Manual de Teoria Amada Press Brake

Page 2
Glossary
Glossary
ACUTE ANGLE:
An included angle tighter (less than) than 90 degrees. (The

material has been bent past 90 degrees) (see page 5)
AIR BEND:
A bend determined by one line of force against two lines of

resistance. The BEND RADIUS is determined by die width and
material thickness. The bend angle is determined by punch
penetration.
APEX:
The imaginary point where the two sides of an angle, if extended,

would meet. (see page 5)
BED:
The load bearing surface of the lower beam.
BEND ALLOWANCE:
The length of the neutral line through the bend from tangent line
to tangent line.
BEND DEDUCTION:
Amount deducted from overall size to determine shear

dimensions. Abbreviated as B/D. Also known as K factor.
Equal to two times set back.
BEND LINE:
Line on work piece where punch contacts material.
BEND RADIUS
Curvature of material at the bend, expressed as distance from the

material to the center point of that bend. Also see Inside Radius.
BOTTOM BENDING:
When material is pressed between the punch and die, the punch
tip penetrates the material. The inside radius is determined by the
punch tip. Bend angle is determined by tooling.
COINING:
Process of bending by applying large amounts of force to cause

material to flow. Springback is eliminated, because the material
in the bend zone undergoes plastic deformation. The inside radius
of the bend is determined by the radius of the punch tip.
DIE:
The concave, or female tool. Normally mounted on the bed, or on

spacers mounted on the bed.
DISTANCE PIECE:
Punch holders on Amada style machine. Used to adjust for

varying amounts of ram and/or beam deflection.
FLANGE:
The portion of sheetmetal that has been formed up or down to

obtain rigidity or desired shape.
Amada School
Bending Workbook
Version 1.4d, April 2002
Glossary
Page 3
HEM:
A bend where the sheetmetal is folded over on top of itself. This

may be done to provide a smooth edge, to provide stiffness, or to
join two pieces together.
INCLUDED ANGLE
Angle formed around the punch.
INSIDE RADIUS
Distance from the inside surface of the material at a bend to the

center point of that bend. Abbreviated as IR. (see page 5)
HYDRAULIC
Machine driven by fluid power provided by hydraulic pump.
NEUTRAL LINE:
Line through the material that remains at constant length when

the material is bent. (see page 26) Used for flat pattern
development.
OBTUSE ANGLE:
An included angle of greater than 90 degrees. (The sheet metal

has not been bent far enough to reach 90 degrees)
OPEN HEIGHT:
Distance between the ram and bed of machine when the ram is
fully retracted.
PRESS BRAKE:
Machine designed to form metal parts using punch and die.
PUNCH:
The convex (male) tool. Normally mounted to the upper beam.
RAM:
Beam that moves to supply bending force, can be upper or lower.
SET BACK:
Amount of material deducted from flange length to place bend

line. Same as of the bend deduction or K factor.
SHEAR SIZE
Dimension of blank piece before bending.
SHUT HEIGHT:
Distance between upper and lower beams when the ram is fully
extended.
SPRINGBACK:
Tendency of material to return to flat condition after forming.

(see page 26)
TANGENT:
The point where a line meets a radius.
TENSILE STRENGTH:
Measurement of resistance (in pounds/square inch or similar

units) that metal can be stretched before fracture.
UPPER BEAM:
Upper part of machine that holds tooling and supplies bending

force or resistance depending on machine style.
YIELD STRENGTH:
Measurement of resistance (in pounds/square inch or similar

units) that metal can be stressed before forming.
Bending Workbook
Amada School
Page 4
The Basics of Brake Bending

