Most of the time, sheet metal bending tools, called brakes, are used, but you can also do it without one.If the piece of sheet metal is small and thin, it is easy to bend it by hand.If you learn how to bend sheet metal, you will be able to complete home and hobby projects with ease.
Step 1: You should gather your materials.
The process will go smoothly if the right tools are on hand.To bend your sheet metal with a vise and hammer, you will need: 2 wooden or metal form blocks Block of hardwood and heavy-duty hammer or mallet
Step 2: Determine the thickness of your sheet.
The thickness of your sheet metal can be measured with a tape measure or ruler.This measurement is needed to calculate your bend allowance.Special machinery, like a brake or a torch, can be used to bend your sheet into a desired shape if it's too thick.
Step 3: Determine your bend allowance.
The bending will warp the metal so that it is bigger.You will need to know your bend allowance to calculate the expansion that will take place on the outside.You can find your bend allowance by using the following formula: (/180) x B x (IR + K x MT), where B is the angle that is closest to your desired bend angle (1 to 180 degrees).If you want to know your K-Factor, inside radius, and material thickness, you should use a chart.If you want to bend 24 gauge sheet metal at a 90 angle, the calculation would be: 0.017453 x 90 x (0.020 + 0.25 x 0.024)If you bend a brittle metal beyond its limits, it could break.
Step 4: You should mark your bend lines.
Take your protractor and draw a line with your marker across the point at which you will bend your sheet metal now that you know your bend allowance.The second bend line is the intervening distance between your bend lines.With the application of your bend, the space between your lines will expand.
Step 5: You should cut your sheet to size.
It's a good idea to leave a little trim on your sheet.Cracks in your metal can be caused by nicks and rough edges, so be sure to file and smooth your sheet.
Step 6: Put your forms in a vise.
Your forms should match the angle of your bend.Put your forms in the vise with the form block guide angle facing upwards.The rounded edge of your form will help you achieve your desired bend.
Step 7: Attach the sheet metal to your vise.
You should put your sheet between your form blocks now.Keep your bend line even with the guide angle of your forms.
Step 8: Support your sheet metal.
If you have sheet metal hanging outside of your form blocks, you need to support it so that it doesn't bounce wildly and negatively impact your bend.A colleague or friend might be able to fix this piece with their hand.Gloves should be worn to prevent accidental cuts.
Step 9: Use your mallet to bend the metal.
It's best to use a rubber, plastic, or rawhide mallet to gently tap the metal to prevent damage.You can achieve your desired angle gradually and evenly by bending it toward the form block.The beginning of your tapping should be at the end of the bend.Slowly work between your bend lines until the sheet metal is bent to the desired angle.
Step 10: Determine the thickness of your bend allowance calculation.
The value is not actually named.If you want your calculation to be correct, you need to use the standard gauge thickness as a reference.
Step 11: Make sure you check your bend angle.
If your bend allowance calculation seems off, it's likely that you made a mistake.If you want to bend at an angle less than 90, you need to take the opposite angle to your desired bend.If you subtract 45 from 180, you get a bend angle of 135.
Step 12: Make sure your vise is adjusted.
There will be significant pressure applied to bend your sheet metal.If you don't have a vise up to the challenge, your forms may slip, or you may bend your sheet metal in a way that is not intended.
Step 13: For difficult bends, apply heat.
This should be done with care and extreme caution.If you want to bend a thick piece of sheet metal, you can use a blowtorch along the seam of your bend line.Many kinds of fabricated metal have high melting points, and applying your torch injudiciously could cause damage to your sheet metal or equipment.