219
Forming Radius must be specified on drawing.

0.06 inch is Standard Forming Radius for 0.030 inch to 0.125 inch including thick material.
0.19 inch is Standard Forming Radius for 0.180 inch and 0.250 inch thick material (except 0.250 thick Cold Drawn Steel
which will fracture if 0.19 inch radius is used). Use 0.25 inch minimum Forming Radius for 0.250 inch Thick Cold Drawn
Steel.
B
R
A
T
DEV. LG =
(2R + K)
90
T
DEV. LG =
(A + B + ) (2R + K)
90
DEV. LG = A + B + K
X arc
X for 90 bends = 1.571 (R + Y) (4 inch RAD = Bend allowance 1.65 inch)

Other angles are proportional.
Y (for low carbon steel) = 0.4 T.
Bend allowance (K) = 0.628 T 0.429 R (per K formula).
For values of K which are not included in Table 2, use the above formula.
Y
T
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 7
January 2000
0.125
3.00
2.13
1.75
0.88
Example:
Developed length = Sum of all inside dimensions.
Plus the algebraic sum of all bend allowances.
Developed length = 2.13 + 1.75 + 3.00 + 2.13 + 0.88 + 0.216 = 10.106 or 10.11 inches.
All bends 90 0.06R, K for four bends = 4 (+0.054) = +0.216

5.1.1 Minimum Flange Dimensions
TABLE 3
Minimum Flange
Using A Bend Allowance
Developed Length = A + B + C
B
min
T
R
C
min
T
0.030
0.036
0.040
0.060
0.090
0.105
0.120
0.180
0.250
B or C, min
0.38
0.38
0.38
0.38
0.38
0.38
0.38
1.12
1.12
R
0.060
0.060
0.060
0.060
0.060
0.060
0.060
0.188
0.188
5.1.2 Developed Length for Wraparound Bends

TABLE 4
B Minimum. See Table 3.
B
T
0.030
0.036
0.044
0.060
0.090
0.105
0.120
GENIUM PUBLISHING
Developed length
A + B + 0.05
A + B + 0.06
A + B + 0.08
A + B + 0.09
A + B + 0.14
A + B + 0.16
A + B + 0.19
DRAFTING MANUAL
Section K18.0
Page 8
January 2000
5.2 Aluminum
TABLE 5
For UNS A95052 and UNS96101 Aluminum Sheet and Plate
R
Radius
1/64
1/32
1/16
3/32
1/8
3/16
1/4
5/16
3/8
7/16
1/2
9/16
5/8
0.032
+0.012
+0.006
0.007
0.020
0.035
0.062
0.098
0.114
0.144
0.170
0.196
0.211
0.252
Bend allowance A for 90 bend = 0.597T 0.429R

Material thickness T
0.063
0.094
0.125
0.187
0.250
+0.031
+0.049
+0.068
+0.111
+0.142
+0.024
+0.043
+0.061
+0.105
+0.136
+0.012
+0.030
+0.049
+0.092
+0.123
0.001
+0.017
+0.036
+0.079
+0.110
0.016
+0.002
+0.021
+0.064
+0.095
0.044
0.026
0.007
+0.037
+0.068
0.069
0.051
0.032
+0.011
+0.042
0.095
0.077
0.059
0.015
+0.016
0.125
0.107
0.089
0.045
0.014
0.151
0.133
0.115
0.071
0.040
0.177
0.159
0.145
0.101
0.070
0.192
0.174
0.156
0.112
0.081
0.233
0.215
0.197
0.153
0.122
3/8
+0.219
+0.213
+0.200
+0.187
+0.172
+0.145
+0.119
+0.093
+0.063
+0.037
+0.007
0.004
0.045
1/2
+0.291
+0.285
+0.272
+0.259
+0.244
+0.217
+0.191
+0.165
+0.135
+0.109
+0.079
+0.068
+0.027
Forming radius must be specified on drawing.

THE INSIDE RADIUS FOR 90 (OR LESS) BENDS IN QUARTER HARD OR SOFTER ALUMINUM MUST BE AT LEAST
EQUAL TO THE THICKNESS OF THE MATERIAL.
A for 90 bend = 1.571 (R + Y) 2R

X for 90 bend = 1.571 (R + Y) (Other angles proportionate).
Y = 0.38T
Y
T
TABLE 6
(180 Bend can be used for dead soft aluminum only.)
B
T
0.032
0.063
0.094
0.125
B, min
0.25
0.25
0.38
0.38
GENIUM PUBLISHING
Developed length
A + B + 0.073
A + B + 0.073
A + B + 0.130
A + B + 0.186
DRAFTING MANUAL
Section K18.0
Page 9
January 2000
5.3 Stainless Steel

TABLE 7
R
Radius
1/64
1/32
1/16
3/32
1/8
3/16
1/4
5/16
3/8
7/16
1/2
9/16
5/8
0.032
+0.010
+0.004
0.009
0.023
0.037
0.065
0.090
0.117
0.114
0.172
0.198
0.223
0.253
Bend allowance A for 90 bend = 0.53T 0.429R

Material thickness T
0.094
0.125
0.187
0.250
+0.043
+0.060
+0.094
+0.126
+0.037
+0.053
+0.087
+0.119
+0.024
+0.040
+0.075
+0.107
+0.009
+0.025
+0.060
+0.092
0.004
+0.012
+0.047
+0.079
0.032
0.016
+0.019
+0.051
0.057
0.041
0.007
+0.025
0.084
0.068
0.033
0.001
0.111
0.095
0.060
0.028
0.139
0.122
0.088
0.056
0.165
0.148
0.114
0.082
0.190
0.174
0.140
0.110
0.221
0.204
0.170
0.140
0.063
+0.027
+0.018
+0.006
+0.010
0.020
0.048
0.074
0.100
0.127
0.155
0.181
0.207
0.237
3/8
+0.192
+0.185
+0.173
+0.158
+0.145
+0.117
+0.091
+0.065
+0.038
+0.010
0.015
0.050
0.080
1/2
+0.258
+0.252
+0.239
+0.225
+0.211
+0.184
+0.158
+0.131
+0.104
+0.076
+0.050
+0.025
0.005
0.172
0.066
Forming radius must be specified on drawing when bend allowance is used.

1/16 inch standard forming radius for 0.032 to and including 0.125 thick material when bend allowance is used.
3/16 inch standard forming radius for 0.180 and 0.250 thick material when bend allowance is used.
For any other forming radius check available tools and manufacturing process, because thick material will require annealing
when formed on small radius.
A for 90 bend = 1.571 (R + Y) 2R

X for 90 bend = 1.571 (R + Y) (Other Angles Proportionate)
Y = 0.34T
Y
T
TABLE 8
B
T
0.032
0.063
0.094
0.125
B, min
0.25
0.25
0.38
0.38
GENIUM PUBLISHING
Developed Length
A + B + 0.046
A + B + 0.100
A + B + 0.125
A + B + 0.201
DRAFTING MANUAL
Section K18.0
Page 10
January 2000
6.0 SHEET METAL WELDING

There are three commonly used methods of welding sheet metal:
Arc welding
Spot welding
Projection welding
Refer to Section K14.1.1 of this manual for applicable welding symbols.
6.1 ARC WELDING
Standard joint design and welding practices apply to this most commonly used application.
6.2 SPOT WELDING
Spot welding requires the availability of resistance welding equipment, and some production volume for economic application.
6.2.1 Carbon and Stainless Application Data
6.2.1.1 Equal Material Thickness
This data covers carbon and stainless steels for structural purposes. The minimum weld spot spacing given is that for which no
special precautions need be taken to compensate for the shunted current effect of adjacent welds. The maximum total of indentation takes the depression on both sides into account.
Nominal thickness
piece
T, inch
Minimum
overlap
L
0.010
0.021
0.031
0.0360.040
0.050
0.0600.062
0.078
0.0900.094
0.1050.109
0.1200.125
0.1800.187
0.250
0.38
0.44
0.44
0.50
0.56
0.63
0.69
0.75
0.81
0.88
1.13
1.38
Minimum weld spacing

center line to center line
2PCS
3PCS
0.25
0.38
0.50
0.75
0.88
1.00
1.25
1.50
1.63
1.75
3.00
5.00
0.38
0.50
0.75
1.00
1.25
1.38
1.63
2.00
2.13
2.38
Minimum
diameter weld
D, inch
Maximum total
indentation, inch
Minimum shear
strength pounds
one spot
0.100
0.130
0.160
0.190
0.220
0.250
0.290
0.320
0.350
0.380
0.560
0.750
0.002
0.008
0.012
0.016
0.020
0.026
0.032
0.040
0.044
0.050
0.075
0.100
130
320
570
920
1350
1850
2700
3450
4150
5000
10000
15000
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 11
January 2000
6.2.1.2 Unequal Material Thickness