In brake bending, the material is supported by a die and a punch is forced into
the material. The punch is centered between the two edges of the die, causing
the material to bend evenly on each side of the punch.
The first illustration below shows
a punch and die with material
partially bent. The second
illustration shows some of the
forces involved and the material
motion during the bend.
Simple bend
Punch
material
motion
material
motion
Die
Forces in simple bend
Amada School
Bending Workbook
Page 5
Bend Angle
When sheet metal is bent in a press brake, it (usually) begins in the flat. As
it is bent, the angle can be described by either of two numerical values:
The included angle is the angle formed around the punch.
The complementary angle is the amount the metal has been bent from flat.
The two angles always sum to 180 degrees.
45 complementary angle,
135 included angle
135
45
0.234"
IR
1.815"
90
90
le A
Ang
IR
H
30
le A
Ang
IR
Apex
Bending Workbook
Amada School
Materials
Page 10
Materials
Materials
Purpose of chapter
This chapter contains general information about various materials, such as
Carbon Steel, Aluminum and various alloys. Also presented are Inch-Metric
conversions, Fraction to decimal equivalents, and sheet weights for various
material thicknesses and sheet sizes.
Amada School
Bending Workbook
Materials
Page 11
Conversions
Inch
Fractions
Inch
Decimal
Millimeters
Inch
Fractions
Inch
Decimal
Millimeters
1/64
0.015625
0.397
37/64
0.578125
14.684
1/32
0.031250
0.794
19/32
0.593750
15.081
3/64
0.046875
1.191
39/64
0.609375
15.478
0.062500
1.588
0.625000
15.875
5/64
0.078125
1.984
41/64
0.640625
16.272
3/32
0.093750
2.381
21/32
0.656250
16.669
7/64
0.109375
2.778
43/64
0.671875
17.066
0.125000
3.175
0.687500
17.463
9/64
0.140625
3.572
45/64
0.703125
17.859
5/32
0.156250
3.969
23/32
0.718750
18.256
0.171875
4.366
47/64
0.187500
4.763
13/64
0.203125
5.159
7/32
0.218750
5.556
15/64
0.234375
5.953
0.250000
6.350
17/64
0.265625
6.747
9/32
0.281250
7.144
19/64
0.296875
7.541
0.312500
7.938
21/64
0.328125
8.334
11/32
0.343750
8.731
23/64
0.359375
9.128
1/16
1/8
11/64
3/16
1/4
5/16
3/8
5/8
11/16
0.734375
18.653
0.750000
19.050
49/64
0.765625
19.447
25/32
0.781250
19.844
51/64
0.796875
20.241
0.812500
20.638
53/64
0.828125
21.034
27/32
0.843750
21.431
55/64
0.859375
21.828
0.875000
22.225
57/64
0.890625
22.622
29/32
0.906250
23.019
59/64
0.921875
23.416
3/4
13/16
7/8
15/16
0.375000
9.525
0.937500
23.813
25/64
0.390625
9.922
61/64
0.953125
24.209
13/32
0.406250
10.319
31/32
0.968750
24.606
27/64
0.421875
10.716
63/64
0.984375
25.003
0.437500
11.113
1.000000
25.400
29/64
0.453125
11.509
15/32
0.468750
11.906
0.484375
12.303
1 cm = 0.3937
0.5000000
12.700
1 mm = 0.0394
33/64
0.515625
13.097
17/32
0.531250
13.494
35/64
0.546875
13.891
0.562500
14.288
7/16
31/64
9/16
1 = 25.4 mm = 2.54 cm
Bending Workbook
Amada School
Page 12
Materials
MM to Inch
MM
MM
INCH
INCH
MM
INCH
0.1
0.0039
30
1.1811
68
2.6772
0.2
0.0079
31
1.2205
69
2.7165
0.3
0.0118
32
1.2598
70
2.7559
0.4
0.0157
33
1.2992
71
2.7953
0.5
0.0197
34
1.3386
72
2.8346
0.6
0.0236
35
1.3780
73
2.8740
0.7
0.0276
36
1.4173
74
2.9134
0.8
0.0315
37
1.4567
75
2.9528
0.9
0.0354
38
1.4961
76
2.9921
0.0394
39
1.5354
77
3.0315
0.0787
40
1.5748
78
3.0709
0.1181
41
1.6142
79
3.1102
0.1575
42
1.6535
80
3.1496
0.1969
43
1.6929
81
3.1890
0.2362
44
1.7323
82
3.2283
0.2756
45
1.7717
83
3.2677
0.3150
46
1.8110
84
3.3071
0.3543
47
1.8504
85
3.3465
10
0.3937
48
1.8898
86
3.3858
11
0.4331
49
1.9291
87
3.4252
12
0.4724
50
1.9685
88
3.4646
13
0.5118
51
2.0079
89
3.5039
14
0.5512
52
2.0472
90
3.5433
15
0.5906
53
2.0866
91
3.5827
16
0.6299
54
2.1260
92
3.6220
17
0.6693
55
2.1654
93
3.6614
18
0.7087
56
2.2047
94
3.7008
19
0.7480
57
2.2441
95
3.7402
20
0.7874
58
2.2835
96
3.7795
21
0.8268
59
2.3228
97
3.8189
22
0.8661
60
2.3622
98
3.8583
23
0.9055
61
2.4016
99
3.8976
24
0.9449
62
2.4409
100
3.9370
25
0.9843
63
2.4803
26
1.0236
64
2.5197
27
1.0630
65
2.5591
28
1.1024
66
2.5984
29
1.1417
67
2.6378
Amada School
Bending Workbook
0.001 = 0.0254 mm
Materials
Page 15
Standard gauges of sheet metal
Bending Workbook
Amada School
Page 16
Materials
Specifications of selected Materials
Amada School
Bending Workbook
Materials
Page 17
Other Alloys
Type
Element
Hastelloy-X Co 1.5 Fe 18.5 Cr 22.0

Mo 9.0 W0.6 C0.15
C0.17 Ni bal.
Stock
Yield
Strength
Tensile Strength
Rockwell
Wrought Sheet
mill annealed
Investment Cast
26000
23300
56000
33500
-
20.8
18.4
-
Application: high strength, high temp engine parts, resistant to oxidation at high temps.
Hastelloy-C
Cr 16.0 Fe 6. W 4. C
.15 Mo 17. Ni bal.
Sand cast (anneal.)

Investment cast
Rolled (anneal.)
25000
25000
35500
39000
40000
65000
21.3
23
22
Inconel-C
Cr 13. Cb 2.
Mo 4.5 C .15
Ti .6 Al 6.
Ni (+Co) bal.
Investment cast
(anneal.)
51000
60000
Application: high strength, high temp engine parts, resistant to oxidation at high temps
Inconel-X
Ni (+Co) 72.85
Mn .65 S .007
Cu .05 Al .75
Cb (+Ta) .85 .04 Fe
6.8 Si .3
Cr 15. Ti 2.5
(Anneal.)
Age Hardened
25000
52500
52500
87500
16
32.2
Waspoloy
C .08 Cr 19.5 Mo 4.3

Ti 3. Co 13.5
Cold Rolled
13500
137500
51
Udimet 700
C .08 Cr 15. Mo 5. Ti
3. Al 4.3 Co 18.5
Cold Rolled
140000
142500
53
Zinc-40
Cu 1. Zn bal.
Hot Rolled
Cold Rolled
12000
15500
5.6
6.4
Application: Weatherstripping, spun pieces.

Zinc ASTM
B69
Cd .35 Pb .08 Zn bal.
Hot Rolled
9.75
4.1
Zilloy-15
Cu 1.0 Mg .01
Zn bal.
Hot Rolled
Cold Rolled
14.5
6.5
Bending Workbook
Amada School
Page 18
Amada School
Materials
Bending Workbook
Materials
Page 19
Aluminum
Bending Workbook
Amada School
Page 20
Amada School
Materials
Bending Workbook
Materials
Page 21
Notes on Aluminum
Three common grades of aluminum are:
5052-H32
Easy to work with, warps easily.
5051-H32
6061-T6
Usually quite flat but doesnt form well. (cracks)
Hardness may be designated by T and a number, 0~8

0 = dead soft
2 = hard
4 = hard
6 = hard
8 = full hard
Bending Workbook
Amada School
Bending Theory
Page 26
Bending Theory
Bending Theory
This chapter describes how material responds to bending stress, the three types
of bends, and what happens to the work piece as it is being formed.
Stresses and springback

While a blank is still flat, both sides and the middle are all the same length. As
we form the material in the die space the material towards the inside of the
neutral line is compressed, and the material towards the outside of the neutral
line is stretched. Material that is compressed or stretched enough will stay
permanently deformed. That material has been plastically deformed.
Now picture a band of metal following the neutral line that has not been
compressed or stretched enough to reach a plastic condition. This band of
material maintains an elastic condition. This elastic material will tend to
return to its original unbent position, tending to straighten the material. The
forces of the elastic metal (trying to return to its original condition) and the
forces of the plastic metal (trying to stay permanently deformed) come to an
equilibrium, determining spring back.
The amount of spring back is determined by the amount of material

stressed enough to reach a plastic condition.
Harder metals will have more spring back due to the higher elastic limit, which
results in a larger elastic band at the bend.
As metal is bent farther (through more degrees) the plastic zone becomes
larger, reducing the amount of springback.
A sharper or smaller bend radius will reduce spring back by creating a larger
plastic zone, due to the higher tensile stresses at the outside surface of the
material at the bend radius. This may also cause tearing or fracturing.
OUTER ZONE PLASTICALLY
DEFORMED BY TENSION
SPRINGBACK
FORCES
TENSILE STRESSES
ELASTIC ZONE
COMPRESSIVE
STRESSES
Amada School
INNER ZONE PLASTICALLY

