BEST PRACTICES FOR SHEET-METAL PART DESIGN

Prepared By: Mahammad rafi Bagawan

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Material selection When selecting material for your design, try to choose the most efficient and common type and thickness of material. If possible, try to select similar material being used in other areas of project. Thicknesses to .188 and above usually are considered plate. Is it Structural or Non-Structural? This determines what material should be used. Customer requirements. Analyze function of the part. The part function may effect the: material choice, surface finish. Here are the most common types used in SPG: Aluminum sheet: 6061 T6 Stainless Steel sheet: 301 , or Full hard Steel sheet: 4130 N

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Design of sheet metal Internal Features:

Cutting out the features of a sheet-metal part can be generated several ways besides with a CNC punch press. Laser or Plasma cutters are often used. When a design can be improved by adding a shape that would be best made by a laser cutter, it should be considered. Keeping designs as simple as possible will help keep costs to a minimum. Thru Holes: Per FAA requirements the edge of a hole/slot described above can not be closer than two times its diameter, plus 0.030 from hole center to an edge. On rare occasions this is not feasible. In this case testing will approve design.

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The diameter of hole needs to be 1.5 times thickness of the material or larger to be punched and it is 1.0 times material thickness for laser cut parts. If a smaller hole is needed, an additional process to drill hole will be required, avoid this when ever possible

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Material = .134 Thick .134 x 1.5 = .201 .201 is the minimum diameter we can punch. So, these .125 diameter holes would need to be drilled.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Holes for Rivets: Rivet holes need to be 2 times there diameter away from edges or other features with the exception of nut plates. Model Rivet Holes to the Following Common Punch Sizes: Rivet Diameter 3/32 1/8 5/32 3/16 1/4 Hole Diameter Range .097 - .100 .129 - .133 .160 - .164 .192 - .196 .257 - .261 Common Punch Size .097 .132 .162 .194 .259

Tapped Holes: The use of tapped threads in sheet-metal parts is discouraged and would need engineering manager approval. The most common solution is the use of riveted on Nut Plates to get enough thread engagement.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Slots: The use of slots can be beneficial in some circumstances.

Keep width to a standard thru hole size, length is not as critical as several increments can be made by a punch to achieve required length.

Slots:
.130 X .320 .200 X .320 .281 X 1.531 .370 X .840 .131 X .171 .202 X .390 .250 X 1.000 .384 X 1.354 .156 X .500 .213 X .500 .321 X .962 .427 X .820 .188 X .500 .218 X .500 .321 X 1.024 .446 X .840

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Standard Winston Manufacturing Punch Sizes SQUARES .250 .270 .625 .750 .500 sq with .125 corner radii 1.00 sq with .250 corner radii

.375 1.00

.500 2.00

RECTANGLES:
.062 X .500 .125 X.250 .250 X 2.000 .070 X .250 .125 X 1.00 .500 X 1.600 .093 X .250 .250 X 1.00 1.49 X 2.640

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Lightening Features: Keep a .25 distance away from other features and edges. A lesser amount of larger cutouts is usually better that a greater quantity of smaller ones. Be aware of the integrity of the part when placing them.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Countersunk Holes: 1. 2. 3. 4. 5. Use Standard Counter Sunk sizes. Verify the countersink angle matches the angle of the fastener. Primary hole may enlarge due to thin material and countersink angle. Model & Dimension what is expected. Counter Sunk: 60, 82, 90, 100 and 120 Degrees

Sheet-metal part Machined part may need to match the countersink of the part above. Model what is needed/expected.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Pockets & Profiles: Internal Features: Keep internal features, holes, pockets and cut-outs a minimum of 1.5 times material thickness from each other and part edges. Note: This only applies if it is NOT a Structural Fastener Feature!!

Similar Features: When designing keep features similar wherever possible. Meaning try to keep holes, radii and slots consistent if possible. This will save tool change operations.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

AVAILABLE B/E PUNCHES

ROUNDS
Fastener Size #0 (.060) #1 (.073) #2 (.086) #3 (.099) #4 (.112) #5 (.125) #6 (.138) #8 (.164) #10 (.190) 0.250 0.321 0.375 0.437 0.500 0.625 0.750 0.875 1.000 1.125 1.250 1.375 1.500 Model Hole To: 0.078 0.093 0.105 0.116 0.132 0.162 0.173 0.203 0.221 0.281 0.344 0.406 0.469 0.563 0.688 0.813 0.938 1.094 1.218 1.344 1.500 1.625 Free Fit Range .078-.082 .089-.095 .102-.108 .116-.122 .128-.135 .156-.163 .170-.177 .196-.203 .221-.228 .281-.290 .344-.354 .406-.416 .469-.479 .562-.572 .688-.698 .812-.824 .938-.950 1.094-1.105 1.219-1.235 1.344-1.360 1.500-1.516 1.625-1.641 Model Hole To: 0.070 0.083 0.097 0.109 0.125 0.144 0.156 0.183 0.210 0.270 0.328 0.391 0.453 0.531 0.656 0.781 0.906 1.031 1.156 1.281 1.438 1.562 Close Fit Range .067-.071 .081-.085 .094-.098 .106-.110 .120-.124 .141-.146 .154-.159 .180-.185 .206-.211 .266-.272 .328-.334 .391-.397 .453-.460 .531-.538 .656-.663 .781-.789 .906-.914 1.031-1.039 1.156-1.164 1.281-1.291 1.438-1.448 1.562-1.572