Two 3 or more spot welds
One spot weld only

A
3)
When the spacing of two or more welds on the same piece exceeds 10 inches, the minimum overlap as shown in
Figures 1, 2, 3, and 4 may be used.
This data covers low-carbon sheet/strip steels. The minimum overlap is that which provides, (without special electrodes, and their
high cost of maintenance) minimum indentation on the thin piece, sufficient mechanical clearance for the electrode in contact
with the thick piece, and avoids expulsion of the weld. It is recommended that the minimum overlap be made greater wherever
possible.
1. To avoid necessity of locating weld in the exact center of overlap.
2. To use stocked widths of material.
When a design requires an overlap less than the minimum a projection weld should be considered. The recommended minimum
weld spacing is that which is required to avoid distortion of parts with multiple welds. When size of parts do not permit this
spacing, space welds apart as far as possible, but not less than the minimum.
Nominal thickness
Thin
Thick
PC
PC
0.036
0.060
0.036
0.090
0.036
0.105
0.036
0.120
0.060
0.090
0.060
0.105
0.060
0.120
0.060
0.180
0.060
0.250
0.090
0.105
0.090
0.120
0.090
0.180
0.090
0.250
0.090
0.375
0.105
0.120
0.105
0.180
0.105
0.250
0.105
0.375
0.120
0.180
0.120
0.250
0.120
0.375
Minimum overlap
Thin
Thick
PC. A
PC. B
0.28
0.31
0.31
0.38
0.34
0.41
0.38
0.44
0.31
0.38
0.34
0.41
0.38
0.44
0.44
0.56
0.50
0.69
0.34
0.38
0.38
0.44
0.44
0.56
0.50
0.69
0.56
1.00
0.44
0.50
0.50
0.56
0.56
0.69
0.63
1.00
0.56
0.56
0.63
0.69
0.69
1.00
Minimum Maximum indentation

diameter
Thin
Thick
weld D
PC
PC
0.17
0.003
0.004
0.004
0.005
0.003
0.005
0.25
0.004
0.005
0.004
0.005
0.004
0.005
0.005
0.007
0.007
0.010
0.30
0.004
0.007
0.004
0.008
0.005
0.009
0.007
0.011
0.30
0.009
0.013
0.35
0.005
0.007
0.005
0.007
0.006
0.008
0.35
0.008
0.010
0.38
0.005
0.006
0.005
0.006
0.38
0.008
0.008
Minimum shear
Weld spacing
strength pounds
one spot
Minimum Recommended
750
0.63
1.00
1.50
1.63
1.75
1850
1.00
1.50
1.63
1.75
3.00
4.00
3540
1.50
1.63
1.75
3.00
4.00
3540
1.50
5.00
4200
1.63
1.75
3.00
4.00
4200
1.63
5.00
5000
1.75
3.00
5000
4.00
5000
1.75
5.00
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 12
January 2000
Overlap allowances
A
B
2
B
2
Size and strength

B
2
Weld spacing
R
B
A
Thickness
of material
welded
1/32 to 1/32
1/16
3/32
0.040 to 0.040
0.060
1/16 to 1/16
3/32
1/8
3/16
1/4
3/32 to 3/32
1/8
3/16
1/8 to 1/8
3/16
1/4
3/16 to 3/16
1/4
1/4 to 1/4
B
Straight or flat
surface in contact
Desirable
Minimum 5
C
A
C
Minimum
diameter
weld
Tensile shear strength (minimum) 4

Group
1
2
3
D
Weld
spacing
minimum
3/4
1/2
0.14
240
210
170
3/4
3/4
1/2
0.15
310
300
225
7/8
1/8
5/8
0.20
620
670
400
3/4
0.25
1090
910
640
1-1/4
1-1/4
1-1/8
0.28
1630
1050
790
1-1/2
1-1/2
1-3/4
1-1/4
1-1/2
0.35
0.40
3000
4800
1300
2200
1100
1400
1-3/4
2
4) Minimum ultimate tensile shear strengths. Use required factor of safety.

5) Actual minimum; does not include manufacturing tolerances.
NOTE: Electrode indentation of each sheet will be approximately 10 % of the thinnest sheet in combination or 0.005 inch,
whichever is greater.
6.3 PROJECTION WELDING
6.3.1 Application
a. These techniques are generally applicable to high resistance ferrous materials.
b. This technique is used when part overlap is insufficient for spot welding.
c. It is also used for projection welded hardware.
6.3.2 Method
a. Projections are formed in the sheet with special dies.
b. Fusion is created by heat which is focused by projection.
c. For unequal material thicknesses, the projection is placed in the heaviest sheet.
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.0
Page 13
January 2000
6.3.3 Recommended Projections

S min = 2D
H
T
D
L
D
L
Spherical
shape
L+S
Sharp
corner
This data covers carbon and stainless sheet steels. Welding conditions and size of projection are determined by the thickness of
the thinnest piece, and data is for two thicknesses only. Projection should be on thickest piece where possible, and in the center of
the overlap, when one is used. When projection has to be on the thinnest piece, maximum ratio between thicknesses is 3 to 1.
Below are recommended projection; however, one of smaller size may be substituted with corresponding decrease in strength, if
design requires.
Project
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Nominal thickness
of thinnest piece
T
0.010
0.014
0.016
0.021
0.025
0.034
0.044
0.050
0.062
0.070
0.078
0.094
0.109
0.125
0.140
0.156
0.171
0.187
0.203
0.250
Minimum
overlap
L
0.13
Diameter of project D 6
minimum diameter
of weld, inch
0.055
Height
of project
H, inch
0.015
Minimum shear
strength pounds
one project
180
0.16
0.067
0.017
250
0.22
0.094
0.022
500
0.28
0.119
0.028
0.38
0.156
0.035
0.44
0.50
0.63
0.69
0.75
0.81
0.88
0.94
1.00
1.25
0.187
0.218
0.250
0.281
0.312
0.343
0.375
0.406
0.437
0.531
0.041
0.048
0.054
0.060
0.066
0.072
0.078
0.085
0.091
0.110
Project number
1 and 2
3 and 4
5 thru 15
D, , inch
0.003
0.005
0.007
1950
3200
5000
8000
12000
H, , inch
0.003
0.003
0.007
6) Tolerance
GENIUM PUBLISHING
GENIUM PUBLISHING
J
4.40
3.05
6.65
24.65
(W) .375 hls
C .03
2.60
(Typ) 1.80
Unless otherwise indicated

Tolerances 0.06
Mfg. Allowances to 2191K450
1.00
1.00
F .03
(U) loc mks

on back
1.72
.44
.80
6.20
3.84
.80
.92
.50
(2) .500 hls
1.00
.50
.50
(typ)
.25
P .25
B .03
Figure 9 Door, H.V.
2.30
2.00
1.10
4.82
1.40
2.41
ref
(2) .44 .750

R.E. slots
1.00
1.40
1.00
1.01
.10
.91
1.50
.30
A .03
Commercial quality low carbon,

hot rolled steel sheet
Stl.
B8A3X
(UNS
G101000 $ G10120)
0.090
(#13 GA.)
0.090 x A
A x F (#13
GA.)
1.01
Section K18.0
Page 14
January 2000
DRAFTING MANUAL
7.0 SHEET METAL DRAFTING PRACTICE
Sheet metal drafting lends itself to simplified drafting as defined in Section K5.7 of this manual. Figures 9 through 11 are typical
drawings where simplified practice has been used.
DRAFTING MANUAL
Section K18.0
Page 15
January 2000
1.30
.40
1.30
C
+.04
.02
.40
.82
1.21
.82
1.21
1.30
1.89
D .03
1.30
.80
0
L
B
4.85
1.30
.80
Notes:
1 Weld & 63 all corners
to A6190K544
2 Paint to EPS 90.047
(Olive)
Tolerances 0.04

hot Stl.
rolled
steel sheet
B8A3X
(UNS
G101000
A $B G10120)
(#13 GA.)
0.090
0.090 x A x B (#13 GA.)
Figure 10. Hood, Cabinet
GENIUM PUBLISHING
GENIUM PUBLISHING
B
A
13.16
16.16
18.16
21.16
23.16
Pt No.
01
02
03
04
05

Tolerances 0.04
B
30.41
35.41
40.41
45.41
49.41
35.66
40.66
45.66
50.66
43.66
D
15.06
17.56
19.56
22.56
24.56
.35
Figure 11.Brace, Front
34.72
39.72
44.72
49.72
53.72
.40 3.7 0 HL.
(1) .547 hole
(3) .50 .80 slots

(see note)
NOTE:
Rect. slots permissible
F
18.76
21.26
23.26
26.26
28.26
.75
1.93
1.00
.55
1.60
2.57
3.67
30.32
35.32
40.32
45.32
49.32
36.00
41.00
46.00
51.00
55.00
CAB.
HGT.

hot rolled steel sheet
Stl. B8A3X
(UNS G101000
$ G10120)
x DGA.)
(#13 GA.)
3.67x3.67
D (#13
0.090 0.090

hot
steel sheet
Stl. rolled
B8A3X
(UNS
G101000
(#13 GA.)
0.090 3.67 $DG10120)
0.090 x 3.67 x D (#13 GA.)
1.84
1.10
1.00
1.66
Section K18.0
Page 16
January 2000
DRAFTING MANUAL
DRAFTING MANUAL
Section K18.1
Page 1
August 1, 1987*
Sheet Metal Design Documentation

Update30
1 General
1.1 Stamping
Stamping is the art of press working sheet metal to
change its shape either with or without accompanying
shearing or punching. This section provides
information about the methods used to produce this
change in shape. Other information is included to aid
in specifying material designations, stock
requirements, and enhancements for producibility.
This section also provides basic empirical layout and
drafting practices specifically related to metal
stampings.
1.2 Small-Parts Manufacturing
This section covers practices that are generally
accepted and used by small-parts manufacturers in the
production of metal stampings that are produced on
standard types of punch presses. Items such as air
frames, air foils, automobile bodies, sheet-metal
piping and ductwork, and similar large sheet metal
products are omitted. Some of the information shown
in this section has been incorporated as an aid in
laying out and delineating a part that will be subject to
metal-stamping processes. Information such as
references to methods of fabrication and die
clearances, etc., has been included for reference
purposes. This type of information is not specified on
the production drawing, however, except in special
cases.
1.3 Effect of Manufacturing Equipment
An important consideration in sheet metal fabrication
is that for a given drawing configuration the
production equipment used may have a bearing on the
accuracy of the part produced. For this reason, where
possible, consult the producibility engineer before
releasing the drawing. In particular, he should
evaluate the specified dimensions and tolerances
versus the anticipated performance of the
manufacturing equipment that may be used to produce
the part. The evaluation will provide an experts
opinion of the reasonableness of the method of
dimensioning used and the tolerances specified.
be instances when the developed configuration of a

part is necessary. Because the predictability of the
shaped part (final configuration) cannot always be
ascertained with confidence (as in, for example,
control of springback), a cautionary note should be
written beneath the developed configuration for
manufacturing guidance. In other words, the
development is provided to assist manufacturing in
visualization and material planning. It is not the end
product that is fully dimensioned elsewhere on the
drawing.
2 References
American National Standards Institute (ANSI),
Dimensioning and Tolerancing, Standard Y14.5M,
1982; Abbreviations for Use on Drawings, Standard
Y1.1, 1972.
3 Dimensioning
3.1 Height and Depth Dimensions
Height or depth dimensions of a stamping should
generally be given to the same side or surface of the
part either punch side or die side. Exceptions are
provisions for interchangeabilityof the matching
portions of mating parts-or cases where close tolerances are involved because of subsequent
requirements.
3.1.1 Locating Dimensions. Locating
dimensions for sheet metal parts may be given to the
point of intersection of the tangents, as shown in
figure 1, part a, or to the locus of a radius as shown
in figure 1, part b. The latter practice is preferred
whenever possible.
3.1.2 Dimensioning Formed Parts.
Dimension formed parts to exclude the stock
thickness from the location dimension and the formed
radius as shown in figure 2, part a. If function
requires that the location of formed radius include the
stock thickness, the tolerance of these dimensions
must be sufficient to cover the variation in stock
thickness and still permit a liberal forming tolerance as
shown in figure 2, part b.
3.2 Specifying Material
1.4 Blank Development of Parts

