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2 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Sheet Metal Design Guidelines Hem Design Guidelines

Issue XII, June 2015

3 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

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4 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

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Welcome to another issue of the DFM Guidebook. We highly appreciate your feedback on our previous issues. Please continue to send us your comments and suggestions for subsequent issues.

This week we cover important design guidelines for sheet metal hemming.

Hemming is a sheet metal forming operation in which the edge of the sheet is folded back on itself. It serves several purposes: to fasten two sheet metal parts, to improve the appearance of edges (remove burrs and rough edges) and to increase the part stiffness. Hemming is also critical to the overall part functionality as well as assembly quality. There are mainly three types of hems: closed hem, open hem and teardrop hem. In this issue we cover DFM guidelines that can help increase the manufacturability of designs for press brake machines. Read the guidebook for specific guidelines like Open Hem, Rolled Hem, Tear Drop Hem, Rolled Hem to Hole edge Distance, Closed Hem and Knife Edge. If you have any feedback or questions on DFM guidebook, please write to us at info@dfmpro.com

Rahul Rajadhyaksha Senior Product Manager Geometric Limited

5 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Contents

Open Hem ............................................................................................................... 6

Rolled Hem .............................................................................................................. 7

Tear Drop Hem ........................................................................................................ 8

Rolled Hem to Hole Edge Distance ......................................................................... 9

Closed Hem ........................................................................................................... 10

Knife Edge ............................................................................................................. 11

6 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Open Hem

A Hem has a full round feature and a return flange. In open hem bend angle is equal to 180

degrees.

It is recommended that the ratio of the open hem radius to the sheet metal thickness should be

greater than or equal 0.5.

Also, the ratio of return flange height to the sheet metal thickness should be greater than or

equal to 4.

Where,

H = Return flange height

D = Open hem diameter

T = Sheet metal thickness

7 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Rolled Hem

It is recommended that the ratio of the external radius of a rolled hem to material thickness

should be greater than or equal to 2.

Also, the ratio of the rolled hem opening to material thickness should be greater than or equal to

1.

R = Rolled hem's external radius

D = Rolled hem's opening

8 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Tear Drop Hem

In tear drop hem the bend angle is greater than 180 degrees. It is recommended to consider the

following guidelines while designing a tear drop hem -

The ratio of the radius of a tear drop hem to the sheet metal thickness should be greater

than or equal to 0.5

The ratio of the return flange height to the sheet metal thickness should be greater than or

equal to 4.0

The ratio of the hem opening (spacing between the hem edge and the part) to the sheet

metal thickness should be greater than or equal to 0.25

Where,

d = Diameter of a tear drop hem.

H = Return flange height of the tear drop hem.

D= Hem Opening

T = Sheet Metal Thickness

9 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Rolled Hem to Hole Edge Distance

The ratio of the distance between the rolled hem and the edge of a hole to the sheet thickness

should be greater than or equal to 1.

T = Sheet metal thickness

D = Distance

10 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Closed Hem

Hems without any inside radius are called as closed hem. Closed hems are not recommended if

the hem geometry is to be painted or if the material used is SST or Aluminum.

In closed hems, return flange length from outside the bend should be equal to or greater than

four times the material thickness.

H = Return flange height of the tear drop hem

T = Sheet Metal Thickness

11 A DEFINITIVE GUIDE TO DESIGN FOR MANUFACTURING SUCCESS

Knife Edge

Knife edge features on sheet metal parts should be avoided for ease of manufacturing. To achieve

knife edges on sheet metal parts, additional operations may be required which increases the cost

of the product. Knife edge conditions can also lead to fatigue failures in certain conditions.

It is recommended to avoid knife edge conditions as it can either increase the manufacturing cost

and complexity or lead to fatigue failures.