DEFORMED BY COMPRESSION
NEUTRAL AXIS
NEUTRAL AXIS
Bending Workbook
SPRINGBACK
Bending Theory
Page 27
Considering no change in the inside radius, thicker materials have less spring
back since there is more plastic deformation.
Overcoming Spring back

Methods of overcoming spring back include over-bending, bottoming or
setting, and stretch bending.
OVER BENDING is bending the material past the target angle, so that it relaxes to the correct position. This may be accomplished using common methods: tooling with an angle smaller than the required bend, or cam dies.
BOTTOMING consists of striking the metal severely at the radius. This compresses the material beyond the yield strength and causes a larger plastic zone.
Bottoming must be carefully controlled. When adjusting ram depth settings,
forces will rise at a high rate, careless operation can cause die breakage and
even machine failure.
STRETCH BENDING uses a special setup or special tooling to stretch the
workpiece to bring the entire bend zone into yield, so that it retains its shape
when released.
When a work piece is flat the neutral line is in the center of the material. As
the material is formed the neutral line shifts toward the inside radius of the
bend.
As the radius of the bend is decreased the neutral axis of the material will shift
closer to the inside surface.
The length of the neutral axis, which is the object of the blank size
calculations, is dependent on the following factors:
type of forming employed
material type and hardness
inside bend radius (as related to material thickness)
grain direction
Since the neutral line is affected by each of the variables listed, accurate
blank size calculations can be difficult. There are several methods or formulas
commonly used to calculate precise blank sizes. These formulas and charts are
listed in the Bend Allowance Chapter. (See page 46 )
Bending Workbook
Amada School
Page 28
Bending Theory
Bending Methods
There are basically three types or methods of bending sheetmetal with a press
brake: Air Bending, Bottoming, and Coining
Air Bending
The angle is determined by the penetration of the punch tip into the die
opening. The inside radius of the bend is determined by the width of the die
opening, except soft materials such as some aluminums which may conform to
the punch radius. An inside radius of 15% of the vee die width can be expected
when forming mild steels. Smaller vee die widths decrease inside radius while
increasing tonnage requirements.
If the die width is too small, excessive tensile stresses will occur, which can
cause fracturing. Larger die widths increase inside radius and reduce tonnage.
Excessive die width will draw too much material into the vee and may cause a
bulge in the outside radius of the bend.
Air bending requires minimum tonnage,
extending the brakes capacity and reducing
wear. Tooling becomes more versatile and less
per job tooling is required.
Air forming is practical for precision work. The
ability to determine the inside radius by vee
width rather than punch radius can increase the
shop versatility, allowing the brake operator to
fudge on bend deduction figures by changing
inside radiuses. This allows the operator the ability to adjust for blanks that
may not meet tolerances. Within reasonable vee sizes, material imperfections
will not greatly affect the given angle.
Amada School
Bending Workbook
Bending Theory
Page 29
Bottom Bending
Bottoming is accomplished by striking the
material severely at the bend radius. Tooling
configuration determines bend angle, part
shape, and inside radius. Material greater than
16 gauge is seldom bottomed due to the large
tonnage requirements.
Bottoming puts a tremendous amount of force
on the brake and tooling. Great care must be
taken during set up to avoid damage to
machine tooling and the operator. Press
maintenance becomes crucial to press life. Bending accuracy can be very
consistent but extensive set up by experienced operators must take place first
Coining
A coining operation is one in which the amount of force applied to the work
piece is enough to cause the material to flow. If you look at the cross section
of a coin you will notice that the material has been struck so hard that the
material between the thinner areas of the die set have been forced to flow
into the thicker areas. Forces of 100 tons per square inch are not uncommon.
Coining is seldom performed on a press brake due to the tonnage requirements
although bottom bending is often referred to as coining in many shops.
Bending Workbook
Amada School
Blueprint reading
Page 34
Blueprint reading
Blueprint reading
This section presents some commonly used symbols, followed by samples and
exercises in basic blueprint reading.
Figure 1
Amada School
Bending Workbook
Blueprint reading
Type of
control
Datum
symbol
Page 35
Perpendicularity
Reference
datums
Modifier
.XXX
M B C
Angularity
Parallelism
Position
Tolerance
Third-angle
First-angle
U.S. customary projection
ISO projection
First-angle or Third-angle projection describes how the part is rotated from

view to view.
Bending Workbook
Amada School
Page 36
Blueprint reading
12.00"
4.50"
9.00"
0.75"
0.206 RO
(4 plcs)
2.00"
9.00"
1.50"
1.00"
2.00"
Figure 2
Amada School
Bending Workbook
Blueprint reading
Page 37
0.50"
1.25"
0.50"
0.437"
0.375"
0.38"
0.63"
0.875"
0.88"
0.688
1.25"
Figure 3
Bending Workbook
Amada School
Page 38
Blueprint reading
0.500"
0.767"
0.187"
0.125"
1.250"
0.250"
1.000
0.126 DIA
(2 PLCS)
1.000"
0.375"
0.250
1.250"
Figure 4
Amada School
Bending Workbook
Blueprint reading
Page 39
The drawing on this page shows an assembly of three individual parts.