Although blank developments of parts are shown
extensively throughout this text, the developments are
intended principally as tutorial. However, there will
Material specification, temper, and stock thickness

and its tolerances should always be specified on the
drawing. Never specify material specification such as
STEEL, ALUMINUM, etc., alone.
GENIUM PUBLISHING
*Supersedes Issue of
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 2
August 1, 1987*
Fig. 1. Dimensioning Sheet Metal Parts
Fig. 2. Dimensioning Formed Parts
3.3 Material Name
annealing to a specific grain size, or heat treating to a

specified hardness.
Specify the name of the material on the drawings so

that it will be easily identified by all concerned. If a
particular type or grade of material lends itself to the
fabrication desired, it should be specified. Always use
the material specification numbers of the company
originating the drawing or commonly recognized
industrial standard designations (such as SAEs and
ASTMs). An example of this would be SAE 1010,
Steel. When specifying special materials, furnish a
more complete description to facilitate procurement
and incoming inspection. Avoid the use of trade
names for the specification of materials. However, if
the use of a trade name is necessary, include the name
of the vendor as well.
3.4 Temper or Hardness
The selection of the temper in sheet metals should be
governed by experience and experimentation, because
it is a very important factor in the proper functioning
of the part and the methods of fabrication involved.
The term temper, when applied to sheet metal parts,
refers to the amount of cold rolling they are subjected
to or a particular heat treatment such as annealing,
March 1, 1987
3.5 Designations
If temper or treatment is not already covered in the
material specification, it should be specified on the
drawing in terms commonly used in industry to
facilitate purchasing of material having the desired
properties. Consult ANSI, SAE, or ASTM
designations or industrial catalogs for this purpose.
3.5.1. International Material Designations.
An invaluable reference for international material
designations is Geniums International Metallic
Materials Cross-Reference, third edition,
prepared by Daniel L. Potts and John Gensure.
The unique, clear, and useful format of this book is
organized by material designations and includes
chemistries. If you know one designation, you can
quickly find it and all of the designations assigned to
equivalent materials by forty-five nations and
international organizations.
The materials covered in International Metallic
GENIUM PUBLISHING
DRAFTING
MANUAL
Materials Cross-Reference include carbon steels; alloy

steels; tool steels; stainless steels, wrought; specialty.
steel tubing; grey cast irons; ductile cast irons; aluminum and its alloys, wrought and cast; magnesium
alloys; nickel alloys; aerospace alloys; and electrical
steels. Nations and organizations represented in this
book include the United States Federal Government,
the Peoples Republic of China, DOD, ASM, ASTM,
API, AISI, CDA, SAE, Euronorm, ISO, and
COPANT. Full details are available upon request
from Genium Publishing Corporation.
Section K18.1
Page 3
August 1, 1987*
3.8 Tolerances
The American Iron and Steel Institute tolerances for
stock thickness constitute the nationally accepted
standard. These tolerances are governed by thickness,
sheet or strip size, and quality. W hen closer
tolerances are specified. costs are increased; therefore,
avoid their use unless they are specifically required
for considerations of producibility. Acceptable
methods of specifying metal thickness and material
specification are shown in figure 3.
3.6 Abbreviations
.0165 -.0225 STOCK -- SAE 1010 STEEL
Abbreviations may be used for designating standard

tempers but should not be used for special tempers. If
abbreviations are used, use only the approved ones as
specified in ANSI Y1. 1, Abbreviations for Use on
Drawings. Examples of these abbreviations are CR
(cold roll) or HR (hot roll).
.0195.0030 STOCK-- SAE 1008 STEEL
4 Types of Stampings
3.7 Stock Thickness
4.1 Classifications
For stock up to and including 0.2499, the thickness

can be specified in any decimal value without being
considered nonstandard. However, those dimensions
shown in boldface type
, , in table 1 are the preferred
thicknesses for uncoated, thin, flat metals under
0.2500 inch. For stock thicknesses of 0.2500 inch
and greater, specify decimal equivalents of fractions.
Metal stampings are divided into two general classes:

(1) those made by cutting or shearing the material,
either to change a peripheral outline or to produce
openings in the interior of the piece, and (2) those
made by forming the material to the shape desired
from a flat piece-without cutting or shearing the metal.
4.2 Material Cutting (Shearing Operations)
Table 1
Preferred
Fig. 3. Material Specifications
Thicknesses
for Uncoated Metals and Alloys

------0.236
0.224
0.212
0.200
0.190
0.125
0.118
0.112
0.106
0.100
0.095
0.063
0.060
0.056
0.053
0.050
0.048
0.032
0.030
0.028
0.026
0.025
0.024
0.016 0.008 0.004

0.015 . . . . . . . . . . . . . .
0.014 0.007 . . . . . . .
0.013 . . . . . . . . . . . . . .
0.012 0.006 . . . . . . .
.............. .......
0.180
0.170
0.160
0.150
0.140
0.132
0.090
0.085
0.080
0.075
0.071
0.067
0.045
0.042
0.040
0.038
0.036
0.034
0.022 0.011 . . . . . . . . . . . . . .
....... ..............
0.021
0.020 0.010 0.005 . . . . . . .
0.019 ------- . . . . . . . . . . . . . .
0.018 0.009 . . . . . . . . . . . . . .
0.017 ------- . . . . . . . . . . . . . .
Note: All dimensions are given in inches. Twenty-series numbers

are in boldface type.
4.2.1 Blanking. Blanking is the process of

producing a sheet metal part by cutting its entire
periphery in a die with one stroke of the press.
Examples of blanks are shown in figures 4,5, and 6.
4.2.2 Nesting of Blanks. In high-volume
production work the development of stamped parts
should be analyzed for arrangement on sheet stock to
minimize scrap (see figs. 5, 6, 7, and 8). Cut off
projecting comers or flanges at the top, bottom, or
sides of the sheet unless strength or function is
affected (see fig. 8). Parts that cannot be satisfactorily
nested may be more economically made in two pieces,
thus reducing the amount of scrap.
4.2.3 Direction of Grain. If the metal grain
runs in a direction contrary to the strength of the part
the strength of the stamping may be reduced
considerably. Therefore, when designing highly
stressed parts, the direction of the grain of the metal
should be considered, and, where necessary,
GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 4
August 1, 1987*
Fig. 4. A Simple Blank
HIGN PERCENTAGE OF SCIIAP
REOUCED SCRAP
SCRAPLESS- DESIGN
HIGH PERCENTAGE OF SCRAP
Fig. 5. Nesting of Blanks
Fig. 6. Stock saving by Design Changes

March 1, 1987
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.1
Page 5
generally shown as illustrated in figure 10, because

this allowance is sometimes needed to obtain the
economical nesting of parts.
Sheet or strip
I
GRAIN DIRECTION
Fig. 9. Grain Direction
Fig. 7. Nesting of Blanks
Fig. 10. Grain Direction Variation

4.2.4 Radii on Blanked Parts. Wherever
possible provide ample radii in order to facilitate tool
construction. If function of the part permits, specify
full radii, or half the width of the blank or opening
(see fig. 11).
Stock
saving
Corners removed ~
New size
Fig. 8. Stock Saving

on the drawing (see fig. 9). If not specified, grain
may run in any direction. In most cases the direction
of the grain can be as much as 45 degrees from the
theoretically ideal direction (perpendicular to the bend)
before trouble would occur during the bending
operation. In view of this, a permissible variation is
GENIUM
Fig. 11. Radii on Blanked Parts
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18. 1
Page 6
August 1, 1987*
4.2.5 Punching (Interior Openings).

Punching is a method of cutting to produce a hole or
an opening in a part. It is similar to blanking except
that in punching, the material surrounding the punch
is the workpiece, and the punched-out material is
scrap. In blanking it is the workpiece that is punched
out. This method is also known as perforating and
differs from piercing in that a portion of the material is
sheared from the workpiece (see figs. 32 and 34).
4.2.6 Piercing. Piercing is a term that is
sometimes used synonymously with punching.
However, the punch used for piercing is usually
pointed, which allows puncturing of the material
before forming the opening in the part. The result of
this is that no metal is removed from the part.
4.2.7 Trimming. Trimming is a term applied to a
number of distinctly different kinds of operations,
such as cutting off the superfluous metal around the
edges of drawn pieces or trimming strip metal along
the edges to produce blanks without resorting to
conventional blanking dies.
Drawn-Part Trimming. To facilitate trimming of
a drawn part, the part should incorporate an
adequate flange (see fig. 12).
performed in special cam-operated punch and dies

or special trimming machines.
Pinch Trimming. If the material is soft, and the
thickness of the shell as shown in figure 15 does
not exceed 0.032 inch, flanges may be removed by
an operation known as pinch trimming. This
operation, depicted in figure 15, is usually
performed at the bottom of the stroke of a
combination blank-and-draw punch and die.
The slight step on the outside of the shell can
be eliminated by the position of a blank, draw,
and pinch-off punch and die having a swaging
feature, as illustrated in figure 16.
4.2.8 Notching. Notching is an operation in
which the individual punch removes a piece of metal
from the edge of the blank or strip. Notches fall into
two groups: (1) those which are part of the design
and are provided for such purposes as clearance,
attachment, and location; and (2) those which are
added to flanges to facilitate forming the part, as when
a notch is placed at a corner when the flange is to be
formed by a flanging operation.
Notches with Vertexes. Notches in highly

stressed parts should be specified with a radius at the vertex, because a sharp V may provide the
starting point of a tear or crack. The radius should
beat least twice the thickness of the metal. A sharp
vertex is allowed on lower or unstressed parts
when it will aid in lowering die costs. If the shape
and design of the part permits, make
an allowance for distortion so that a notch
can be added in the blank (see fig. 17).
Notched Corners. A hemmed edge should be
notched at the comers to eliminate gathering of
metal in the flanging operation (see fig. 18).
Fig. 12. Flange for Trimming
Preferred Notch Designs. Figures 19 through 23

illustate preferred designs of comer notches and
cutouts for flanges.
Square-Edge Trimming. If straight sides are

required, an additional operation can be performed
on a trimmed-part configuration that will wipe
down the flange as shown in figure 13. If the ridge
of wiped-down trimming is objectionable, the part
can be trimmed perpendicular to the side wall as
shown in figure 14. This is known as squareedge or flat-edge trimming and is usually
Semi-Notching. Punching of holes of any shape

in a strip to free metal for subsequent forming or to
produce surfaces that later coincide with the outline
of a blanked part is sometimes called seminotching. The punched area may outline a portion
of one part or two or more adjacent parts in a strip.
Progressive die layouts incorporating seminotching are illustrated in figure 24.
March 1, 1987
GENIUM
PUBLISHING
DRAFTING MANUAL
Section K18.1
Page 7
August 1, 1987*
MAW
TRIM
WIPE DOWN
Fig. 13. Wipe-Down Trim

t
.- -- .--.
>
\ ..
Fig. 14. Square-Edge Trim
SLIGHT
STEP
FLAT
AFTER TRIM
Fig. 15. Pinch Trimming

GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 8
August 1, 1987*
STRAIGHT
SURFACE
A-A
Sharp vertex permitted

for low stressed parts
Fig. 17. Notches with Vertexes
-.
-.
Fig. 18. Notched Corner
-.
-------------- ---------- --II

II
I
I1
-. -. .. ..
------------- ----------- -FORMED
DEVELOPMENT
Fig. 19. Preferred Corner Notches
March 1, 1987
GENIUM PUBLISHING
II
:
8II
DRAFTING MANUAL
Section K18.1
Page 9
August 1, 1987*
rig. 20. Preferred Corner Notches
FORMED
DEVELOPMENT
I
:
- . II
I
II
II
!
1
DEVELOPMENT
Fig. 22.
I
II
I
I
I
I
- ------ ------------FORMED
Preferred Corner Notches

GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
page 10
August 1, 1987*
Galvanized, 0.0075 in.

Fig. 24. A Cutoff from a Semi-Notched Strip
4.3 Shaving and Burnishing
Shaving is used for stamped parts that require a closer
tolerance and/or a better edge finish than can be
produced by the normal stamping process. Shaving
can be accomplished by providing stock in local
critical areas of the stamping and then removing this
stock to specified dimensions with a shave operation.
This method removes a small amount of material
March 1.1987
(usually a few thousandths of an inch) from a blank

or a punched hole by means of a Punch and die to
produce a full bearing surface with dimensions having
very close tolerances (see fig. 25). Burnishing
operations differ from shaving operations in that
insufficient stock is allowed on the blank to permit a
cutting action. The blank is first shaved 0.0005 to
0.001 inch over size and then forced through a
burnishing die to produce a highly polished surface.
GENIUM PUBLISHING
DRAFTING MANUAL
Section 18.1
Page 11
August 1, 1987
Fig. 25. Shaving

4.4 Cutting Off
4.5 Shearing Strip Stack
Cutting off, as shown in figure 26, is a process of

cutting a blank to length from a strip of metal that has
been slit or sheared to the correct width in a previous
operation. It is used when wide tolerances are
permitted on the length of a part.
Avoid making feather edges when shearing strip stock

(see fig. 27). The corners along the edge of the strip
should be sharp, and those not adjacent to the edge
should be round (see fig. 28).
SLUG
PARTING TYPE CUT-OFF
SHEARING TYPE CUT-OFF

Fig. 26. Cutting-Off
Preferred
Fig, 27. Feather Edges
Not recommended
Fig. 28. Strip Stock

GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 12
August 1, 1987*

-.
4.5.1 Redesign to Facilitate Shearing.

Where an original design results in sliver or feather
edges upon shearing, the part should be redesigned to
facilitate the cutoff operation (see fig. 29).
4.6 Lancing
Lancing is a press operation in which a single-line cut
or slit is made partway across the strip stock without

removing any material. Generally, lancing is done to
free metal for forming, as shown in figure 30, or in
forming louvers, as shown in figure31. The cut does
not have a closed contour and does not release a blank
or a piece of scrap. In addition to its use in freeing
metal for subsequent forming, lancing is also used to
cut partial contours for blanked parts, particularly in
progressive dies.
Fig. 29. Redesign to Facilitate Cutoff
Lanced
Lanced and formed

for air vent
Fig. 30. Lanced to Free Metal for Forming
*Supersedes issue of
March 1, 1987
Fig. 31. Lancing
GENIUM PUBLISHING
DRAFTING
MANUAL
4.7 Fine Blanking

Fine Blanking (also known as fine-edged blanking,
smooth-edged blanking, or fine-flow blanking)
produces precise blanks in a single operation without
the fractured edges characteristically produced in
conventional blanking and punching. In fine
blanking, a V-shaped impingement ring is forced into
the stock to lock it tightly against the die. This forces
the work metal to flow toward the punch so that the
part can be extruded out of the strip without fracture
or die break. Die clearance is extremely small, and
punch speed is much slower than in conventional
blanking.
Section K18.1
Page 13
August 1, 1987*
4.9.1 Punched Holes. A punched hole is made

by a punch that shears a hole of the desired size and
shape (see fig. 33). This plain hole has essentially
straight sides and is produced by a flat-ended punch.
4.8 Fine Punching

Fine punching can be done either separately or at the
same time as fine blanking. In punching small holes,
an impingement ring may not be needed.
4.8.1 Finishing. No further finishing or machine
operations are necessary to obtain blank or hole edges
comparable to machined edges or to those that are conventionally blanked or punched and then shaved.
A quick touch-upon an abrasive belt or a short
treatment in a vibratory finisher may be used to
remove the small burr on the blank.
Fig. 33. Plain Punched Hole

4.9.2 Hole Size. Where holes are punched,
approximately one-third of the metal thickness is
sheared cleanly to the size of the punch. The remainder is torn out-by the pressure exerted on the sheared
slug. Punching produces a rough hole that tapers to a
diameter larger than the punch size by approximately
10 percent of stock thickness (see fig. 34). This taper
4.9 Holes
Where holes are necessary in stamped parts, they can
be made by punching, extruding, or piercing
(see fig. 32).
Fig. 34. Punched Holes
Fig. 32. Methods for Producing Holes
is particularly important where the sides of the hole

act as a bearing surface. Avoid hole diameters that are
less than stock thickness, because they lead to
manufacturing complexities and high cost. Where
possible, base hole sizes on available standard
punches (see table 2).
GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 14
August 1, 1987*
4.9.4 Pierced Holes. A pierced hole is made by

a sharp, pointed punch such as a cone point, nail
point, or bullet-nose (ogive) punch that follows
through to flange the sides. The displaced metal is
drawn down, forming a hole with tom or irregular
edges (see fig. 36).
Table 2
Standard Punches
Round Holes
.031 to .999 in Increments of

.001
Square Holes
.031 x .031 to .700 x .700 in

Increments of .001 x .001
Oblong Holes
.031 x .078 to .985 x .999 in

Increments of .001 x .001
1
Note: Some punch vendors offer standard punches in

hexagonal, triangular, rectangular, and other shapes.
4.9.3 Extruded Holes. An extruded hole is

usually formed in one operation by a shoulder type of
punch that punches a smaller hole and then follows
through to flange the sides. In this process a small
hole is produced by the flat end of the punch and then
enlarged to the desired size by the body of the punch.
The metal flows into the die opening, producing a
projection with a fairly smooth edge, as shown in
figure 35. In some instances a hole flange is specified
that is longer than can be formed in one operation.
This operation necessitates drawing metal in from
outside of the hole by first forming an embossment
much larger than the hole and then, by successive
steps, forming the desired flange and finally punching
out the hole. This method increases costs and can be
limited by keeping the specified flange length to an
absolute minimum.
)
Fig. 36. Pierced Hole
4.9.5 Special Holes. In many instances special
shapes are needed for particular functions. Figure 37
depicts holes similar to the one shown in figure 35,
except that the flanged portion is embossed-or formed
to a desired shape. Figure 38 depicts a hole similar to
the one shown in figure 33, except that the edges are
rounded by a secondary swaging or coining
operation.
Registration of Holes in Mating Parts. If two or
more holes are used in mating parts, it is necessary
to consider the problem of alignment. This can be
accomplished by making the holes large enough to
compensate for accumulated tolerances or by elongating the holes in a direction most advantageous
for proper registration with the mating part.
4.10 Burrs
A burr is an undesired displacement of metal caused
by cutting tools. It is a sharp, uneven projection on
an edge or a comer of a part. Give careful consideration to burrs in the design of each part. Specify the
term BURR SIDE on part drawings to indicate the
side of a stamping on which burrs are permitted.
Fig. 35. Flanged Hole

March 1, 1987
4.10.1 Burr Control. The shape, height, and

roughness of burrs should be controlled to some
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 15
Fig. 37. Holes Embossed to Desired Shape

Disadvantage of Burr Removal. Burr removal
adds to production costs. Burrs should be removed
only where their removal would be essential to
ensuring the proper functioning of the part,
eliminating possible interference in assembly, and
eliminating hazards in handling.
Permissibility of Burrs. The amount of burr that
may be tolerated depends upon the end use of the
part. Specify where only certain edges or a portion
thereof must be burr free on the drawing, as
illustrated in figure 39. The practice of limiting burr
removal to essential edges often leads to
economical production:
L
.
Fig. 38. Swaged Hole
APPROX.
DIMENSION
degree in nearly all blanking operations. Complete

elimination of burrs is not possible, but their
formation can be minimized by the proper clearance
between punch and die and by good maintenance.
Exposed burrs on the finished part can be unsafe and
unsightly. Burrs on some blanked work can also
cause difficulties in forming and can increase
production costs.
4.10.2 Burr Removal. Part drawings should
clearly indicate those comers and edges on which
burrs are not permitted. If all burrs are to be removed,
the drawing should bear the note REMOVE
BURRS. This note requires an operation such as
filing, grinding, buffing, tumbling, or rolling that will
smooth the burred edges. Other deburring methods
include chemical and electrolytic deburring, belt
grinding, polishing, and ultrasonic methods. Hand
scrapers can be used to remove burrs from irregular
shapes or soft metal parts.
GENIUM
Fig. 39. Free from Burrs between Arrows