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Forming Sheet-metal
Air Bending is the most common forming operation. Air Bending is defined as: Forming process to bend metal with a Brake press. The process is done with the punch touching the work piece and the work piece not bottoming in the lower cavity, or bottom die.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Standard Acceptable Bend Radii:

Once material and thickness has been selected reference Bend Radii chart to see minimum bend radius for your choice. You can select a larger common radius, but not a smaller one unless manufacturing approves. Once bend radius has been selected use this radius for all bends in part unless absolutely necessary. Additional radii will require additional set-ups which will increase cost of the part. Select radii from chart. Do not deviate from this unless management and/or manufacturing approval is obtained. Keep radii to standard sizes

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Acceptable Bend Radii

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Stepped radii:
Stepped radii can be done for radii over 0.75 but are very costly to produce in volume. See Figure below for an illustration of stepped radii in a part.

Avoid radii over .75 if possible. Bends like the one above are made by Stepping (slightly bending part at several locations to achieve required radii) or custom tool is needed. This process is time consuming or expensive but may be necessary.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Internal features can be placed up to tangent line of bend radius with minimal deformation. If this is acceptable note on drawing that deformation is acceptable in this area. If a fastener is going to be installed thru hole close to the bend consider the head of fastener, washer or bolt will not go into the radius.
Features may be designed up to tangent line but consider if fasteners are going to be put into them. Minimal bulging may be present.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Minimum Flange Length: There are limits to how small a flange can be without additional operations. If it needs to be smaller than noted in table it will be formed longer and require an additional operation to cut it down to size. Refer to Minimum flange length charts for your material. Flange dimensions are to outside. In this case .30.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Minimum Flange Lengths

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Whenever possible keep bends parallel with flange edge. That makes forming easier since they form off of the brake press back stop; if not parallel a scribe line or fixture is needed adding cost.

Flange edge & Bend line are not parallel.

Flange edge & Bend line are not parallel.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Chamfer Rule
Chamfer on flanges should be designed as shown. See Figure below If they go closer to bend the will bulge out because of tooling restraints. If bulging is acceptable, note on drawing.

Bringing a chamfer below the 2R+T rule will cause this area to bulge out.

SLIGHT BULGING ACCEPTABLE IN THIS AREA

Refer to Bend Radii charts for correct bend radius for your material selection.

2R + T

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Boxed corners Boxed corners: If two flanges, 90 apart from each other are needed then you may need a bend relief. The main function of a bend relief is to reduce cracking in corners. Make relief to common size punch. Dimension as a reference dimension in case manufacturing wants to change size.

Select bend relief radii large enough to cross all bend lines and keep to common size punch diameter.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Rules of Thumb
Keep holes and pockets a minimum 1.5 X Material thickness away from edges. Reference bend radii charts to select correct radii for material type. Reference chart for minimum flange lengths. Hole/pocket can be made up to tangent line of bend radii but consider fastener head, washer or minimum deformation. Punch / Laser diameter needs to be greater than 1.5 X part thickness to punch / laser. If less than this, the hole will need to be drilled. Avoid tapped holes in sheet-metal. Critical dimensions needed for profile, feature location, and bend radii. Keep bends parallel to edges of part. Model features with standard tooling, i.e. holes, slots, and cutouts. When designing countersunk holes, model/dimension what is expected.

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Sheet metal Manufacturing Process followed in SPG-WS

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Step 1: Raw material to overall size

CNC Turret head

Step 2: Fix the raw material in CNC Punch press CNC punch die arrangement

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Step 3: They will take out flat pattern

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Step 4: They will remove all sharp corners and burrs from flat pattern in deburring station. Burrs

DEBURRING STATION
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Back stoppers
Step 5: Air Bending CNC press machine is used for Forming Operations.

Air Bending Brake Press Dies

CNC punch press

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

Operation being done

Different Kinds of Brake Press Dies

Measuring flange length and angle value

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,

e-mug Technologies Pvt. Ltd, Aerospace Division - DEDC for B/E Aerospace Inc.,