On the following pages, the individual parts are drawn.
PART 2
PART 3
1.343"
PART 1
0.563"
Figure 5
Bending Workbook
Amada School
Page 40
Blueprint reading
Part 1
Material thickness: 0.094
1.844"
0.578"
0.313"
0.501"
0.405"
0.672"
0.188"
0.281"
0.250"
1.688"
0.688"
1.657"
Figure 6
Amada School
Bending Workbook
Blueprint reading
Page 41
1.125"
0.656"
0.156"
0.125"
1.345"
0.156"
0.125"
0.469"
0.313"
0.078"
0.500"
Part 2
material thickness: 0.094
0.656"
0.313"
1.657"
2.281"
Figure 7
Bending Workbook
Amada School
Page 42
Blueprint reading
1.657"
1.033"
0.312"
0.280"
0.125"
Part 3
Material thickness: 0.094
1.406
1.000"
0.156"
0.359"
0.313"
0.375"
0.688"
0.156"
0.344"
0.297"
0.500"
1.657"
Figure 8
Amada School
Bending Workbook
Bend Allowance
Bend Deduction
Page 46
Bend Allowance, Bend Deduction

Introduction
When bending material, several factors must be considered to create accurate
results. The neutral line, (herein referred to as N/L), is an imaginary line that
splits the material thickness. The N/L is used in blank development
calculations.
A
NEUTRAL LINE
Neutral line touches

calipers at points A
Figure 9: N/L of flat material

The N/L is easily measured when the stock is flat. (See Figure 9) Now let us
consider this same piece of stock after it has been formed to 90 degrees.
Note the location of the N/L in reference to the measure points. On the left end
of figure 10 the N/L is unchanged. On the right side the N/L is within the
material and cant be measured directly. In the shop we can only measure
from the outside or the inside of the flange at point B. Measuring to the
outside edge of the flange is usually easy and accurate, and has become the
most common and preferred way to develop flat patterns. In either case
(outside or inside measurement)
we must compensate for the
material that is between the
measurement point and the N/L.
A
NEUTRAL LINE
Neutral line touches calipers at
point A, but not at point B
Distance between the

edge of the part and
the Neutral Line
Figure 10: N/L of material with bend
Amada School
Bending Workbook
Page 47
Bend Deduction
This material that lies between the N/L when measuring between points A
also exists if we measure between points A, B. This would seem to make
the part grow when bent. The material does stretch some and, as we
discussed in the chapter on theory, we know that the N/L shifts a little
during bending.
The Bend Deduction (hereinafter referred to as B/D) found in the charts or
formulas in this book is adequate for most jobs. This assumes that precision
equipment is used and the tooling setup is known and correct for the job.
This also assumes that the material thickness and strength correspond to those
used in developing the charts.
In some cases, it may be necessary to make a test bend using actual tooling
and material.
Bend Radius
All the computations for bend allowance and bend deduction assume that the
bending radius is known. The bend radius may be predicted as follows:
Bottoming or Coining:
Punch tip radius = bend inside radius.
Air Bending:
Determined by material thickness and Vee-Die opening. See the Air Bending
Force Chart in the Amada Press Brake Tooling catalog.
Usage of Bend Deduction

The bend deduction method is most useful when a part (or bend within a part)
is at 90 degrees or is dimensioned to the apex of the bend. When a bend is not
90 degrees and is dimensioned to the material instead of the apex, the bend
allowance method may be easier. (see page for the bend allowance method)
To use B/D: add the outside (apex) dimensions together, then subtract one B/D
for each of the bends in the part.
Note: for a 90 degree bend, the outside dimension is the same as the
dimension to the apex of the bend.
On the following pages we have provided a Bend Deduction chart for 90
degree bends. This chart is generated from formula 3 on page 50.
The chart is provided for classroom use, and not shop use.
Bending Workbook
Amada School
Inside
Radius >
Material
thickness
0.016
0.018
0.020
0.030
0.032
0.036
0.040
0.048
0.050
0.056
0.059
0.060
0.063
0.074
0.080
0.090
0.105
0.120
0.125
0.135
0.188
0.250
Amada School
Bending Workbook
0.106
0.114
0.128
0.148
0.169
0.176
0.190
0.262
0.104
0.112
0.126
0.146
0.167
0.174
0.187
0.260
0.347
0.091
0.089
0.345
0.087
0.070
0.068
0.084
0.059
0.057
0.085
0.054
0.052
0.083
0.048
0.046
0.081
0.045
0.043
0.079
0.032
0.030
0.073
0.029
0.027
0.071
0.026
0.010
0.024
0.005
0.350
0.265
0.192
0.178
0.172
0.151
0.130
0.117
0.108
0.093
0.089
0.088
0.084
0.075
0.073
0.062
0.056
0.051
0.048
0.034
0.032
0.029
0.016
0.356
0.271
0.199
0.185
0.178
0.157
0.137
0.123
0.115
0.100
0.096
0.094
0.090
0.082
0.079
0.068
0.063
0.057
0.054
0.041
0.038
0.035
0.031
0.363
0.278
0.205
0.192
0.185
0.164
0.144
0.130
0.122
0.107
0.103
0.101
0.097
0.089
0.086
0.075
0.070
0.064
0.061
0.048
0.045
0.042
0.047
0.075
0.370
0.285
0.212
0.198
0.191
0.171
0.150
0.136
0.128
0.113
0.109
0.108
0.103
0.095
0.093
0.082
0.076
0.071
0.068
0.054
0.051
0.049
0.375
0.290
0.217
0.204
0.197
0.176
0.156
0.142
0.134
0.119
0.115
0.113
0.109
0.101
0.098
0.087
0.082
0.076
0.073
0.060
0.057
0.054
bend deduction
0.062
0.383
0.298
0.226
0.212
0.205
0.184
0.164
0.150
0.142
0.127
0.123
0.121
0.117
0.109
0.106
0.095
0.090
0.084
0.082
0.068
0.065
0.062
0.094
0.397
0.312
0.239
0.225
0.218
0.198
0.177
0.164
0.155
0.140
0.136
0.135
0.131
0.122
0.120
0.109
0.103
0.098
0.095
0.081
0.078
0.076
0.125
0.404
0.319
0.246
0.232
0.225
0.205
0.184
0.170
0.162
0.147
0.143
0.142
0.137
0.129
0.126
0.116
0.110
0.105
0.102
0.088
0.085
0.083
0.141
0.409
0.324
0.251
0.238
0.231
0.210
0.190
0.176
0.168
0.153
0.149
0.147
0.143
0.135
0.132
0.121
0.116
0.110
0.107
0.094
0.091
0.088
0.154
0.417
0.332
0.259
0.245
0.239
0.218
0.197
0.184
0.175
0.160
0.156
0.155
0.151
0.143
0.140
0.129
0.123
0.118
0.115
0.101
0.099
0.096
0.172
Page 48
Inside
Radius >
Material
thickness
0.016
0.018
0.020
0.030
0.032
0.036
0.040
0.048
0.050
0.056
0.059
0.060
0.063
0.074
0.080
0.090
0.105
0.120
0.125
0.135
0.188
0.250