4.10.3 Source of Burrs. The elimination of
burrs results in substantial cost savings in
metalworking. Their avoidance cannot always be
predicted because they are related to the ductility of
the material. For example, copper and aluminum
materials exhibit a greater tendency to form burrs than
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 16
August 1, 1987*
thickness of the material. See figure 40 for common

bending terms.
soft steel and brass. Conversely, semihard sheet steel

is prone to less burr formation than the nonferrous
materials and soft steel. Therefore, where possible,
consider the selection of material not only in the
context of its design characteristics, but also for its
producibility characteristics, such as burr avoidance.
5.1.1 Clearance of Bends. On parts that are to

be bent, clearance at the bends should be provided as
shown in figure 41 so that there is no edgewise metal
interference to prevent the tools from producing a
satisfactory bend.
5 Material Forming (Nonshearing Operations)

5.1 Bending
Bending is the uniform stretching of material, usually
flat-sheet or strip metal, by moving it around a
straight axis that lies in the neutral plane and is normal
to the lengthwise direction of the sheet or strip. This
operation takes place usually without changing the
5.1.2. Flange Relief. Where flanges extend

over a portion of a highly stressed part, a notch or
circular hole should be used to eliminate tearing of the
metal (see fig. 42). The circular hole, type A relief, is
preferred when it is permissible so that part of the
relief occurs in the bent portion of the flange. The
notch, type B relief, is preferred when the relief notch
is not to occur in the flange.
Fig. 40. Bending Terms

March 1, 1987
GENIUM
PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 17
August 1, 1987*
Fig. 41. Bend Clearance
1
\
5.1.4 Outside Flanges. Outside flanges and

flanges around openings should preferably have a
height of at least two times the metal thickness or a
minimum of 0.12 inch (see fig. 44). Other flange
considerations are shown in figure 45.
- -.--
- -
B
---- --
~*
*
I
,,
Fig. 42. Flange Relief
Fig. 44. Outside Flanges
5.1.3 Tapered Flanges. Do not allow tapered

flanges to taper to the face of the metal. Cut them off
so that the narrowest section will be at least two times
the metal thickness but not less than 0.12 inch
measured from the inside of the metal (see fig. 43).
5.1.5 Offset Flange. In a case where a flanged

piece is bent in the shape of an offset inside radii
should be as large as practical to avoid any excessive
wrinkling (see fig. 46).
5.1.6 Flange Trimming. To facilitate the
trimming operation, minimum flange width should be
two times the metal thickness, as shown in figure 47,
part a. When a sharp edge is permissible, the flange
condition appears as shown in figure 47, part b. The
absence of a flange requires expensive trim if the
value designated by X is maintained and the edge held
even, because trimming must be done on a horizontal
plane (see fig. 47, part c).
Fig. 43. Tapered Flange
5.1.7 Flange Holes. Whenever holes are

included in a flange, give consideration to the
practices shown in figure 45.
GENIUM PUBLISHING
March 1, 1987
DRAFTING
Section K18.1
Page 18
August 1. 1987*
MANUAL
Scallop flange
wherever possible
to reduce weight
Radius = two times

metal thickness min.
Round corners only

where sharp corners
may cause injury
Keep flange to minimum to

prevent tearing of metal
Use tab on corners only when

absolutely necessary for
attachment
Wherever the design permits, make allowance for distortion and variation in tab shape and hole size to permit
piercing and notching in blank.
Fig. 45 Flange Composite
Preferred
(a) FLANGE TRIM

permissible
Fig. 46. Offset Flange

5.1.8 Right-Angle Bends The variation from
the 90-degree bend shown at E in figure 48 will
change according to the kind of material, thickness,
thickness variation, and hardness, etc. The table
shows the average variations to be expected from mild
steel parts as they are removed from the bending dies.
Where closer adherence to 90 degrees is necessary,
additional operations are required that are usually
. more costly than normal. To avoid such costs, bend
tolerances should be as large as possible, consistent
with design requirements. - Supersedes Issue of
March 1, 1987
(b] SHARP EDGE TRIM

Not recommended
(c) HORIZONTAL TRIM
Fig. 47. Trimming Practice
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 19
August 1, 1987*
typical formed parts may be those of shallow cups,

beads, ribs, and curved and circular flanges around
holes where the metal has been stressed in
compression or tension during forming. The line of
demarcation between a pure bending operation and a
pure forming operation is not always clear. A
stamping operation is sometimes classified as either
bending or forming may actually include both.
IJ
Fig. 48. Right-Angle Variation
5.1.9 Bend Radii. The radius required for a rightangle bend varies according to the kind and temper of
the material, the direction of grain, and the type of
dies used. As shown in figure 49, the general rule is
to allow a radius equal to or greater than the thickness
of the material. -
Figure 49. Formed Radii

5.2 Forming
Forming is a metalworking operation in which the
shape of the punch and die is directly reproduced in
the metal with little or no metal flow. The shapes of
5.2.1 Embossed Forms for Precision RightAngle Bends. If necessary, an embossed form can
be incorporated into the part to provide rigidity and
maintain accuracy of angle or bend. It is also
applicable as a stiffener in many parts where welding
or welded gussets may otherwise be required. Figure
50 illustrates the application and proportions of an
embossed form.
5.2.2 Gussets. Properly designed gussets add
considerable rigidity to angles and flanges, etc.
Frequently, the thickness of the part may be as much
as halved by judicious use of the stiffeners. Figure51
illustrates application of a gusset in a right-angle
bend.
5.2.3 Strengthening Ribs. The typical
strengthening ribs shown in figures 52 and 53 are
designed so that the angle of the sides will normally
allow their use not only on flat surfaces but also on
angular and curved surfaces without producing back
draft. The most common types of ribs in use are the
flat-bottomed rib, the round-bottomed rib, and the V
rib.
SECTION B-B
SECTION A-A
Fig. 50. Embossed Right-Angle Bend

GENIUM PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 20
August 1, 1987*
optional construction
Fig. 51. Gusset Right-Angle Bend
Fig. 53. Flat-Bottomed Rib
.L
Optional construction
R = 2T minimum
Fig. 52. V Rib
Rib in Strip Stock. When a part is made from
strip stock, show it with irregular sides to allow for
the rib (see fig. 51).
Rib in Flanged Part. The height of ribs in a
flanged pa should be formed in the same direction
as the flange to facilitate die construction (see
fig. 54).
SECTION A-A
R = 2T minimum
Fig. 54. Rib in Flanged Part

5.3 Drawing
5.2.4 Hemmed Edges. In designing hemmed

edges, it is recommended that the comers be notched,
m shown in figure 55, to eliminate gathering of metal
in the flanging operation.
Drawing is an operation in which a punch forces flat

metal to flow between its surface and that of a die and
to assume a cylindrical, box, or cup shape. The metal
flow is similar to that of a viscous liquid, and there is
little or no change in the thickness of the original
metal (see fig. 57).
5.2.5 Position of Burr Side on Formed

Parts. Wherever possible the burr side of a blank
should be on the inside of a bend, as shown in figure
56, in order to minimize fracture of material during
the stretching of the outer edges.
5.3.1 Shallow Drawing versus Deep Drawing

The distinction between shallow drawing and deep
drawing is arbitrary. Shallow drawing generally
refers to the forming of a cup no deeper than half its
diameter with little thinning of the metal (seep. 22).
Much 1.1987
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.1
Page 21
August 1, 1987*
OR
SECTION A-A
Fig. 55. Notches in Hemmed Edges
Fig. 56. Burr Side Location
BEFORE DRAWING
AFTER DRAWING
Fig. 57. Blank Drawing

GENIUM PUBLISHING
March 1, 1987
DRAFTING
Section K18. 1
Page 22
August 1, 1987*
MANUAL
In deep drawing, the cup is deeper than half its

diameter; and wall thinning, although not necessarily
intentional, may be more prevalent than in shallow
drawing.
Reducing. Reducing differs from redrawing

in that the diameter is reduced at the mouth of
the shell rather than at the bottom or for the
full length, as shown in figure 59. The top of
the shell is pushed or compressed into the die
rather than pulled through the die by the
punch. Reducing is often referred to as
necking, nosing, or closing.
Depth of Draw. Keep the depth of draw as

shallow as practical in order to reduce the number
of die operations and minimize cost. If the depth
exceeds that attainable with a single operation,
more dies are needed, and the cost increases.
Proportions. Figure 58 shows the maximum
proportions generally adhered to when singleoperation draws are involved.
Fig. 58. Drawing Proportions

Additional Drawing Operations. Additional press
operations performed on drawn workplaces are
redrawing, reducing, expanding, bulging, sizing,
and ironing.
Fig. 59. Reducing (Necking)
Redrawing. Redrawing is used to reduce the

diameter and increase the height of a previously
drawn cup, either for the full length or for a
specified-distance from the bottom. A punch
pulls the cup into the die and reduces the diameter
by either director reverse drawing.
March 1, 1987
GENIUM
Expanding (Bulging). Expanding, or bulging,

is the forming of irregular contours or surfaces
of revolution on shells or rings by expanding or
reducing the diameter for a portion of the cylindrical length. Such shapes cannot be removed
from a regular punch or die. The change in shape
is produced by a wedge-action punch or die or
by the use of a fluid or a rubber punch, as shown
in figure 60.
PUBLISHING
DRAFTING MANUAL
Section K18. 1
Page 23
August 1, 1987*
Fig. 60. Expanding (Bulging)

