Aspects Of Metal Developed Bend Length Page 1 of 12

William Greco w2gre@verizon.net- Warrington,Pa.

2404 Greensward N. , Warrington, Pa. 18976
September 23, 2010

Executive Summary
The purpose of this report is to provide a mathematical treatise concerning developed
bend length equations. The equations have been rearranged to solve for inside bend
radius, metal thickness and bend area neutral axis. Although the equation for bend
developed length is available in many texts, worked equations for required bend
radius, metal thickness and bend area neutral axis variables are not to be found in
any publications.

Main
All metal bending is characterized by material stressed beyond the elastic limit.
Tension occurs along the outside of the bend and compression along the inside of
the bend. The neutral axis actually moves toward the compression or inside of the bend.

Fig. 1 Metal Flow and Distortion

The width of most bending processes is usually much greater than the thickness
of the metal being formed. The greater width resists plastic flow due to compressive
forces. Compressive stress causes additional tension on the opposite side of the bend.
The increased tensile stress results in thinning of the sheet metal at the bend (see Fig.1.)
In most cases the neutral axis will move between 0.5 and 0.3 times the thickness of the
material as measured from the inside of the bend. For most calculations the neutral axis
is taken as 0.4, however 0.4 is not always an accurate assumption.
Empirically established bend lengths have been experimented with by various small
metal fabricators who consider their data proprietary. A Statistically curve fitted
equation could be developed using various bend lengths and radii. Assuming that an
equation with a correlation coefficient above 0.98 can be established the calculations
would improve developed length accuracy.
 Aspects Of Metal Developed Bend Length Page 2 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Equation-1 was found on page 61 of “Techniques Of Pressworking Sheet Metal”

By Donald F. Early and Edward A. Reed published by Prentice Hall 1958.

A
L  2 R  0.4t  equation-1
360
where:
L  Length of bend
A  Angle of Bend (the angle through which metal is bent)
t  metal thickness

Fig. 2 Developed Length Diagram

If the radius (R) was required for a known developed length, material
thickness and radius through which the metal is bent, then equation-1 would be
rearranged as follows:

A
L  2 R  0.4t 
360
cancel common factors by dividing by 2
A
 2 R  0.4t 
A
L  360   R  0.4t 
2 180
 Aspects Of Metal Developed Bend Length Page 3 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Rearrangement to find Radius continued:

multiply A by  :
A  A R  0.4t 
L  R  0.4t  
180 180

multiply both sides by 180:

 A R  0.4t 
L 180  
180
180  180L   A R  0.4t 

Divide each side by  A

180L  A R  0.4t  180L
   R  0.4t 
A A A

move all terms not containing R to the right hand side

180L 0.4 t A  180L
 R  0.4t   R 
A A
0.4 t A  180L
R equation-2
A

Example-1:

As a check for equation-2 the following bend will be calculated first using equation-1:
Metal thickness = 0.06” (t)
Radius of bend = 0.5” (R)
Bend Angle = 900 (A)
L = Developed length of bend

A
L  2 R  0.4t  equation-1
360
90
L
360
 
 2 0.5  0.4 0.06   0.823"

Check for equation-2 :

0.4 t A  180L
R equation-2
A
0.4 t 90  180 0.823
R  0.5
 90
 Aspects Of Metal Developed Bend Length Page 4 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Some other mathematical forms were worked out for calculating required bend radius
assuming neutral axis to be 0.4 are:

2 450 L  A  t 
R equation-2a
5A

and a form of radian measure to eliminate pi:

R  57.296
L  0.006981 A t  equation-2b
A

Note: 57.2960 is equivalent to 1 radian.

Checks for equation-2a and 2b using example-1 variables:

2 450 0.823  90  0.06 

R  0.5 by equation-2a
5 90  

R  57.296
0.823  0.006981 90 0.06   0.5 by equation-2b
90

Considering the fact that varying metal thickness, types of metal, and different
bend radius are normally involved it is more meaningful to take the neutral axis
as a variable (N). Modifying the original equation-1 to introduce 0.4 as the N variable:

A
L  2 R  N t  equation-1a
360
where:
N  Neutral Axis

Solving for N:
A
L  2 R  N t 
360

cancel common factors of 2

A 2 A
L
360

2
R  N t  
180
 R  N t 

2
 Aspects Of Metal Developed Bend Length Page 5 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Rearrangement to solve for (N) neutral radius continued:

multiply the right hand side:

A A  t N +R 
L  R  N t  
180 180

multiply both sides by 180:

A  t N +R 
L 180  180  A  t N +R 
180

Divide both sides by A 

L 180 A 
 t N +R   t N +R 
A A

Subtract R from both sides:

L 180
 R
A

 tN  R  R 
Reverse sides:
L 180
tN R
A

Divide both sides by t:

L 180
R
t N A

t t
simplify:
 A R  180 L
N equation-3
 tA

Check of equation-3 by using example-1 variables (found on page 3 of this report):

 90 0.5  180 0.823

N  0.40
 0.06  90

Another form of this equation is:

 1 
L A  R
180
N  180   equation-3a
A
 Aspects Of Metal Developed Bend Length Page 6 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Use of equation-3 or 3a in concert with empirical data can yield the exact
location of the neutral axis on any bend.

Substituting N for equation-1’s 0.4 neutral axis and solving for R the following
equation can also be used:
 1 
L A  N t
180
R  equation-2c
A

Rearranging equation-1a from page 4 to solve for t, required metal thickness to satisfy
known values of Bend Radius R, Developed length of bend L and Angle A through which
bend occurs :
 A R  180 L
t equation-4
 AN

Another equation form to solve for t is:

 1 
L A  R
180
t  180   equation-4a
A

Graphs- Graphs could be developed for each material and neutral axis condition.
1

0.9

0.8

0.7
Bend Radius

0.6

0.5

0.4

0.3

0.2
0.4 0.55 0.7 0.85 1 1.15 1.3 1.45 1.6
Developed Length
trace 1

Graph -1 Bend Radius and Developed Length

Assuming Neutral axis as 0.4 with 90 degree bend for .06” material thickness
 Aspects Of Metal Developed Bend Length Page 7 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

1.75

1.5

1.25
Bend Radius

0.75

0.5

0.25

0
0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5
Developed Length
trace 1
Graph -2 Bend Radius and Developed Length
Assuming Neutral axis as 0.4 with 90 degree bend for 0.125” material thickness

2.5

2
Bend Radius

1.5

0.5

0
0.5 0.875 1.25 1.625 2 2.375 2.75 3.125 3.5
Developed Length
trace 1
Graph -3 Bend Radius and Developed Length
Assuming Neutral axis as 0.4 with 90 degree bend for 0.1875” material thickness
 Aspects Of Metal Developed Bend Length Page 8 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Tabulation Table -1 Bend Radius and Developed Length

Assuming Neutral axis as 0.4 with 90 degree bend for 0.1875” material thickness

Developed Bend
Length Radius

Tabulation tables are available in many texts however using empirical data and
developing curve fitted equations tailored to specific company operations could
afford excellent accuracy and speed developed length calculations.
The table above is given as an example but is developed from the original
Equation-1a found in texts.

Rate Change Derivatives

Finding the derivatives of various developed length variables is not very useful
because all bend radius equations are linear and not exponential.
The derivative (rate of change) of the bend angle with respect to radius from equation-1
is given on page-9 to illustrate this obvious point.
 Aspects Of Metal Developed Bend Length Page 9 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Rate Change Derivatives (continued from page 8)

A
L  2 R  0.4t  equation-1
360
A
 2 R  0.4t 
360
multiply A by 2 to get 2 A and cancel the common factors:
2  A R  0.4 t 
360 180  A R  0.4 t 

2 180
d  A R  0.4 t 
dR 180
chain rule of a composite function find the derivatives of each portion
of the function

d  Au d
R  0.4 t
du 180 dR

multiply the base u by the exponent 1 subtract 1 from the exponent 1  1  0 

since the exponent is now 0, u is eliminated
d  Au 1 A A
 
du 180 180 180

multiply the base R by the exponent 1 subtract 1 from the exponent 1  1  0 

since the exponent is now 0, R is eliminated from the term
d d
R  0.4t  1  0.4t
dR dR

d
add 0 to 1 to get 1 and R  0.4t  1
dR
A A
form the derivative 1 
180 180

d  A R  0.4 t   A

dR 180 180
 Aspects Of Metal Developed Bend Length Page 10 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Rate Change Derivatives (continued from page 9)

Table indicating rate of change of developed length from 80 to 90

with respect to radius
d  A R  0.4 t   A

dR 180 180

Rate of
Change
Of developed
Length Angle of Bend

The rate of change from 810 to 800 = 1.414 to 1.396 = - .018

The rate of change from 900 to 890 = 1.571 to 1.553 = - .018

Considering developed length as y and angle of bend as x the points

(80,1.396) and (90,1.571) could be used to determine the slope of the line.