0.170
0.174
0.189
0.197
0.211
0.231
0.252
0.259
0.273
0.345
0.430
0.168
0.183
0.191
0.205
0.226
0.246
0.253
0.267
0.340
0.425
0.153
0.148
0.164
0.142
0.137
0.168
0.137
0.131
0.163
0.131
0.126
0.164
0.128
0.123
0.159
0.115
0.109
0.156
0.112
0.150
0.109
0.106
0.203
0.104
0.190
Bending Workbook
0.437
0.352
0.279
0.266
0.259
0.238
0.218
0.204
0.196
0.181
0.176
0.175
0.171
0.163
0.160
0.149
0.144
0.138
0.135
0.122
0.119
0.116
0.219
0.444
0.359
0.286
0.272
0.265
0.245
0.224
0.210
0.202
0.187
0.183
0.182
0.177
0.169
0.166
0.156
0.150
0.145
0.142
0.128
0.125
0.123
0.234
0.312
0.451
0.365
0.293
0.279
0.272
0.252
0.231
0.217
0.209
0.194
0.190
0.188
0.184
0.176
0.173
0.162
0.157
0.151
0.149
0.135
0.132
0.129
0.477
0.392
0.319
0.306
0.299
0.278
0.258
0.244
0.236
0.221
0.216
0.215
0.211
0.203
0.200
0.189
0.184
0.178
0.175
0.162
0.159
0.156
bend deduction
0.250
0.491
0.406
0.333
0.319
0.313
0.292
0.271
0.258
0.249
0.234
0.230
0.229
0.225
0.217
0.214
0.203
0.197
0.192
0.189
0.175
0.173
0.170
0.344
0.504
0.419
0.346
0.333
0.326
0.305
0.285
0.271
0.263
0.248
0.244
0.242
0.238
0.230
0.227
0.216
0.211
0.205
0.202
0.189
0.186
0.183
0.375
0.528
0.443
0.370
0.356
0.350
0.329
0.308
0.295
0.286
0.271
0.267
0.266
0.262
0.254
0.251
0.240
0.234
0.229
0.226
0.212
0.210
0.207
0.430
0.558
0.473
0.400
0.387
0.38
0.359
0.338
0.325
0.317
0.301
0.297
0.296
0.292
0.284
0.281
0.270
0.264
0.259
0.256
0.242
0.240
0.237
0.500

Page 49
Amada School
Page 50
Bend Allowance
There are several ways that formed
parts are dimensioned. In certain
cases it is easier to add the flat
segments of a piece (measured to
tangent points rather than apex)
together, then add a bend allowance.
Tangent line
Bend Allowance is the length of the

N/L between tangent lines.
(see figure 11)
Tangent line
BA = Length of
Neutral Axis
T = 0.048
I.R.
R = 0.030
Figure 11
Note:
The bend angle used in Formulas 1, 4 (below) is the
complementary angle, not the included angle.
(For angle definitions, conversions, and illustrations, see the
following pages)
B/A, B/D Formulas

Formula 1 is used to compute the B/A. This may be needed when computing
blank layout or finding the B/D for an angle much bigger or smaller than 90
degrees.
Formula 1:
[(.0078 x Mat. Thickness )+ (.017453 x IR)] x bend angle = B/A
Bend Deduction Formulas

Formulas 2, 3 provide the B/D for a 90 degree bend. When used for non-90
degree bends, they will be less accurate. For high accuracy of non-90 bends,
see formula 4 on page 51.
Formula 2:
0.454 for air bend
(3 x (Mat. Thickness + IR)) x
= B/D for 90
0.434 for bottom bend
Formula 3:
(.43 x IR) + (1.372 x Mat. Thickness) = B/D for 90
Amada School
Bending Workbook
Page 51
Bend Deduction (cont.)

To determine B/D for angles other than 90 degrees, use formulas 1 and 4.
Formula 1 provides the B/A , which is used in formula 4 to develop the B/D.
Formula 4:
Bend Angle
(MtrlThickness + IR) B / A* =B / D
2 Tan

* See formula 1 (page 50) for B/A

*Note: Any B/D divided in half equals set back for that bend.
Arc Length
Arc Length: The length of a segment of a circle. This formula is used in step
bending.
*A = Included angle as shown in

figures - on page 52.
Outside arc length
Angles
The Included Angle is the angle
measured on the inside of the
material. It is the angle used when
programming an Amada
backgauge.
T = 0.048
Tangent line
The examples on the following

page illustrate included and
complementary angles, as well as
other details of a bend. Also see
page 5.
Tangent line
180 A *
= Arc length
6.28 radius
360
Bending Workbook
R = 0.030
Figure 12
Amada School
Page 52

45 complementary angle
135 included angle
135
45
IR
Figure 13: Obtuse angle
90 complementary angle,
90 included angle
Angles (continued)
The complementary angle and
included angle always add up to
180 .
90
90
le A
Ang
IR
Acomp. + Aincluded =180 deg
Figure 14: Right angle
150 complementary
angle, 30 included angle
150
30
le A
Ang
IR
Apex
Figure 15: Acute angle
Amada School
Bending Workbook
Page 53
When to Use B/A

Figure16 depicts a piece bent at an acute angle.
Length B can be directly measured, as can the thickness. When a drawing is
dimensioned to B or C as shown, use the B/A method (formula 1, page 50)
If the bend is dimensioned to the apex, use the B/D method instead.
(beginning page 47)
B
IR+thk
Apex
C
thk
IR
Figure 16: Measuring acute angle
Bending Workbook
Amada School
Page 54
Hems
HEM: Where the material is folded on top of itself.
It is generally safe to use 43% of the material thickness for a hem deduction
(up to about 0.080 thick).
.005
0.059 (material thickness)
x 0.43
0.025 (hem deduction)
.005
Figure 17: Closed Hem
For tolerances closer than about .005 in both directions, it is better to
pretest a piece of the material
.750
-.025 (hem deduction)
.750
2.25
.725
+2.250
2.975 = developed length
Open Material Hem: Hem deduction is usually 0.