Sizing. Sizing is used for forming workplaces
to specific dimensions. The final forming of
sharp radii should be combined with a small
reduction in the cross-sectional area of the part.
The metal should be crowded and not stretched
into sharp comers. When the sizing operation is
designed to eliminate an effect called oilcanning in the sidewall of a box or to establish
a depth, the metal is stretched.
Ironing. Ironing is the intentional thinning of the
wall of a drawn shell. The operation provides
uniform wall thickness or produces a thinwalled, thick-bottomed part, as shown in figure
61. The clearance between the punch and the die
is less than metal thickness; this reduces wall
thickness and increases the height as the shell is
drawn through the die by the punch. Some slight
redrawing takes place as the wall is thinned by
ironing. The small reduction in diameter
is employed mainly to permit free entry of the
punch into the shell. Because the ironed shell
clings to the punch, the stresses in the metal are
compressive. A part with an ironed sidewall is
less susceptible to cracking and distortion in
machining than is a drawn part that has not been
ironed.
Fig. 61. Ironing

5.4 Compression Operations
Compression or squeezing operations consist of
squeezing material to change its form by means of
direct application of compressive forces. The applied
force depends upon the area to be squeezed, extent
and speed of the squeeze, and freedom of the flow of
the metal. These operations may be divided into four
general classifications: sizing, s-waging, coining, and
extruding.
5.4.1 Sizing. Sizing is the flattening and
smoothing of areas of stampings by squeezing the
metal to a desired dimension. There is little, if any,
GENIUM PUBLISHING
March 1, 1987
DRAFTING
Section K18.1
Page 24
August 1, 1987*
MANUAL
restriction to metal flow, and the volume of metal

removed is relatively small compared with the volume
of the workpiece.
5.4.2 Swaging. Swaging is more severe than
sizing. Because the shape of the blank is considerably
altered as part of it flows into the contours of the die,
the remaining metal is unconfined and flows generally
at an angle to the direction of applied force. The metal
flows outward and forms a flash that maybe trimmed
off in a subsequent operation (see fig. 62). Compared
with sizing, there is greater restriction to metal flow,
although more metal is moved.
5.4.3 Coining. Coining operations usually force

metal to flow within ache but not out from it, so that
all work surfaces are confined or restrained. This
results in a well-defined imprint of the die on the
workpiece. The distances through which the metal
flows are comparatively short but most or all of the
metal flows to form new surface contours, thus
necessitating extremely high pressures. Portions of a
blank or workpiece may be coined; corners of
previously formed or drawn cups maybe built up or
filled in or indented; or raised sections of a blank may
be formed by coining dies. Figures 63 and 64 show
dies used for coining and examples resulting from
Fig. 62. Swaging

such an operation. Embossing of sharply defined but
relatively shallow indented or raised letters, lines, or
designs in thin metals with theoretically no change in
metal thickness may require only moderate pressures.
This is also classified as a type of coining.
5.4.4. Extruding. Extruding is a process of
forming metal by-forcing it through or into a die
opening by means of a punch. There are three general
classifications of this process: (1) direct extrusion, in
which the punch forces the metal through or into an
opening located in the die; (2) inverted extrusion, in
which the opening through which the metal is to flow
is located in the punch or ram; and (3) impact
extrusion, in which the metal (usually soft alloy) is
made to flow into the clearance between a punch and a
blind hole in the die, as shown in figure 65.
5.5 Welding Projection
Figures 66 and 67 illustrate proportions and designs
of types of commonly used welding projections.
Fig. 63. Dies for Coining

March 1, 1987
GENIUM
PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 25
August 1, 1987*
Fig. 64. Examples of Coining
Fig. 65. Impact Extruding

The information provided here may be used for
noncritical applications. For more critical
consideration, see section K18.2, which provides
more specific and detailed information.
5.5.1 Location of Projections. In general, the
GENIUM
recommended positioning of projection-welding

embossments should be in accordance with that
shown in figure 68.
5.5.2 Design Considerations. Consider the
following design criteria when applying data shown
in figures 66, 67, and 68.
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 26
August 1, 1987*
Fig. 66. Button Type of Welding Projection
Fig. 67. Cone Type of Welding Projection

* Supersedes Issue of
March 1, 1987
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 27
August 1, 1987*
Fig. 68. Embossment Location

Size of Projection. The size of the projection is
normally determined by the thickness of the
inner piece. The projection should be on the
thicker piece where possible.
shows the use of extruded projections as locating

dowels in welded assemblies.
6 Curling
Data in Figures. Data in figures are based on the

thickness of the thinner sheet and for two
thicknesses only.
Curling is usually done in two steps using special dies

such as those shown in figure 72.
Contacting overlap. Contacting overlap does not

include any radii from forming, etc.
6.1 Straight Curling for Flat Stampings
Weld. The weld should be located in the center of

the overlap.
Straight curling is a process of forming a rounded

edge or curl on the end of a flat bank, as shown in
figure 73. The most common application for such
curls is in hinge manufacturing. If accuracy is
required in the shape or size of the curl, pins are inserted during curling.
Projection. The projection should be made on the

piece of higher conductivity when dissimilar
metals are used.
Height. The height of all projections on any one
part should be within fairly close limits (usually
0.003 inch) of each other.
6.2 Round-Work Curling for Drawn

Stampings
5.5.3 Dowels. Dowels that serve as rivets,

locating buttons, or stops for restricting the movement
of assembled parts can be extruded from metal
blanks, as shown in figures 69 and 70. Figure 71
GENIUM
Round-work curling is the process of curling the edge

of drawn shells, etc. The curl may be applied toward
the outside or the inside of the shell. In most cases the
proportions shown in figure 74 should apply to roundwork curling.
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.1
Page 28
August 1, 1987
LARGER
Fig. 69. Extruded Dowels, Thin Material
THIS DESIGN USED WITH

THICK MATERIAL ANO WHERE
LENGTH Of DOWEL (H)
ExCEEDS 1/2 T* DIAMETER
Fig. 70. Extruded Dowels, Thick Material
Fig. 71. Use of Extruded Projections

March 1, 1987
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.1
Page 29
August 1, 1987*
CURLED EDGE
First bend
Completion of curl
Fig. 72. Punches and Dies for Curling
Fig. 73. Straight Curling
Fig. 74. Round-Work Curling

7 Multiple Operations
7.1 Compound Operations
Most metal-stamping operations are a combination of

two or more press-working operations that are
commonly classified and defined by the characteristics
of the die design or by the type of press or machine
used. The terms compound and combination are
frequently used interchangeably to define process
of using a single-station die. The elements of such
dies are located around a common centerline (usually
vertical) in which two or more operations are
performed by a single stroke of the press.
Compound operations usually perform cutting

operations only.
GENIUM
7.2 Combination Operations

Combination operations include a cutting and a
noncutting operations.
7.3 Progressive Operation
A progressive operation is a multiple operation on
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18. 1
Page 30
August 1, 1987
strip stock that moves through a die having several

stations where, at each press stroke, a different
operation is performed and one or more parts are
produced. This type of die is called a progressive,
a follow, or a cut-and-carry die.
8 Tabs and Lugs
A tab or internal lug is a sheared portion of the blank
usually bent at a right angle to the surface of the part
as shown in figure 75. It is produced by a specially
shaped punch that shears the metal on all except one
side. The tab is bent down across the unsheared

section by a follow-through stroke of the punch in
the die, thus forming an opening. Tabs are generally
used for (1) fastening other parts to stock by twisting,
bending, or staking, as shown in figures 76 and 77;
(2) mechanical positioning; and (3) electrical ground
connections.
9 Drawn Holes for Subsequent Tapping
Where a design calls for drawn tapped holes, a
material having adequate ductility should be specified.
1
Fig. 75. Tab or Lug
Fig. 77. Staked Tab
Fig. 76. Bent Tab

March 1, 1987
GENIUM
PUBLISHING
DRAFTING
MANUAL
Generally, the number of perfect threads in an

extruded tapped hole is less than those in the standard
nut. Consequently such threads will withstand light
torque. The recommended dimensions specified in
figure 78 will serve as a guide in obtaining
satisfactory form and number of threads.
9.1 Positioning of Drawn Holes
Minimum distances, as shown in figure 79, are required from a drawn hole to bends, edges, and other
drawn holes in order to avoid distortion of the holes.
9.1.1 Minimum Distance between Hole and
Bend. Whenever possible, the minimum distance
between the edge of a drawn hole and the inside edge
Section K18.1
Page 31
August 1, 1987*
of the nearest bend should be three (3) times the

thickness of the metal plus the inside radius of the
bend, but not less than 0.003 inch plus the inside
radius of the bend.
9.1.2 Minimum Distance Where No Bend
Exists. Where no bend exists, minimum distance
between a drawn hole and the edge of the metal
should beat least three (3) times the thickness of the
metal, but not less than 0.006 inch.
9.1.3 Minimum Distance between Drawn
Holes. Minimum distance between drawn holes
should be not less than six (6) times the thickness of
the metal.
Fig. 78. Extruded Tapped Hole
I
I
Fig. 79. Locating Diatance of Drawn Holes
GENIUM PUBLISHING
March 1, 1987
DRAFTING
MANUAL
Section K18..2
Page 1
August 1, 1987*
Sheet Metal Design Considerations

Update 30
1 General Design Considerations
The following design considerations illustrate some of
the important points that should be factored into the
design of stampings to promote standardization of
elements and features of approved detail design.
When unusual conditions occur in the design, consult
a specialist in die engineering.
must be considered when punching thick stock. In the

cases where this increment is substantial, it is
generally economical if the assembly of parts or
subsequent machining operations are made from a
certain side of the punched hole. For example, it is
desirable to countersink or counterbore from the large
end of punched holes so that the basic size of the
punched hole is maintained.
1.1 Die Clearance
1.3 Distance from Edge and between Holes
Except in special cases, a clearance must be

maintained between the diameter of a punch and die
when the normal depth of penetration (using a
substantially flat-ended punch) is from one-third to
one-half of the metal thickness, and the remainder of
the workpiece is torn instead of sheared. The actual
depth of penetration will depend upon metal
thickness, temper, and the die clearance. The resultant
punched hole will not have straight sides for its entire
depth (see fig. 1). For general purposes, the
The distance between holes or between a hole and the

edge of a part should be large enough to prevent
tearing of metal and excessive die wear. As
demonstrated in table 1 and figure 2, the following
minimum distance dimensions should be observed to
minimize the distortion in sheet metal stampings
where holes are punched close to an edge or close to
other openings (see table 1).
Table 1
Minimum Distance of Edges from Features
Metal Thickness (T)
Minimum Distance
Up to 0.03
0.06
Over 0.03
2T but Not Less Than 0.12
Fig. 1. Punched-Hole Configuration

allowance or die clearance E, which is added to the
diameter of a punched hole, is based on an overall
punch-and-die clearance of 10 percent of the stock
thickness. Here is an example:
D = 0.316 Diameter
(Tolerances Apply to This Dimension)
T = 0.090 - Stock Thickness
E = 0.090 x 0.10 = 0.009
D + E = O. 136 + 0.009= 0.325
(Diameter of Punched Hole at Large End).
1.2 Die Clearance, Thick Material
Although increment E is negligible in thin material, it
GENIUM
Fig. 2. Minimizing Distortion

