SHEET METAL DESIGN DOCUMENT

Sheet Metal Design Guidelines F eatur es L ist F o x c o nn do c _ r ev 0 1

HON HAI PRECISION ENCLOSURE GROUP

 SUB J ECT :     D OCUM ENT NO : 9 8 -0 5 3 0 0 7

Sheet Metal Design Guidelines F eatur es L ist F o x c o nn do c _ r ev 0 1

THE MOST COMMONLY SHEET METAL FEATURES:

Sheet Metal Design Guidelines H o le F o x c o nn do c _ r ev 0 1

TI TLE: HOLE & SLOT ( P UNCH) ( #0 1 )

DESCRI P TI ON: A c u t i n the m i ddl e of the sheet m etal su r f ac e i s c al l ed a Hol e

DESI GN GUI DELI NE: The m i ni m u m di am eter of a hol e (or wi dth of a sl ot) shou l d be eq u al to 1.2 ti m es

m ater i al thi c k ness p l u s 008”, or 048”, whi c hev er i s g r eater

GUI DELI NES FOR 3D GEOMETRY: 3D m odel shou l d i nc l u de the hol e di am eter , l eng th and wi dth of the

sl ot

HOLE

D (m i ni m u m ) = 1.2x T + 008“, or 048“, whi c hev er i s g r eater

Rec o m m en ded

Sheet Metal Design Guidelines H o le F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Ho l e t o Ho l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (G) between hol es i s di r ec tl y p r op or ti onal

to the si z e and shap e of the hol es and the m ater i al thi c k ness

Bu t the m i ni m u m di stanc e between c i r c u l ar hol es i s 1.2 ti m es m ater i al thi c k ness

Ho l e t o Edg e

Des i g n Gu i del i n e: The m i ni m u m di stanc e (G) between a hol e and the edg e of the m ater i al m u st be

m ai ntai ned The m i ni m u m r ec om m ended di stanc e between the hol e and the edg e i s di r ec tl y

p r op or ti onal to the si z e and shap e of the hol e and the m ater i al thi c k ness

Fea t u r e P o s i t i o n

D: Di am eter or m i ni m u m di m ensi on of sl ot L: Leng th of sl ot

T: Mater i al Thi c k ness G: m i ni m u m Di stanc e di m ensi on When L i s T to 10T then m i ni m u m G = 2T

Sheet Metal Design Guidelines H o le F o x c o nn do c _ r ev 0 1

Ho l e t o Ben d

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between the edg e of a hol e to a bend

i s two ti m es the m ater i al thi c k ness p l u s the r adi u s of the bend

Sl o t t o Ben d

Des i g n Gu i del i n e: The m i ni m u m di stanc e (D3) f r om the i nsi de su r f ac e of a bend to the edg e of a

sl ot i s di r ec tl y p r op or ti onal to the l eng th of the sl ot, m ater i al thi c k ness and the r adi u s of the bend

Ho l e t o Fo r m

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) f r om the edg e of a hol e to the base of the f or m i s thr ee ti m es the m ater i al thi c k ness p l u s the f or m r adi u s

Ho l e t h r o u g h a Ben d

Des i g n Gu i del i n e: When a hol e g oes thr ou g h a bend, the l eadi ng edg es of the hol e shou l d ex tend a

m i ni m u m di stanc e (D5) bey ond (or both si des of ) the bend Thi s m i ni m u m di stanc e shou l d be two

ti m es the m ater i al thi c k ness or the thi c k ness of m ater i al p l u s the r adi u s of a bend, whi c hev er i s

g r eater

Fea t u r e P o s i t i o n

D2 (m i ni m u m ) = 2T + R1 When R1 = <.118” and

L < 1.0” then D3 (m i n) = 2.5T + R1

L i s 1.0” to 2.0” then D3 (m i n) = 3T + R1

L > 2.0” then D3 (m i n) = 3.5T + R1 When R1 > 118” and

L i s l ess than 20T then D3 (m i n) = 3.5T + R1

L i s ov er 20T then D3 (m i n) = 6T + R1 D4 (m i ni m u m ) = 3T + R2

Sheet Metal Design Guidelines R elief F o x c o nn do c _ r ev 0 1

TI TLE: RELI EF ( #0 5 )

