Content

• Steps
• Part 1 of 3: Prepare to Bend Sheet Metal in a Vise
• Part 2 of 3: Bend Sheet Metal in a Vise
• Part 3 of 3: How to Troubleshoot Potential Problems
• Tips
• Warnings
• What do you need

Most often, expensive sheet bending machines are used to bend metal sheets, but you can also perform this operation without such devices. You can bend sheet metal by hand if it is small and thin enough to work with. Learn how to bend sheet metal to do a variety of jobs without using a bending machine.

Steps

Part 1 of 3: Prepare to Bend Sheet Metal in a Vise

1. 1 Get everything you need ready. The right tools will help you get the job done quickly and easily. To bend sheet metal using a vise and hammer, you will need the following:
   • 2 wooden or metal mold blocks;
   • a block of hardwood and a sturdy sledgehammer or hammer (optional);
   • bending calculator or online calculator;
   • marker;
   • protractor;
   • rubber, plastic or leather hammer;
   • ruler or measuring tape;
   • sheet metal;
   • vice.
2. 2 Measure the thickness of the sheet metal. This can be done with a ruler or tape measure. The thickness must be known in order to calculate the bending tolerance.
   • If the sheet metal is too thick, you may need special equipment, such as a bending machine or blowtorch, to obtain the desired bend.
3. 3 Calculate the bending tolerance. As a result of bending, the sheet deforms and becomes larger. To calculate how much the sheet will elongate on the outside of the bend, you need the bend tolerance. The bending tolerance can be calculated using the following formula: (π / 180) x B x (IR + K x MT) = bending tolerance (BA), where B is the angle associated with the bending angle (i.e. complementary to 180 degrees), MT - material thickness, IR - inner radius, K - K-factor.
   • You can use the Bend Tolerance Calculator (in English) to determine the decimal values ​​for the K factor, inside radius, and material thickness.
   • For example, if you want to bend a sheet of standard 24 (0.64 millimeters thick) 90 °, the calculation will give the following bending tolerance: 0.017453 x 90 x (0.020 + 0.33 x 0.024) = 0.0438558984 in = 1, 11 mm.
   • Please note that metals have different ductility. Excessive bending of brittle metal can lead to cracking and fracture.
4. 4 Mark the bending lines. After calculating the bend tolerance, take a protractor and a marker and draw a clear line through the point where you will bend the metal sheet. Then, based on the calculated bend tolerance, draw a second line midway between the bend lines (bend radius). The distance between the bending lines will increase as the sheet bends.
5. 5 Cut the sheet to the desired size. It is recommended to leave a little (about 6 millimeters) excess material around the edges. Be sure to file and smooth the edges as burrs and cracks around the edges can cause the entire sheet to crack.

Part 2 of 3: Bend Sheet Metal in a Vise

1. 1 Place the mold blocks in a vise. The corners of these blocks should correspond to the angle to which you want to bend the sheet. Position the blocks in the vise so that this corner protrudes from the top of the vise.
   • Typically, one of the molding blocks has a rounded corner, the radius of which corresponds to the radius of the bend, which allows you to obtain the desired bend.
2. 2 Clamp a sheet of metal in a vise. Having placed the molding blocks in a vice, it is necessary to securely clamp the metal sheet between them. Make sure that the curvature line coincides with the edges of the blocks.
3. 3 Support the overhanging edge of the sheet. If the edge of the sheet protrudes far from the vise, secure it so that it does not wobble, as this can adversely affect the bending.
   • Consider asking a friend or colleague to hold back the overhanging edge of the paper. Be sure to wear gloves to avoid cutting yourself.
4. 4 Bend the metal with a hammer. In order not to damage the sheet of metal and to avoid ugly dents, it is better to gently knock on it with a rubber, wooden or leather hammer. Knock on the sheet until it bends against the forming block and gets the smooth curve you want.
   • Begin tapping on one side of the forming bend. Gradually move along the bend line back and forth until the sheet bends to the angle you want.

Part 3 of 3: How to Troubleshoot Potential Problems

1. 1 Check to see if you took the material thickness into account when calculating the bending allowance. The name of this value can be misleading.It meets the standard for sheet thickness and must be entered as a decimal.
2. 2 Check the bend angle again. It is possible that when calculating the bend tolerance, you made a mistake with the angle. If you want to bend the material at an angle less or more than 90 °, you must substitute in the formula conjugate him a corner.
   • For example, if you want to bend a sheet 45 °, subtract this value from 180 ° and substitute an angle of 135 ° into the formula.
3. 3 Adjust the vise. When bending sheet metal, considerable effort must be made to it. If you do not grip the sheet enough in a vice or do not properly secure them on the table, the metal may slip out or bend not the way you wanted.
4. 4 If the metal does not bend well, try heating it. In this case, you should be extremely careful. If you want to bend a thick sheet, you can heat it along the bend line with a blowtorch to make it deform more easily.
   • Please note that many industrial metals have very high melting points and careless use of a blowtorch can damage sheet metal or your tools.

Tips

• To correct or improve an uneven bend, attach a block of hardwood to the bend and tap the bend line with increasing force with a strong sledgehammer or hammer.
• In some cases, such as bending thick metal sheets, you may need a plate bending machine. There are fairly inexpensive plate bending machines on the market for homework or small businesses. At the same time, computer controlled hydraulic plate bending machines are very expensive and are designed for large factories and industrial works.

Warnings

• Check if you have calculated the bend tolerance correctly before starting work. If you make a mistake in the calculations, the bend will turn out to be incorrect and the sheet may collapse.

What do you need

• Two blocks of wood or metal.
• A block of hardwood and a sturdy sledgehammer or hammer (optional).
• Calculator or online calculator for calculating bending.
• Marker.
• Protractor.
• Rubber, plastic or leather hammer.
• Ruler or measuring tape.
• Sheet metal.
• Vise.