1.3.1 Distance from Hole to Locus of Radius
The distance from the edge of a hole to the locus of a
radius should be at least two times the metal thickness
(see fig. 3).
1.3.2 Forming a Bend near a Hole. The edge
of a hole should not be closer than twice the stock
thickness to the form line (see fig. 7). Where a design
requires the edge of a hole to be closer than twice the
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.2
Page 2
August 1, 1987*
2.1 Flat Blanks

For economy and ease of manufacture, parts
should be designed so that straightedges can be
maintained on the flat blanks for formed parts.
Straight edges eliminate the need for expensive
blanking dies (see fig. 5).
I
Fig. 3. Distance from Hole to Locus of Radius
stock thickness to the form line, and the function of
the part permits it, the following note should be added
to the drawing: DISTORTION CAUSED BY
FORMING IS PERMISSIBLE. Where distortion is
not permissible, a secondary operation is required to
add the hole.
2 Drawn-Stamping Radii
A minimum radius of four times the thickness of the
metal is preferred at the bottom of a drawn stamping.
A small radius requires extra operations and extra
dies. In using a small radius on the punch, the metal
may fracture between punch and die; whereas if the
punch has a large radius, this problem may be
avoided (see fig. 4).
w
Fig. 5. Flat Blanks

2.2 Box-Shaped Parts
Design box-shaped parts so that the sides and corners can be produced by forming (see fig. 6,
parts a and b). Use drawn comers only when
they are required for strength or appearance (see
fig. 6, part c).
2.3 Form-Bulge Condition
Fig. 4. Drawn Stamping Radii

March 1, 1987
Where a design requires a sharp inside radius for

heavy material, a distortion condition occurs where
the material is bent (see fig. 8). It is hardly noticeable
on material thickness of less than 0.06 inch, or where
the inside-forming radius is large in comparison to the
material thickness. Wherever possible, keep the
tolerance on the dimension that covers the possible
distorted or bulge area large enough to avoid any
secondary operation.
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.2
Page 3
August 1, 1987*
Corner cut at 45 degree in blank permits folding flanges and often requires
no further trim.
Notching corners in blank has the same

advantages as the 45 degree corners but
often is more desirable for appearance.
Continuous flange,.as shown requires a

draw operation and a developed blank.
(a)
(b)
(c)
Fig. 6. Box-Shaped Parts
T = Thickness of Stock
X = 2 T (Min)
Centerline of Hole
Form Line
Fig. 7. Forming Bend near Hole

GENIUM
PUBLISHING
March 1, 1987
DRAFTING MANUAL
Section K18.2
Page 4
August 1, 1987*
Fig. 9. Blank Development

by the following formula:
Length for 90 Bend =
(R + l/3T).
Table 2 indicates the bend allowance for one and

ninety degrees of bend. When a thirty-degree bend is
specified, for example, it is necessary only to multiply
thirty by the length given for the one degree in order
to determine the bend allowance.
~/
3.3 Additional Practices for Various Materials
Fig. 8. Form Bulge Condition

3 Blank Development
It is not general practice to show blank developments
on production drawings; therefore, the following
formulas are presented only for reference.
3.1 Blank Development Formula
The following formula may be used for blank
development:
Total Length = A + B + Bend Allowance.
See figure 9 and table 2. Note that table 2 displays a
limited range of stock thicknesses.
In addition to the simplified bend-allowance design

practices shown in paragraph 3.2, more extensive and
detailed practices for various materials are also shown
in the following paragraphs. These practices have
been retained out of consideration for those
subscribers to the Modern Drafting Practices and
Standards Manual who wish to continue to use these
detailed practices.
3.3.1 The data in table 3 are intended for use with
carbon steel. This table (parts a, b, and c) indicates
methods for calculating developed lengths of bends
for various angles and radii not specified in table 3.
3.3.2 For values of K that are not included in table 3,
the following formulas may be used (see fig. 10):
For 90-Degree Bends, x = 1.571 (R+ Y);
Other angles are proportional.
3.2 Bend Allowance
For Low-Carbon Steel, y = 0.4x T;
The bend allowances shown in table 2 were computed

March 1, 1987
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.2
Page 6
August 1, 1987*
Table 3
Values of K
Values of K (Bending Allowance) for Ninety-Degree Bends on V Dies
Note: The forming radius must be specified on the drawing. The standard forming radius for 0.030-to0.125-inch-thick material is 0.06. The standard forming radius for 0.180-inch- and 0.250-inch-thick
material (except 0.250-inch-thick cold-drawn steel, which will fracture if a 0.19-inch radius is used ) is
0.19 inch. Use a 0.250-inch minimum forming radius for 0.250-inch-thick cold-drawn steel. The
following examples are methods for calculating the value of K for various configured angles.
March 1.1987
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.2
Page 7
August 1, 1987*
Table 4
Bend Allowance,
K = 0.628 x T - 0.429 x R (per K formula)
In figure 10, the developed length equals the sum of
all inside dimensions plus the algebraic sum of all
bend allowances. For example:
Developed Length = 2.13 + 1.75 + 3.00 +2.13
+ 0.88 +0.216 = 10.106 or 10.11 Inches.
Note: All bends are ninety degrees, and radii are
0.06R. It will be noted that the K bend allowance
from table 3 is 0.054. Because there are four bends,
the total bend allowances equal 4 x 0.054, or 0.216.
Minimum Flange Dimensions

B or C
Minimum
0.38
0.38
0.38
0.38
0.38
0.38
0.38
1.12
1.12
T
0.030
0.036
0.040
0.060
0.090
0.105
0.120
0.180
0.250
R
0.060
0.060
0.060
0.060
0.060
0.060
0.060
0.188
0.188
Fig. 10.
3.3.3 Minimum Flange Dimensions.
Minimum flange widths for commonly used stock
thicknesses are shown in table 4.
3.3.4 Developed Length for Wraparound
Bends. Minimum values for wraparound flanges
are provided in table 5. Because of the physical
limitations of the material, only a selected number of
thicknesses are shown.
3.3.5 Aluminum. The bend allowances A for
quarter-hard or softer aluminum are provided in
table 6. In addition, the inside radius for ninetydegree bends or less must be at least equal to the
thickness of the material. In all cases, the forming
radius must be specified on the drawing.
Table 5
Developed Length for Wraparound Bends
T
0.030
0.036
0.044
0.060
0.090
0.105
0.120
Developed Length
A + B + 0.05
A + B + 0.06
A + B + 0.08
A + B + 0.09
A + B + 0.14
A + B + 0.16
A + B + 0.19

Bends. Minimum values for wraparound flanges
are provided in table 7. Because of the physical
limitations of the material, only a selected number of
thicknesses are shown.
3.3.7 Stainless Steel. The bend allowances A
for stainless steel are provided in table 8 for a broad
range of material thicknesses.
GENIUM
PUBLISHING
March 1, 1987
DRAFTING
Section K18.2
Page 8
August 1, 1987*
MANUAL
Table 6
Aluminum
Radius
Bend Allowance A for Ninety-Degree Bend . 0.59T - .429R

T (Material Thickness)
A for 90 Bend = 1.571 (R+Y) - 2R

X for 90 Bend= 11571 (R+Y)
Other Angles Are Proportionate
Y = 0.38T
March 1, 1987
GENIUM
PUBLISHING
DRAFTING
MANUAL
Section K18.2
Page 9
August 1, 1987*
adjacent welds. The maximum total of indentation

takes into account the depression on both sides.
Table 7
T
0.032
0.063
0.094
0.125
B Minimum Developed Length
A + B + 0.073
0.25
A + B + 0.073
0.25
0.38
A + B + 0.130
0.38
A + B + 0.186
Note: A 180degree bend can be used only for

dead-soft aluminum.
.-

Bends. The developed length for wraparound
bends on stainless steel is provided in table 9. Again,
the material characteristics govern the number of
thicknesses shown in the table
Unequal Material Thickness. The data in this

section covers steels only. The minimum overlap is
that which provides minimum indentation on the
thin piece with sufficient mechanical clearance for
the electrode in contact with the thick piece and
avoids expulsion of the weld without special
electrodes and their high cost of maintenance. It is
recommended that the minimum overlap be made
greater wherever possible to (1) avoid the necessity
of locating the weld in the exact center of
the overlap, and (2) to use stocked widths of
material. When a design requires an overlap less
than the minimum overlap allowance, a
projection weld should be considered. The
recommended minimum weld spacing is that
which is required to avoid distortion of parts with
multiple welds. When the sizes of parts do not
permit this spacing, space the welds apart as
far as possible, but not less than the minimum. See
table 11 and associated illustrations for
recommended letter values of spacings for one or
more spot welds.
5. Projection Welding
4 Sheet Metal Welding