Material is folded over with a gap of 1 material thickness left between the
hem.
Note: Depending on how hard a hem is hit with a set of flattening dies the hem
deduction can vary.
Distortion from flattening
Material thk.
Coining squeezes material out
Material thk.
Amada School
Bending Workbook
Page 55
Joggles
Generally, a joggle is formed by making a single hit with a special punch and
die set. A test bend can be made with the material to be used, if the adjustment
is not already known for the particular tool and material combination.
IF THIS DIMENSION IS EQUAL TO A MATERIAL

THICKNESS THEN IT IS CALLED AN OFFSET
MATERIAL IS PULLED IN
WHEN FORMING A JOGGLE
2.952"
JOGGLE ADJUSTMENT
PART MEASUREMENT + JOGGLE ADJUSTMENT = BLANK LENGTH
Figure 18
Bending Workbook
Amada School
Flat Pattern Development
Page 60

Flat pattern development consists of several steps. These include calculation of
shear size, location of holes in the flat, determining other features such as
notches, and drawing or sketching the actual flat pattern.
Dimension Points
For bends other than 90 , the dimensions may be to the apex, or the tangent
lines, or the physical inside or outside of the bend. For a 90 bend, the apex
and outside measurements are the same.
Determining Shear Size

This procedure uses the B/D method.
Step 1: Closely check the way your blueprint is dimensioned. Note which
dimensions are to the outside and or inside of the material.
Step 2: Determine Material thickness.
Step 3: Add together all of the OUTSIDE dimensions. (At each dimension called
out to the inside, add one material thickness to get the outside dimension.)
Step 4: Determine IR. (Refer to tooling catalog if needed)
Step 5: Use the B/D charts (pages 48, 49) or one of the formulas (page 50) to
determine the B/D. If more than one bend angle is used, then compute the
B/D for bends of each angle.
Step 6: Add up number of bends for each bend angle.
Step 7: Take number of bends times the B/D.
(if different angles, then number of bends of each angle times the B/D for
that angle, add it all up)
Step 8: Shear Size.= (outside dimension in Step 3 ) - (total from step seven)
Amada School
Bending Workbook
Page 61
Example 1
Step 1: Dimensions check- this drawing
only has a 90 bend, so the apex
and outside dimensions are the
same.
Step 2: Thickness is 0.125
Step 3: Total outside dimensions are
1.000 + 2.000 = 3.000
Step 4: Inside radius = 0.500
Step 5: Computed B/D = 0.387
Step 6: Number of bends = 1
Step 7: Total B/D 1 x 0.387 = 0.387
Shear Size 3.00 - .387 = 2.613
Bending Workbook
Amada School
Page 62
Acute Angle / Apex

In this example, the dimensions are called out to the Apex of the angle (point
A). The B/D method is used.
If your print is dimensioned to the edge of the part (dimensions B) you can
either:
a. Calculate (using Trigonometry) the position of the Apex, and use the B/D
method of Example 1
b. Subtract a material thickness and an inside radius to find the tangent dimension (A), then use bend allowance formula to solve (as in example 3).
When a bend is dimensioned to the tangent points (dimensions A):
Use the bend allowance formula to solve, as in example 3, page 63. For part
measurement, add a material thickness and an inside radius to find the outside
dimension.
Example 2
Step 1: Dimensions check: angle is
dimensioned to apex.
1
Angle is 180 - 70 = 110 degrees.
Step 2: Thickness is .07"
0.070"
A
70
Step 3: Total outside (apex) dimensions

are 2.5 + 3.5 = 6.000
3.50"
Step 4: IR = 1.000
1.00 R
Step 5: B/D = 1.076

(Formula 4, page 51)
Step 6: Number of bends = 1
Step 7: Total B/D 1 x 1.076 = 1.076
B
2.50"
Shear Size 6.000 - 1.076 = 4.924
Note the use of complementary angle here.
Amada School
Bending Workbook
Page 63
Acute Angle / Tangent

Step 1: This part (Example 3) is dimensioned differently than Example 2. Here, the
dimensions are to the tangent lines, not the apex.
Step 2: Add together the lengths of the flat segments. (from the edges of the part to
the tangent lines.)
Step 3: Determine material thickness.
Step 4: Refer to the B/D, B/A chapter, page 50. Using formula 1, calculate the B/A
for the given conditions.
Step 5: Add the results of Step 2 to the B/A (from step 4) = Shear Size.
Example 3
Step 1: Dimensions check : dim to tangent.
Find complementary angle:
180 - 70 = 110 degrees
Step 2: flat length 1.500 + .750 = 2.25
Step 3: material thickness = 0.060
Step 4: B/A 1.491
Step 5: Shear Size 2.25 + 1.491 = 3.741
Bending Workbook
Amada School
Page 64
Features in the Flat

To locate a hole or other feature in the flat, follow these steps:
Step 1: Determine shear size
Step 2: Add OUTSIDE dimensions from edge of part to hole center.
(Where dimensions are called out to the inside, be sure to add material
thickness to arrive at outside dimension.)
Step 3: Using the B/D that you used when developing the shear size, add the
number of bends between the edge of the part and the hole center. Take
B/D times the number of bends.
This assumes all bends of same angle and radius. If angle and radius vary,
use the B/D computed for each bend.
Step 4: Distance of hole from edge = outside dimension (total from step 2 ) - total
B/D from step 3
Example 4
Step 1: (t = 0.056, ir = 0.062, B/D = 0.103)
Shear size 1.647
Step 2: total outside dimension 1.00 + .375 = 1.375
Step 3: B/D x # bends 1 x 0.103 = 0 .103
Step 4: step2 - step3 1.375 - .103 = 1.272
Thickness = 0.056
Amada School
Bending Workbook
Page 65
Sketching the Layout

An easy way to draw a flat layout is to use mold lines. See the following
drawing and explanation
1.440"
t = 0.056
ir = 0.062
B/D = 0.103
B/D
B/D
0.254"
C
B
0.750"
C
0.375"
1.008"
1.000"
Example print
Mold Line Drawing
Using MOLD LINES

The Mold Lines represent the outside lines of the flanges after they are bent.
The distance between each pair of Mold Lines equals one B/D. In the above
example flange A is represented by dimension A on the M/L drawing.
Flange B and C are shown the same way.
Once the M/L are in place, features located anywhere on the blueprint are
easily placed on the M/L drawing.
Each bend line is located midway between the corresponding pair of Mold
Lines. See D above.
A=
B=
C=
Shear Size =
Bending Workbook
Amada School
Page 66
Corner To Corner Notches