DESCRI P TI ON: When a bend does not ex tend the enti r e l eng th of a p ar t, or a f or m i s c l ose

to other sheet m etal f eatu r es, the r el i ef c an hel p c ontr ol the sheet m etal m ater i al behav i or and

p r ev ents u nwanted def or m ati on

The r ec om m ended r el i ef ty p e i s r ec tang u l ar

The obr ou nd ty p e r el i ef i s p r ef er r ed (H/ T)

DESI GN GUI DELI NE: The m i ni m u m dep th of a bend r el i ef (D) i s eq u al to the m ater i al

thi c k ness p l u s the r adi u s of a bend The m i ni m u m wi dth (W) of a bend r el i ef i s eq u al to 1.5

ti m es m ater i al thi c k ness or 0.059” (1.50m m ), whi c hev er i s g r eater

RELI EF

Sheet Metal Design Guidelines R elief F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Rel i ef t o Ben d

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e between a r el i ef and a bend

f ol l ows the r u l es of a hol e to a bend The m i ni m u m r ec om m ended di stanc e (D) i s thr ee

ti m es the m ater i al thi c k ness

Sheet Metal Design Guidelines N o tc h F o x c o nn do c _ r ev 0 1

TI TLE: NOTCH (#0 9 )

DESCRI P TI ON: An i ntr u si on or c u t i nto the edg e of the sheet m etal i s c al l ed a Notc h

DESI GN GUI DELI NE: The m i ni m u m p r ef er r ed wi dth of a notc h i s 060” or 1.5 ti m es the

m ater i al thi c k ness whi c hev er i s g r eater Ty p i c al notc h l eng th c an be u p to f i v e ti m es the wi dth, when p u nc hed at the m i ni m u m wi dth di m ensi on

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y show f ol l owi ng i nf or m ati on:

Sheet Metal Design Guidelines N o tc h F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

No t c h t o No t c h

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between notc hes i s two

ti m es the m ater i al thi c k ness

No t c h t o Ho l e o r Cu t o u t

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) m u st be m ai ntai ned between a hol e and edg e of a notc h The m i ni m u m r ec om m ended di stanc e i s 1.2 ti m es the m ater i al thi c k ness

Rec o m m en ded

Sheet Metal Design Guidelines P er f o r ated m etal F o x c o nn do c _ r ev 0 1

TI TLE: P ERFORATED METAL (#1 1 )

DESCRI P TI ON: A p atter n wi th hol es on sheet m etal su r f ac e i s c al l ed p er f or ated m etal

DESI GN GUI DELI NE: The r ec om m ended m i ni m u m di stanc e between the hol es i s eq u al to 1.2 ti m es the m ater i al thi c k ness

GUI DELI NES FOR 3D GEOMETRY: 3D m odel shou l d c ar e f or the di stanc e (D) between the

P ERFORATED HOLE

D (m i ni m u m ) = 1.2 T Rec o m m en ded

Sheet Metal Design Guidelines P er f o r ated m etal F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

P er f o r a t ed h o l e t o Ben d

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D) i s:

Fr om the edg e of a c i r c u l ar hol e to a bend (D1) i s thr ee ti m es the m ater i al thi c k ness

Fr om the r ec tang u l ar hol e to a bend (D2) i s eq u al to 3.5 ti m es the m ater i al thi c k ness

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 3T

D2 (m i ni m u m ) = 3.5T

Rec o m m en ded

Sheet Metal Design Guidelines C o unter sink F o x c o nn do c _ r ev 0 1

TI TLE: COUNTERSI NK (#1 3)

DESCRI P TI ON: A Cou nter si nk i s a c oni c al dep r essi on at an ex i sti ng hol e i n the sheet m etal

su r f ac e A c ou nter si nk u su al l y u sed i n c onj u nc ti on wi th har dwar e

DESI GN GUI DELI NE: The m i ni m u m dep th of the nec k seg m ent (S ) of a c ou nter si nk i s eq u al

to 008”

COUNTERSI NK

Sheet Metal Design Guidelines C o unter sink F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Co u n t er s i n k t o Fo r m

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) between the m aj or

di am eter of a c ou nter si nk and a f or m i s f ou r ti m es the m ater i al thi c k ness p l u s the f or m

r adi u s

Co u n t er s i n k t o Ben d

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) between the m aj or

di am eter of a c ou nter si nk and a bend i s f ou r ti m es the m ater i al thi c k ness p l u s the bend

r adi u s

Co u n t er s i n k t o Co u n t er s i n k

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D3) between the m aj or

di am eter s of two c ou nter si nk s i s eq u al to si x ti m es the m ater i al thi c k ness