There are three commonly used methods of welding
sheet metal: (1) arc welding, (2) spot welding, and
(3) projection welding. Refer to section K14.1.1 of
this manual for applicable welding symbols.
4.1 Arc Welding
Standard joint design and welding practices apply to
this most commonly used application.
4.2 Spot Welding
Spot welding requires the availability of resistancewelding equipment and some production volume for
economic application.
4.2.1 Carbon and Stainless Steel Application
Data
Equal Material Thickness This data covers
selected carbon and stainless steel materials. The
minimum weld spot spacing given in table 10 is
that for which no special precautions need be taken
to compensate for the shunted current effect of
5.1 Application
Projection-welding techniques are generally applicable
to high-resistance ferrous materials when part overlap
is sufficient for spot-welding and for projectionwelded hardware.
Projections are formed on the material with special
dies. The materials are fused by heat to form an
indestructible assemblage. When unequal thicknesses
of materials are to be fused or projection welded, the
projection is placed on the thickest material.
Recommended projections are shown in table 12 and
associated illustrations.
5.2 Welding Conditions and Projection Size
Welding conditions and size of projection are determined by the thickness of the thinnest piece. The data
shown in table 13 is for two thicknesses only. Projection should be on the thickest piece, where possible, and in the center of the overlap when one is
used. When projection has to be on the thinnest
piece, the maximum ratio between thicknesses
should be 3 to 1.
March 1, 1987
GENIUM PUBLISHING
DRAFTING MANUAL
Section K18.2
Page 10
August 1, 1987*
Table 8
Stainless Steel
I Radius
Bend Allowance (A)
.Note:
. . A l/16-inch standard forming radius is used for 0.032 to and including 0.125-inch-thick material when
bend allowance is used. A 3/16-inch standard forming radius is used for 0.180 and 0.250.inch-thick material
when bend allowance is applied. For any other forming radius, check available tools and manufacturing
processes, because thicker material will require annealing when formed with a small radius.
J
)
A for 90 Bend= 1.57 (R + Y) - 2R

X for 90 Bend= 1.57 (R + Y)
Other Angles Are Proportionate
Y = 0.34T
March 1, 1987
GENIUM
PUBLISHING
DRAFTING
MANUAL
Section K18.2
Page 11
August 1, 1987*
Table 9
Table 10
Minimum Spot Weld Spacing for Materials of Equal Thicknesses
Nominal
Thickness
Piece
(T)
Minimum
Overlap
(L)
0.010 Inch
0.021 Inch
0.031 Inch
0.036-0.040 Inch
0.050 Inch
0.060-0.062 Inch
0.078 Inch
0.090-0.094 Inch
0.105-0.109 Inch
0.120-0.125 Inch
0.180-0.187 Inch
0.250 Inch
0.38
0.44
0.44
0.50
0.56
0.63
0.69
0.75
0.81
0.88
1.13
1.38
Minimum
Weld Spacing
CL to C L
2
PCS
0.25
0.38
0.50
0.75
0.88
1.00
1.25
1.50
1.63
1.75
3.00
5.00
3
PCS
0.38
0.50
0.75
1.00
1.25
1.38
1.63
2.00
2.13
2.38
-----.-----
GENIUM
Minimum
Diameter
Weld
(D)
0.100 Inch
0.130 Inch
0.160 Inch
0.190 Inch
0.220 Inch
0.250 Inch
0.290 Inch
0.320 Inch
0.350 Inch
0.380 Inch
0.560 Inch
0.750 Inch
PUBLISHING
Maximum
Total
Indentation
0.002 Inch
0.008 Inch
0.012 Inch
0.016 Inch
0.020 Inch
0.026 Inch
0.032 Inch
0.040 Inch
0.044 Inch
0.050 Inch
0.075 Inch
0.100 Inch
Minimum
Shear
Strength
Pound
One Spot
130
320
570
920
1350
1850
2700
3450
4150
5000
10000
15000
March 1, 1987
DRAFTING MANUAL
Section K18.2
Page 12
August 1, 1987*
Table 11
Spot Weld Spacings for Unequal Thicknesses
Nominal
Thickness
Thin
PC
Minimum
Overlap
Thick Thin
PC PC.A
Thick
PC.B
0.036 I 0.060 I 0.28

0.036 I 0.090 0.31
0.036 0.105 0.34
0.036 0.120 0.38
0.060 0.090 0.31
0.060 0.105 0.34
0.060 0.120 0.38
0.060 0.180 0.44
0.060 0.250 0.50
0.090 0.105 0.34
0.090 0.120 0.38
0.090 0.180 0.44
0.090 0.250 0.50
0.090 0.375 0.56
0.105 0,120 0.44
0.105 0.180 0.50
0.105 0.250 I 0.56
0.105 0.375 0.63
0.120 0.180 0.56
0.120 0.250 0.63
0.120 0.375 0.69
0.31
0.38
0.41
0.44
0,38
0.41
0.44
0.56
0.69
0.38
0,44
0.56
0.69
1.00
0.50
0.56
0.69
1.00
0.56
0.69
1.00
ONE SPOT WELD ONLY
Minimum
Diameter
Weld
(D)
0.17
0.25
0.30
0.30
0.35
0.35
0.38
0.38
Maximum
Indentation
Thin
PC
Thick
PC
0.003
0.004
0.004
0.00.5
0.005
0.005
0.005
0.005
0.007
0.010
0.007
0.008
0.009
0.011
0.013
0.007
0.007
0.008
0.010
0.006
0.006
0.008
0.003
0.004
0.004
O.004
0.005
0.007
0.004
0.004
0.005
0.007
0.009
0.005
0.005
0.006
0.008
0.005
0.005
0.008
Minimum
Shear
Strength
Pounds
One Spot
Weld Spacing
C L to CL
Minimum
750
0.63
1850
1.00
3540
1.50
3540
4200
1.50
1.63
4200
5000
5000
5000
1.63
1.75
1.75
Recommended
1.00
1.50
1.63
1.75
1.50
1.63
1.75
3.00
4.00
1.63
1.75
3.00
4.00
5.00
1.75
3.00
4.00
5.00
3.00
4.00
5.00
2 OR MORE WELDS*
I
*When the spacing of two or more spot welds on the same piece exceeds 10 inches, the minimum overlap as shown for one spot weld
may be used.
March 1, 1987
GENIUM PUBLISHING
DRAFTING
MANUAL
Section K18.2
Page 13
August 1, 1987*
Table 12
Selected Data for Spacing and Size of Projections
Number of
Projections
Nominal
Thickness
of Thinnest
Piece
(T)
0.010
0.014
0.016
0.021
0.025
0.034
0.044
0.050
0.062
0.070
0.078
0.094
0.109
0.125
0.140
0.156
0.171
0.187
0.203
0.250
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
*Tolerance
Projection Number
1 and 2
3 and 4
5 through 15
D
0.003 Inch
0.005 Inch
0.007 Inch
Minimum
Overlap
(L)
Diameter of
Projection (D)*
Minimum
Diameter of
of Weld
Height of
Projection
(H)
Minimum Shear
strength
Pounds
(One Projection)
0.13
0.055 Inch
0.015 Inch
180
0.16
0.067 Inch
0.017 Inch
250
0.22
0.094 Inch
0.022 Inch
500
0.28
0.119 Inch
0.028 Inch
0.38
0.156 Inch
0.035 Inch
0.44
0.50
0.63
0.69
0.75
0.81
0.88
0.94
1.00
1.25
0.187 Inch
0.218 Inch
0.250 Inch
0.281 Inch
0.312 Inch
0.343 Inch
0.375 Inch
0.406 Inch
0.437 Inch
0.531 Inch
0.041 Inch
0.048 Inch
0.054 Inch
0.060 Inch
0.066 Inch
0.072 Inch
0.078 Inch
0.085 Inch
0.091 Inch
0.110 Inch
1950
3200
5000
8000
12000
H
0.003 Inch
0.003 Inch
0.007 Inch
Recommended
Projections
S MIN. = 2 D
GENIUM
PUBLISHING
March 1, 1987

Sheet Metal

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DRAFTING MANUAL

SHEET METAL PRACTICE

This section is based on a series of books, The Profitable Way

Tolerance on width is always plus, and varies from 1/8

4.1.2 - Other carbon steel as described in 4.1.1 is available with

4.0 TYPICAL SHEET METAL MATERIALS

4.1.3 - Cold rolled, low carbon STEEL SHEET, commercial

*Supersedes issue of July 1985

SHEET METAL PRACTICE

4.1.4 - Commercial, cold rolled, low carbon steel strip with

The behavior of aluminum in an enclosure can be understood

Table 1 gives an approximation between aluminum and low

4.1.5 - Hot rolled, low carbon, commercial quality, as rolled,

In order to make interpretation easier, beams, posts and sheets

The strength of a given material is the ability of that material to

Tolerances - Thickness: (For 0.105 thick)

(Continued on the next page.)

SHEET METAL PRACTICE

Beam (acting as a horizontal

Post (vertical member acting

Sheet (acting as plain surfaces

Chemical Corrosion The aluminum base alloys resist

*Supersedes issue of July 1985

SHEET METAL PRACTICE

4.2.3 Aluminum alloy UNS A95052, flat sheet. Typically

Temper Tensile strength, ksi

Shearing strength, ksi .....................

*Supersedes issue of July 1985

4.3 STAINLESS STEEL

SHEET METAL PRACTICE

Stainless steel is more difficult to machine or punch than low

Tolerances - Width (inch)

4.3.2 A UNS S30403 type chromium-nickel, austenitic steel

Structures or assemblies utilizing this grade of stainless steel

Tolerance - Flatness (For 46 inch and 48 inch wide sheets)

Chemical Composition % (Ladle Analysis)

Chemical Composition % continued

*Supersedes issue of July 1985

SHEET METAL PRACTICE

Inside Corner Radius

Forming Radius must be specified on drawing.

X for 90 bends = 1.571 (R + Y) (4 inch RAD = Bend allowance 1.65 inch)

*Supersedes issue of July 1985

SHEET METAL PRACTICE

All bends 90 0.06R, K for four bends = 4 (+0.054) = +0.216

5.1.2 Developed Length for Wraparound Bends

*Supersedes issue of July 1985

SHEET METAL PRACTICE

Bend allowance A for 90 bend = 0.597T 0.429R

Forming radius must be specified on drawing.

A for 90 bend = 1.571 (R + Y) 2R

*Supersedes issue of July 1985

SHEET METAL PRACTICE

5.3 Stainless Steel

Bend allowance A for 90 bend = 0.53T 0.429R

Forming radius must be specified on drawing when bend allowance is used.

A for 90 bend = 1.571 (R + Y) 2R

*Supersedes issue of July 1985

SHEET METAL PRACTICE

6.0 SHEET METAL WELDING

*Supersedes issue of July 1985

Minimum weld spacing

SHEET METAL PRACTICE

6.2.1.2 Unequal Material Thickness