The minimum distance between bends in sheet metal is important for maintaining the material’s integrity and avoiding deformation or tearing during bending. This distance depends on the thickness of the sheet, the type of material, and the bending method. Here’s a breakdown of general rules for minimum bend distances:

1. Rule of Thumb for Minimum Distance

The minimum distance between two bends should be at least 2 to 3 times the sheet metal thickness. This allows the material to flow properly during the bending process and helps prevent distortions or tearing at the bend points.

For example, if the sheet metal is 1 mm thick, the minimum distance between two bends should be 2 to 3 mm.

2. Minimum Distance from Bend to Edge

The distance from a bend to the edge of the sheet metal should be at least 4 times the sheet thickness. This ensures that the material near the edge doesn’t become too weak or deformed during the bending process.

3. Material and Tooling Considerations

Material Type: Different materials behave differently during bending. For example, ductile metals like aluminum or mild steel may tolerate smaller distances between bends, while more brittle materials like stainless steel require larger distances.

Bending Radius: The bend radius also affects the minimum distance between bends. Larger radii generally require more space between bends.

Bend Angle: Sharper bend angles may require more space to avoid material deformation. For larger bend angles (like 90° or more), you might need to increase the minimum distance.

4. Avoiding Bend Overlap

When bends are too close, they can interfere with each other, leading to overlapping bends or deformities in the sheet metal. The spacing should ensure that each bend forms cleanly without influencing adjacent bends.

5. Design Standards

Some industries may have their own specific guidelines for bend spacing, depending on the application and material being used. Always check relevant standards or guidelines for your specific project.

Example of Minimum Distance Calculation

If you are working with 1.5 mm thick sheet metal and plan to have two 90° bends:

The minimum distance between the bends should be at least 3 mm (2 to 3 times the thickness).

The minimum distance from the bend to the sheet edge should be 6 mm (4 times the thickness).

These guidelines ensure that the sheet metal can be bent cleanly and without damage to its structural integrity.

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