Co u n t er s i n k t o Edg e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between the m aj or

di am eter of a c ou nter si nk and an edg e i s f ou r ti m es the m ater i al thi c k ness

Fea t u r e P o s i t i o n

D1 (m i ni m u m ) = 4T + R2 D2 (m i ni m u m ) = 4T + R1 D3 (m i ni m u m ) = 6T D4 (m i ni m u m ) = 4T Rec o m m en ded

Sheet Metal Design Guidelines C o r ner F o x c o nn do c _ r ev 0 1

TI TLE: CORNER (#2 1 )

DESCRI P TI ON: The c or ner s i nc l u de the shar p , r adi u s (f i l l et) and c ham f er ed

DESI GN GUI DELI NE: For a r adi u s (f i l l et) c or ner , the m i ni m u m r adi u s of the c or ner shou l d nev er be l ess than 012” (H/ T) or 059” (S / T)

Sheet Metal Design Guidelines C o r ner F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Co r n er t o Ben d

Des i g n Gu i del i n e: 1 For Radi u s Cor ner , the m i ni m u m r ec om m ended di stanc e between

r ou nd to the bend i s 2.5 ti m es the m ater i al thi c k ness p l u s 059”.

2 For Cham f er Cor ner , the m i ni m u m r ec om m ended di stanc e between c ham f er to the bend i s 2.5 ti m es the m ater i al thi c k ness p l u s 059”

Sheet Metal Design Guidelines C o r ner F o x c o nn do c _ r ev 0 1

Cor ner P ai nt the su r f ac es wi th S har p Cor ner

Sheet Metal Design Guidelines B ending F o x c o nn do c _ r ev 0 1

TI TLE: BENDI NG (#0 2 )

DESCRI P TI ON: A bend i s a f or m that m ak es the sheet m etal wal l i nto an ang u l ar shap e

DESI GN GUI DELI NE: The bend has two c har ac ter i sti c s: the bendi ng ang l e and the bendi ng

r adi u s The m ax i m u m r ec om m ended r adi u s f or a bend i s 020” A bendi ng ang l e i s

r ec om m ended to be a r i g ht or obtu se ang l e

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:

m i ni m u m bendi ng r adi u s(R) and bendi ng ang l e (A)

BENDI NG

A (m i ni m u m ) = 90 DEG Bend ang l e i s an ac u te ang l e

Sheet Metal Design Guidelines B ending F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Ben d t o edg e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended hei g ht (H) of a bend f l ang e m easu r ed

f r om the i nsi de su r f ac e of the bend i s eq u al to 2.5 ti m es the m ater i al thi c k ness p l u s the

r adi u s of the bend

Fea t u r e P o s i t i o n

H (m i ni m u m ) = 2.5T + R Rec o m m en ded

Sheet Metal Design Guidelines C ur l F o x c o nn do c _ r ev 0 1

TI TLE: CURL (#0 4)

DESCRI P TI ON: A Cu r l i s a f or m that m ak es the sheet m etal f l ang e i nto a r ol l ed shap e It

u su al l y u sed as a m eans of j oi ni ng two c om p onents and i n the f or m of a hi ng e

DESI GN GUI DELI NE: The m i ni m u m i nsi de r adi u s of a c u r l i s eq u al to two ti m es the m ater i al thi c k ness; the m i ni m u m op eni ng g ap i s eq u al to one m ater i al thi c k ness

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on:

m i ni m u m op en g ap (G), i nsi de r adi u s (R)

CURL

G (m i ni m u m ) = T

R (m i ni m u m ) = 2T Rec o m m en ded

Sheet Metal Design Guidelines C ur l F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Cu r l t o Ho l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om a hol e i s:

Fr om a c u r l to the edg e of a hol e (D1a): one ti m es the m ater i al thi c k ness p l u s r adi u s of the c u r l

Fr om a c u r l to the edg e of a sl ot (D1b): two ti m es the m ater i al thi c k ness p l u s r adi u s of the c u r l

Sheet Metal Design Guidelines O f f set b ends F o x c o nn do c _ r ev 0 1

TI TLE: OFFSET BENDS (#0 6)

DESCRI P TI ON: An of f set bend, or a j og g l e, i s two v er y shor t bends (2K <H wher e K i s the K

