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Rules for Twisting Sheet Metal?

Rules for Twisting Sheet Metal?

Rules for Twisting Sheet Metal?

Does anyone have some rules? I want to make a simple 90 degree twist in some thin copper lead frames (0.8 x 1.5mm). Max twist per length? Does the cross section stay reasonably similar? Is this an ok process for volume production (200k-500k/year)

Similar to the image.

RE: Rules for Twisting Sheet Metal?

I think you can reasonably assume that rectangular sections at the ends of the helix remain planar and rectangular and don't change dimension, at least not much.
Given that assumption, you can compare the length of the helix along the straight center line between the rectangles' centroids, to the developed length of the edge at any corner.
If the difference is not larger than the minimum elongation for the material, you should be able to form the helices without cracking the material.

Mike Halloran
Pembroke Pines, FL, USA

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