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Minimum Material Bend Radius

Minimum Material Bend Radius

Minimum Material Bend Radius

(OP)
I'm trying to find a reliable resource for minimum bend radius for various materials.  I'm currently working on a problem of a 2024-T3 formed sheet metal panel that is cracking at one of the panel edges.  The panel isn't heavily loaded and it is in a relatively low vibration environment, so I was initially perplexed.  I started to review the drawing and the sheet thickness is .04" and the bend radius are .12".  So, looking at my old reliable design slide rule I noticed that the minimum bend radius for the above material is .25".  Running this question by another designer, and his slide rule has the minimum bend radius at .12".  I couldn't find anything in the Machinery HNDBK 26, so I was wondering if someone else had another resource.

RE: Minimum Material Bend Radius

The recommended bend radius for 2024-T3 Al sheet that is 1 mm thick (0.04") is 3T to 4T, which would be 3-4 mm (0.12-0.16").  References for this are ASM Alloy Digest data sheet and "How To Design Metal Stampings" by Dayton Rogers Mfg. Co.  This data is for a 90 degree bend.

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