When manufacturing a box where a corner-to-corner type construction is
called for, use this formula for calculating the depth of the notch.
Notch Depth = OUTSIDE flange dimension + material thickness - B/D
Relief Hole Diameter = material thickness x 3.
Center relief holes on bend lines.
The part shown on page 78 has relief holes and mold lines.
corner-to-corner notch
50% weld notch
Closed notch
Relieved notch
Notch Types
Amada School
Bending Workbook
Page 67
Basic Layout Exercises

Use Bend Deduction Charts on pages 48, 49
Exercise 1
Solve for the shear size using Drawing 1
Thickness = .056
I.R. = .062
Shear size = __________
0.750
Exercise 2
Solve shear size for drawing 1
using new conditions.
4.000
DRAWING 1
Thickness. = .09
I.R. = .125
Shear size = __________
Exercise 3
Solve shear size for Drawing 2.
Thickness. = .059
I.R. = .094
1.250
Shear size = __________

Exercise 4
Solve shear size for Drawing 2
0.625
Thickness = .048
1.500
I.R. = .047
Shear size = ___________
DRAWING 2
Bending Workbook
Amada School
Page 68
Exercise 5
Use Drawing 3 and solve shear size.
Thickness = .036
I. R. = .031
Shear Size = __________
0.875
Typ.
Exercise 6
Solve shear size for drawing 3 using
new conditions.
0.750
Thickness = .074
1.750
I. R. = .075
Shear Size =__________
DRAWING 3
Exercise 7
Use Drawing 4 and solve for shear size
Thickness = .056
I. R. = .075
Shear Size =__________
Exercise 8
Solve shear size for drawing 4
Thickness = .105
0.500
typ
2.000
I. R. = .203
0.750
Typ.
Shear Size = _________
DRAWING 4
Amada School
Bending Workbook
Class Exercises
Page 72
Class Exercises
Class Exercises
Exercise 9:
For Drawing 5, determine Bend Allowance then solve for shear size.
Mat. = .125
I.R. = .500
Bend Allowance = ________
Shear Size = ________
DRAWING 5
Amada School
Bending Workbook
Class Exercises
Page 73
Exercise 10:
Use Bend Deduction formula to solve for shear size in Drawing 6.
Mat. = .125
I.R. = .5
Bend Allowance = ________
Bend Deduction = ________
DRAWING 6
Bending Workbook
Amada School
Page 74
Class Exercises
Exercise 11:
Solve for shear size and hole location
using Drawing 7.
All dimension called from side A.
Mat. = .04
I.R. = .031
Hole 1 = ________
Hole 2 = ________
0.250 dia.
0.500"
0.187 dia.
0.031 radius
0.750"
A
0.375"
0.750"
1.000"
DRAWING 7
Amada School
Bending Workbook
Class Exercises
Page 75
Exercise 12:
Solve for shear size and hole location for Drawing 8
All Dimension called out from edge A.
Mat. = .059
I.R. = .062
Hole 1 = ________
Hole 2 = ________
Hole 3 = ________
Hole 4 = ________
2.750"
0.250"
1.500"
1.000"
1
0.500"
typ.
0.500"
2 pl.
3
4
2.000"
0.750"
2 pl.
DRAWING 8
Bending Workbook
Amada School
Page 76
Class Exercises
DRAWING 9
Amada School
Bending Workbook
Class Exercises
Page 77
An important part of bending is determining a workable bend sequence.

Find a workable sequence for Drawing 10.
B
C
The letters A - F on the drawing identify the respective bends.
DRAWING 10
Bending Workbook
Amada School
Page 78
Class Exercises
Drawings 11 and 12 show a simple box in the folded and flat conditions. Determine the blank dimensions.
DRAWING 11
Amada School
Bending Workbook
Class Exercises
Page 79
dim to center of
relief hole
dim to center of
relief hole
DRAWING 12
Bending Workbook
Amada School
Page 81
Bending Sequence
Bending Workbook
Amada School
Page 84
Bending Sequence
Bending Profile 1
Bending Sequence
This chapter illustrates
several bend profiles and
shows a possible sequence
to use in bending each
profile.
14.5
18
14.5
H1
H5
H4
18
75
H2
75
In the upper illustration,

the circled numbers
indicate the bend number.
The flanges are labelled
H1, H2 and so forth.
Legend
H3
Bending Sequence
In the lower illustration, the

numbers following the bend
number indicate the flanges
comprising the distance between
the gauge surface and the bend
being made.
The graphics can be displayed on

Amada press brakes equipped
with graphics displays.
5
*4
*3
Amada School
Bending Workbook
Bending Sequence
Page 85
Bending Profile 2
100
(165)
16
H9
H5
H2
H3
43
H4
H6
H8
18
25
H1
H7
13.5
Bending Sequence
1+2+3
1
4+5
2
*9
*5
*8
Bending Workbook
Amada School
Page 86
Bending Sequence
Bending Profile 3
Bending Sequence
Amada School
Bending Workbook
Bending Sequence
Page 87
Bending Profile 4
H1
H6
H2
21.5
17.5
12.5
11.5
H5
H3
H4
43.5
12
Bending Sequence
*6
*5
Bending Workbook
Amada School
Page 88
Bending Sequence
Bending Profile 5
8 mm
25 mm
20 mm
50 mm
Bending Sequence
NOTE: Using this bend

sequence, the second bend
creates a pinch point.
1+2
*4
Amada School
Bending Workbook
Bending Sequence
Page 89
Bending Profile 6
Bending Sequence
Bending Workbook
Amada School
Page 90
Exercise Answers
Exercise Answers
1. Shear size = 4.647
9. Bend Allowance = 1.067
Shear size = 3.192
10. Bend Allowance = 1.067
Bend Deduction = .718
Shear size = 4.657
Hole 1 = .5
Hole 2 = 1.307
Hole 1 = .25
Hole 2 = .892
Hole 3 = 3.794
Hole 4 = 4.436
Box Sizes
Box L = 7.806
Box W = 5.806
Notch Depth = 0.959
Hole Location = 0.951
Amada School
Bending Workbook
2. SAFETY MEASURES
SAFETY MEASURES
OPERATORS MANUAL HFE M2 X41176A
Chapter 2
1/30
Issue 05/2010
On all machines
Risks of pinching or crushing between tools
Risks of plucking or destruction between worksheet and

tools during bending.
Risks of injuries by sudden movements of the worksheet

during bending.
Electric danger
Refer to the operators manual
SAFETY MEASURES
Chapter 2
9/30
Issue 05/2010
2.3. SAFETY PRECAUTIONS