y2  y1
m 
x2  x1
1.571  1.396
m slope    0.018
90  80
Aspects Of Metal Developed Bend Length Page 11 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Additional References for Calculating Developed Length of Bends

“Machinery’s Handbook 17th Edition” Copyright 1964 page 1615 indicates

the following equation for cold rolled and spring steel =

  A 
L   0.71t  1.57R    equation-5
  90  
where:
L  Length of bend
A  Angle of Bend (the angle through which metal is bent)
t  metal thickness
R  Bend Radius

Check of equation-5 versus equation 1.

  90  
L   0.710.06   1.57 0.5    0.828
  90  
90
L
360
 
 2 0.5  0.4 0.06   0.823

“Mechanical Details For Product Design” by Douglas C. Greenwood, McGraw-Hill 1964

Page-4 gives developed length as:
Sharp Corners up to a bend radius equal to the material thickness:

 t
L  0.0175  R   A  equation-6
 3
And any radius greater than twice the thickness as:
 t
L  0.0175  R   A  equation-6a
 2
Check of equation 6a compared to 5 and 1.
 0.06 
L  0.0175  0.5   90   0.835
 2 
“Mechanical Details For Product Design” also gives equations for developed length
of double bends on page 4 and (3) pages of developed length charts on pages 5 through 7.
 Aspects Of Metal Developed Bend Length Page 12 of 12
William Greco w2gre@verizon.net- Warrington,Pa.
September 23, 2010

Additional References for Calculating Developed Length of Bends (continued)

Also note that “Marks’ Standard Handbook For Mechanical Engineers” 7th Edition
McGraw-Hill Copyright 1967 page 13-27 uses equation-1.

“Manufacturing Processes and Materials For Engineers” 2nd Edition By Doyle, Keyser,
Leach, Schrader, and Singer McGraw-Hill Copyright 1969 page 280 also
references equation-1,

“Machine Design Calculations Reference Guide” by Tyler G. Hicks

McGraw-Hill Copyright 1987 page-174 includes information regarding
Critical minimum Bend Radius.

Conclusion:
As stated earlier a statistically curve fitted equation may be developed using various
empirical test data referring to bend lengths, bend radii and material thicknesses.

References and associated information:

“Techniques Of Pressworking Sheet Metal”

By Donald F. Early and Edward A. Reed published by Prentice Hall 1958. pg.61

“Mechanical Details For Product Design” by Douglas C. Greenwood, McGraw-Hill

1964 pg’s 4 through 7

“Marks’ Standard Handbook For Mechanical Engineers” 7th Edition

McGraw-Hill Copyright 1967 pg. 13-27

“Manufacturing Processes and Materials For Engineers” 2nd Edition By Doyle, Keyser,
Leach, Schrader, and Singer McGraw-Hill Copyright 1969 pg. 280

“Machine Design Calculations Reference Guide” by Tyler G. Hicks

McGraw-Hill Copyright 1987 pg. 174
 Addendum To
Aspects Of Metal Developed Bend Length
William Greco w2gre@verizon.net- Warrington,Pa.
September 27, 2010

Rearrangement of equation-1 note that end results gives the 0.0175 coefficient
found in “Mechanical Details For Product Design” by Douglas C. Greenwood,
McGraw-Hill 1964

A
L  R  0.4t  equation-1
360
2 57.296   360
multiply both sides of equation-1 by 2 57.296 
A
L2 57.296    2 R  0.4t  2 57.296 
360
Cancel all common factors and multiply 2 57.296 
A
L114.592   2 R  0.4t 114.592 
360  180

A 114.592
L114.592   R  0.4t 114.592   0.636622
180 180
 therefore
114.592 L  0.636622 2 A R  0.4t 
Divide by 
2
114.592  L 0.636622 A R  0.4t 

 
Divide by 114.592
114.592 L 0.636622 A R  0.4t 

114.592 114.592
0.636622
 0.005556
114.592
L  0.005556 A R  0.4t 
multiply 0.4 0.005556   0.4 0.005556   0.002222
L  0.002222 At  0.005556  AR
multiply0.002222 and 0.005556   0.006981 and 0.017453
L  0.006981At  0.017453AR equation-1b
where:
L  Length of bend
A  Angle of Bend (the angle through which metal is bent)
t  metal thickness
R = Bend Radius