How and When to Add Bend Reliefs to Sheet Metal Parts

To visualize the importance of bend reliefs, try folding the middle inch of a piece of paper to create a flap—it won't work smoothly because the rest of the paper wants to fold too. Similarly, when working with sheet metal, bending without a relief causes stretching, pulling material from adjacent areas, resulting in unsightly deformation and tearing. A bend relief is a simple solution to this issue.

What is a Bend Relief?

A bend relief involves making two small incisions in sheet metal to free the metal between them, allowing controlled folding. It's necessary when there is material on both sides of a bend. Features like holes or cutouts can act as a relief but should be positioned at least 2-3 times the material thickness away from the bend region to avoid unintended reliefs.

When to Use Bend Reliefs

Bend reliefs prevent tears during transitions between bends or between a bend and a flat surface. They ensure a clean part free from deformation, burrs, and sharp points, especially crucial for parts subject to vibration or flexion. Round reliefs further reduce tear and crack propagation, contributing to a stronger, more stable, and attractive part.

Advantages of Bend Reliefs

Incorporating a bend relief:

1. Prevents Tears and Deformation:

   • Reduces tearing caused by a press brake, resulting in a safer, easier-to-manufacture, and more durable part.

2. Separates Bent and Unbent Elements:

   • Isolates the bent portion, enhancing durability and aesthetics.

3. Ensures Forming Accuracy:

   • Provides flexibility for tool placement, making the press brake operator's job easier, safer, and more accurate, leading to cost savings, especially in higher volume production.

How to Add Bend Reliefs in Designs

Many designs lack bend relief, but adding them is simple and can save time and money. Include a cutout at least 0.030 in. (0.762mm) wide and extending at least 0.015 in. (0.381mm) beyond the bend radius on both sides of the desired bent area. For a 90-degree bend, the equation for the bend relief is Material Thickness + Bend Radius = Bend Relief, or, 0.10 in (2.54mm) + 0.030 in. (0.762mm) = 0.13 in. (3.302mm). Check the illustration for guidance.

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