-f ac tor ) -f or m ed si m u l taneou sl y It i s u sed to j og g l e other sheet m etal su r -f ac e or ser v e as a

Sheet Metal Design Guidelines O f f set b ends F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Of f s et b en ds t o Rec t a n g u l a r Ho l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) f r om the bend i nsi de

su r f ac e to the edg e of a hol e i s eq u al to ei g ht ti m es the m ater i al thi c k ness p l u s the

r adi u s of bend

Of f s et b en ds t o Ex t r u ded h o l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om the bend i nsi de

su r f ac e to the m aj or di am eter of ex tr u si on i s eq u al to 2.5 ti m es the m ater i al thi c k ness

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

TI TLE: HEM (#1 0 )

DESCRI P TI ON: A Hem has a f u l l r ou nd f eatu r e and a r etu r n f l ang e It i s u sed as a m ethod of

el i m i nati ng shar p edg e or to p r ov i de addi ti onal sti f f ness to the edg e of a su r f ac e Ther e ar e thr ee ty p es of hem : c l osed hem , op en hem and tear dr op hem

The c l osed hem i s the str ong l y r ec om m ended op ti on i f the hem i s onl y u sed as a m ethod of

el i m i nati ng shar p edg e The tear dr op hem i s not r ec om m ended

DESI GN GUI DELI NE:

1 For the c l osed hem (no i nsi de r adi u s), r etu r n f l ang e l eng th (H) f r om ou tsi de the bend shou l d be eq u al to or g r eater than f ou r ti m es the m ater i al thi c k ness

Thi s ty p e of hem (c l osed hem ) i s not recommended i n the f ol l owi ng si tu ati on:

The hem g eom etr y wi l l be p ai nted;

The m ater i al i s S S T & al u m i nu m ;

The p ar t i s p ost p l ated;

Cl o s ed Hem

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of c l osed hem shou l d c l ear l y i ndi c ate

f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H) and the z er o r adi u s of the i nsi de r adi u s

2 For op en Hem ( the bend ang l e i s 180 °), the m i ni m u m i nsi de di am eter shou l d be eq u al to the m ater i al thi c k ness, r etu r n f l ang e l eng th (H) f r om ou tsi de the bend i s eq u al to or

g r eater than si x ti m es the m ater i al thi c k ness

The g ap (G) c an be set by i nc r em ents of the m ater i al thi c k ness

GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of op en hem shou l d c l ear l y i ndi c ate

f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H), the i nsi de di am eter (D) and the op eni ng

g ap (G)

Ti p s f o r t h e Op en Hem

The r ec om m ended op ti on f or O p en Hem shown i n bel ow i m ag e i s onl y u sed f or H/ T

The di m p l es on the r etu r n f l ang e ar e u sed to ensu r e the g ap of the op en hem

The g ap of an op en hem shou l d be m or e than 020” i f the m ater i al i s CRS

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

3 For the tear dr op Hem (the bend ang el i s g r eater than 180 °), the m i ni m u m di am eter shou l d be eq u al to the m ater i al thi c k ness, r etu r n f l ang e hei g ht f r om ou tsi de the bend i s

eq u al to or g r eater than si x ti m es the m ater i al thi c k ness The r ec om m ended m i ni m u m hem op eni ng g ap shou l d be eq u al to ¼ of the m ater i al thi c k ness

If the m ater i al i s GI, the Tear dr op hem g eom etr y i s not r ec om m ended

GUI DELI NES FOR 3D GEOMETRY: 3D g eom etr y of Tear dr op hem shou l d c l ear l y i ndi c ate

f ol l owi ng i nf or m ati on: the r etu r n f l ang e l eng th (H), the i nsi de di am eter (D) and the g ap (G)

Tea r dr o p Hem

D (m i ni m u m ) = T, H (m i ni m u m ) = 6T, G (m i ni m u m ) = 1/ 4T

No t Rec o m m en ded

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Hem t o Ho l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) i s:

The m i ni m u m di stanc e (D1a) f r om the edg e of the hol e shou l d be f r om the ou tsi de edg e

of a hem i s two ti m es the m ater i al thi c k ness p l u s the r adi u s of the hem

The m i ni m u m di stanc e (D1b) f r om the edg e of the sl ot hol e shou l d be f r om the l eadi ng edg e of the r etu r n f l ang e i s f i v e ti m es the m ater i al thi c k ness