2.3.1. GENERAL POINTS
During machine installation, operation, and maintenance, apply all necessary safety measures,
and the following in particular:
Do not adjust or service the machine until you have read the manual.
All electrical work must be performed by a qualified and authorized electrician to avoid all
equipment damage or physical injury.
Never place your hands between tools for any reason.
Do not modify the control circuits or any component of the machine.
Never use the machine with any of its safety devices removed or disabled.
Do not enter the safety zone or hazardous area protected by safety device.
Inspect the machine daily before starting work, ensuring that:
- All protective devices are in place.
- The free space between the tools is not obstructed.
- The access area for the various devices is clear.
- The floor around the machine is free of grease, oil, and water.
Never wear a tie, scarf, or loose clothing when adjusting or operating a press brake.
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2.6. PERSONAL PROTECTIVE EQUIPMENTS (PPE)

The so-called Personal Protective Equipments (PPE) are not included in Amada supplies.
You will find below as informative examples the type of Personal Protective Equipments
possibly required on our machines:
gloves,
helmets,
ear guards,
goggles,
safety shoes,
etc.
the user of these so-called PPE should check that they fully comply with the European
directive.
The employer is obliged to:
supply the appropriate PPE,

ensure that the appropriate PPE are selected with regards to the risks involved,
ensure that the employee is using them efficiently,
ensure their compliance with the regulation,
inform people who are responsible for the implementation (work shop manager,
foremen, etc.),
ensure the PPE are in perfect working condition and periodic maintenance is
carried out,
inform users which potential risks are protected by the use of PPE,
train and lead users in the regular use of PPE.
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Figure 2.12
Figure 2.13
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2.7. RULES FOR SAFE OPERATION

Release the part to be bent as soon as it is gripped between tools (Fig. 2.12).
Install or remove the tools in full compliance with the procedure described in the
Operators Manual ( 7.5) and/or the recommendations specific to your tooling. (Fig.
2.13).
To avoid damage to your tooling or any accident, Amada urge you to

follow strictly the procedure below :
Every time you change a program, select adjustment mode and

mute stop.
Carryout a dry cycle
Check visually that all parameters correspond to the tooling
mounted on the machine, the mute point is 6 mm above sheet
pinch point and the end of bend is correct.
Switch to normal cycle.
CAUTION: Handling devices for heavy parts are not included in the
Amada supplies.
They must be installed for risk-free use in accordance with ergonomic
principles.
SAFETY MEASURES
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Figure 2.14
Figure 2.15
Figure 2.16
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Never attempt to support the end of the worksheet by holding it on either

side of the tools. Only install the tool length required for the current job
on the machine (Fig. 2.14).
Never place your hand between the worksheet and the backgauge during
operation (Fig. 2.15).
Never place your part against/over the backgauge finger before backgauge
is positioned on programmed position.
No part of your body must enter the hazardous area during bending
operations (Fig. 2.16).
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Figure 2.17
Figure 2.18
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Beware of sudden movements of the worksheet during bending (Fig.

2.17).
Observe the allowable tool load (Fig. 2.18 and 7.5).

Par example :
- 1,2 T/cm for standard punches, except:
- 1,5 T/cm for heavy punches
- 0,5 T/cm for punches with extra thin blades
(1 T = 10 kN)
The specific value for each tool type is shown in the special Tooling
catalogue (AMADA or equivalent).
SAFETY MEASURES
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Figure 2.19
Figure 2.20
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The dutch bending or hemming tool should be firmly secured to the lower
beam (Fig. 2.19).
This type of tooling shouldnt be used on High Speed press brakes i.e.
where working speed can reach 20 mm/s.
Never hold the sheet by its folded edge; hold it from the sides
(Fig. 2.20).
SAFETY MEASURES
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Manual de Teoria Amada Press Brake

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An included angle tighter (less than) than 90 degrees. (The

A bend determined by one line of force against two lines of

The imaginary point where the two sides of an angle, if extended,

The load bearing surface of the lower beam.

Amount deducted from overall size to determine shear

Line on work piece where punch contacts material.

Curvature of material at the bend, expressed as distance from the

Process of bending by applying large amounts of force to cause

The concave, or female tool. Normally mounted on the bed, or on

Punch holders on Amada style machine. Used to adjust for

The portion of sheetmetal that has been formed up or down to

Version 1.4d, April 2002

A bend where the sheetmetal is folded over on top of itself. This

Angle formed around the punch.

Distance from the inside surface of the material at a bend to the

Machine driven by fluid power provided by hydraulic pump.

Line through the material that remains at constant length when

An included angle of greater than 90 degrees. (The sheet metal

Machine designed to form metal parts using punch and die.

The convex (male) tool. Normally mounted to the upper beam.

Beam that moves to supply bending force, can be upper or lower.

Amount of material deducted from flange length to place bend

Dimension of blank piece before bending.

Tendency of material to return to flat condition after forming.

The point where a line meets a radius.

Measurement of resistance (in pounds/square inch or similar

Upper part of machine that holds tooling and supplies bending

Measurement of resistance (in pounds/square inch or similar

Version 1.4d, April 2002

The Basics of Brake Bending

The Basics of Brake Bending

Version 1.4d, April 2002

The Basics of Brake Bending

Version 1.4d, April 2002

Version 1.4d, April 2002

Version 1.4d, April 2002

Version 1.4d, April 2002

Standard gauges of sheet metal

Version 1.4d, April 2002

Specifications of selected Materials

Version 1.4d, April 2002

Hastelloy-X Co 1.5 Fe 18.5 Cr 22.0

Sand cast (anneal.)

C .08 Cr 19.5 Mo 4.3

Application: Weatherstripping, spun pieces.

Cd .35 Pb .08 Zn bal.

Version 1.4d, April 2002

Version 1.4d, April 2002

Version 1.4d, April 2002

Version 1.4d, April 2002

Easy to work with, warps easily.

Usually quite flat but doesnt form well. (cracks)

Hardness may be designated by T and a number, 0~8

Version 1.4d, April 2002

Stresses and springback

The amount of spring back is determined by the amount of material

INNER ZONE PLASTICALLY

Version 1.4d, April 2002

Overcoming Spring back

Version 1.4d, April 2002

Version 1.4d, April 2002

Version 1.4d, April 2002