Sometimes, a flat sheet of metal will need to be bent into a different shape to form the necessary part. This is sheet metal folding, a vital part of sheet metal fabrication.

Planning a sheet metal fold

First, the folding needs to be planned, often by experts such as those at https://dkmsheetmetal.co.uk/. A design is created, with the correct shape and measurements, to ensure the metal will serve its intended purpose, such as a bracket or cover, effectively. You may also need to think about other sheet metal fabrication processes.

Predicting and solving issues

Software can be used to predict the different phases of the fold, allowing potential issues to be identified. For instance, if the part is too small or too heavy for the machine, or if the metal and the tools are going to collide. Ways to mitigate these problems include part bending, where the metal is only partially folded, then rehit, or overbending, where the part is folded more than necessary, then flattened. Other possibilities include splitting the metal into two and welding it back together, or reconfiguring the tools.

Choosing your tools

Generally, you want a configuration of dies and punches that will allow the lowest tonnage and degree of deformation. They will need to be adapted to the specifics of the project. Common dies include the V die and the Dutch folding die.

If you have a metal part that needs to be bent, understanding sheet metal folding is essential to ensure you can pick the right tools and resolve any issues for your final product.