Hem t o Ben d

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D2) f r om a bend i s:

As an i nter nal bend (D2a): si x ti m es the m ater i al thi c k ness

As an ex ter nal bend (D2b): f ou r ti m es the m ater i al thi c k ness

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

Hem t o Hem

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between two hem s wou l d hav e to be ev al u ated base u p on sp ec i f i c desi g n r eq u i r em ent Ther e ar e two ty p es her e: Both the hem s on the sam e si de: the di stanc e (D4a) i s eq u al to the m ater i al thi c k ness Both the hem s on the di f f er ent si des: the di stanc e (D4b) i s eq u al to f i v e ti m es the

m ater i al thi c k ness

Op en Hem w i t h a Ben d

Des i g n Gu i del i n e: Thi s ty p e hem i nc l u des a i nwar d f l ang e attac hed the edg e of a hem , The

m i ni m u m i nsi de di am eter shou l d be eq u al to the m ater i al thi c k ness, r etu r n f l ang e m i ni m u m hei g ht f r om ou tsi de the bend i s eq u al to or g r eater than ei g ht ti m es the m ater i al thi c k ness The di m p l es or other g eom etr y i s a g ood op ti on to c ontr ol the g ap of an op en hem

Sheet Metal Design Guidelines H em F o x c o nn do c _ r ev 0 1

Sheet Metal Design Guidelines T ab F o x c o nn do c _ r ev 0 1

TI TLE: TAB (#2 0 )

DESCRI P TI ON: A p r otr u si on f r om an edg e i s c al l ed a tab

DESI GN GUI DELI NE: The m i ni m u m wi dth of a tab i s eq u al to two ti m es the m ater i al

thi c k ness or 125”, whi c hev er i s g r eater The m ax i m u m r ec om m ended l eng th (H) of a tab i s

f i v e ti m es the wi dth of the tab

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: the tab

wi dth (W), tab l eng th (H)

TAB

W (m i ni m u m ) = 2T or 125“, whi c hev er i s g r eater

H (m ax i m u m ) = 5W Rec o m m en ded

Sheet Metal Design Guidelines T ab F o x c o nn do c _ r ev 0 1

Sheet Metal Design Guidelines E x tr uded f o r m F o x c o nn do c _ r ev 0 1

TI TLE: EX TRUDED FORM (#0 3)

DESCRI P TI ON: An Ex tr u ded f or m i s a dr awi ng f or m f r om the ex i sti ng hol e on the sheet

m etal su r f ac e The di stor ti on wi l l oc c u r at the f or m c or ner s when f or m ed

DESI GN GUI DELI NE: The m ax i m u m r ec om m ended hei g ht of the ex tr u ded f l ang e i s eq u al to

f ou r ti m es the m ater i al thi c k ness The m i ni m u m r ec om m ended wi dth of the f or m i s eq u al to two ti m es the f or m hei g ht p l u s thr ee ti m es the m ater i al thi c k ness The obr ou nd g eom etr y shap e i s the r ec om m ended op ti on f or thi s f or m

GUI DELI NES FOR 3D GEOMETRY: 3D shou l d c l ear l y i ndi c ate f ol l owi ng i nf or m ati on: f or m

wi dth (W), f or m hei g ht (H), base r adi u s (R), and tap er ang el (A)

EX TRUDED FORM

H (m ax i m u m ) = 4T

W (m i ni m u m ) = 2H + 3T

A (m ax i m u m ) = 90 DEG Rec o m m en ded

Sheet Metal Design Guidelines E x tr uded f o r m F o x c o nn do c _ r ev 0 1

FEATURE P OSI TI ON

Ex t r u ded f o r m t o Ho l e

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D1) i s:

Fr om the edg e of a hol e to the ex tr u ded f or m (D1a) i s f ou r ti m es the m ater i al thi c k ness;

Fr om the edg e of a sl ot to the f or m (D1b) i s di r ec tl y r el ated to the l eng th of the sl ot and the m ater i al thi c k ness

Des i g n Gu i del i n e: The m i ni m u m r ec om m ended di stanc e (D4) between the f or m s i s

ei g ht ti m es the m ater i al thi c k ness

Fea t u r e P o s i t i o n

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The dou bl e ex tr u ded f or m s c an ser v e the Car d Gu i de f u nc ti on