The current empirical methods used to calculate the bend-allowance parameter are examined and the drawbacks associated with them are identified. In this paper an attempt has been made to first review the current industrial practice for the calculation of bend allowance. This may cause mismatch in the final assembly also. This causes the blank size to be incorrect, which in turn causes the location of bend lines, slots, and holes to be inaccurate. Any inaccuracy in calculating the bend-allowance parameter during bending may result in increasing the inaccuracy in the final developed length of the sheet. Bend allowance is defined as the length of the unstretched fiber in the bent portion of the sheet. In precision components, the calculation of the bend allowance is important in arriving at the final dimensions of the developed length of the sheet metal. Sheet-metal components are used extensively in the aerospace and the electronic industry, where high precision is an essential requirements for the final products.
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