Sheet Metal Design Guideline 98053007 30006

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 : Sh e e t M e t a l D e s i g n Gu i d e l i n e s









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Note: T h i s d oc u m en t i s u n d er d ev el op m en t b etw een HO N HA I a n d C i s c o M ec h a n i c a l G u i d el i n es a n d C en tr a l D F M tea m m em b er s . T h e d oc u m en t w i l l b e p u b l i s h ed i n th e C i s c o M ec h a n i c a l P r od u c a b i l i ty G u i d el i n es w eb s i te, m a n a g ed b y C h r i s ti n e Nol a n B r a d y . T h i s d oc u m en t i s ow n ed b y HO N HA I , n ot of f i c i a l l y a p p r ov ed b y C i s c o, a n d s h ou l d b e u s ed f or r ef er en c e on l y , b y i n ter n a l C i s c o E n g i n eer i n g a n d M a n u f a c tu r i n g .

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

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THE MOST COMMONLY SHEET METAL FEATURES: No.| FEATU RE NAME Cu t ou t f eatu r es

No.| FEATU RE NAME

No.| FEATU RE NAME

01 HO LE

05 RELIEF

09 NO TCH

04 CU RL

06 O FFS ET BENDS

03 EXTRU DE FO RM

07 EMBO S S

08 CO INING EDGE

16 HALF-S HEARING

17 RAIS ED LETTER ICO N

18 DIMP LE

11 P ERFO RATED

13 CO U NTERS INK

21 CO RNER

Bendi ng f eatu r es 02 BEND 10 HEM

20 TAB

28 U -BEND

For m ed f eatu r es 12 LANCE FO RM

19 S TAMP ING ICO NS

24 EXTRU DED HO LE 27 S P O O N

14 HO O K FEATU RE

22 CARD GU IDE FO RM 25 THREAD FO RM

15 RIB

23 RO U ND HEM 26 GU S S ET

Notes (f or thi s Desi g n Gu i del i ne sp ec i f i c ati on): 1. The m ater i al i s l ow c ar bon steel ; 2. The standar d m ater i al thi c k ness r ang i ng f r om .030” to .059”;

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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 . 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 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.

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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 When L i s 10T to 25T then m i ni m u m G = 4T When L i s ov er 25T then m i ni m u m G = 6T Rec o m m en ded

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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 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.

the edg e of a hol e to the base of

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 = 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 D5 (m i ni m u m ) = 2T or T + R1, whi c hev er i s g r eater Rec o m m en ded 0 5/ 30 / 20 0 7

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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

W (m i ni m u m ) = 1.5X T or .059”, whi c hev er i s g r eater ; D (m i ni m u m ) = T + R Rec o m m en ded

Tear ty p e r el i ef . No t Rec o m m en ded

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: r el i ef wi dth (W), r el i ef l eng th (D).

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

Mak e the r el i ev es to g o thr ou g h the bend i f D(m i ni m u m ) i s l ess than 3T Rec o m m en ded

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D(m i ni m u m ) < 3T

No t Rec o m m en ded

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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. NOTCH

W (m i ni m u m ) = 1.5x T or .060” whi c hev er i s g r eater Rec o m m en ded

W(m i ni m u m ) < 1.5x T No t Rec o m m en ded

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: notc h wi dth (W).

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

r ec om m ended di stanc e (D1) between notc hes i s two

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. No t c h 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 (D3) f r om the i nsi de su r f ac e of the bend to the edg e of a notc h shou l d f ol l ow r ec om m endati on f or sl ot to bend on p ag e 4. No t c h t h r o Des i g n Gu notc h shou of m ater i al

u g h a Ben d i del i n e: When a notc h g oes thr ou g h a bend, the bottom or si de edg es of the l d ex tend a m i ni m u m di stanc e (D4) bey ond the bend, eq u al to the thi c k ness p l u s the bend r adi u s.

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

L: sl ot l eng th D1 (m i ni m u m ) = 2T D2 (m i ni m u m ) = 1.5T When L i s l ess than 1.0” then D3 (m i ni m u m ) = 2.5T + R When L i s 1.0” to 2.0” then D3 (m i ni m u m ) = 3T + R When L i s ov er 2.0” then D3 (m i ni m u m ) = 3.5T + R D4 (m i ni m u m ) = T + R or 2T, whi c hev er i s g r eater Rec o m m en ded

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

di stanc e between the hol es i s eq u al to

P ERFORATED HOLE

D (m i ni m u m ) = 1.2 T Rec o m m en ded GUI DELI NES FOR 3D GEOMETRY: 3D m odel shou l d c ar e f or the di stanc e (D) between the hol es. If f or ai r f l ow r eason the abov e r ec om m ended di m ensi on c annot be m et, one c an c onsi der the f ol l owi ng : 1. For c osm eti c p er f or ated p ar t, sandwi c h an of f -the-shel f p er f or ated m ater i al between two sheet m etal p ar ts. 2. For non-c osm eti c p er f or ated p ar t, ac c ep t def or m ati on and/ or m ater i al br eak ag e.

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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 Des i g Fr om Fr om

r a t ed h o l e t o Ben d 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: 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. 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

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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 to .008”.

dep th of the nec k seg m ent (S ) of a c ou nter si nk i s eq u al COUNTERSI NK

S (r ec om m ended) = .008“ Rec o m m en ded 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 nec k hei g ht (S ), m aj or di am eter of the c ou nter si nk (D), thr ou g h hol e di am eter (d) and ang l e of the c ou nter si nk (A). Al l these i nf o shou l d m atc h wi th c or r esp ondi ng har dwar e u sed.

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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 D2 (m i ni m u D3 (m i ni m D4 (m i ni m Rec o m

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m )= m )= u m u m m en

4T + R2 4T + R1 ) = 6T ) = 4T ded

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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 nev er be l ess than .012” (H/ T) or .059” (S / T).

r adi u s of the c or ner shou l d

CORNER – Ra di u s

R (r ec om m ended) = .059”(1.50m m ) Rec o m m en ded

R(m i ni m u m ) < .059”(1.50m m ) No t Rec o m m en ded

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: c or ner of the g eom etr y and the ou ter and i nner c or ner shou l d add r adi u s.

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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”. CORNER - Ra di u s

D (m i ni m u m ) = 2.5XT + .059”, R = .059” Rec o m m en ded

D (m i ni m u m ) < 2.5XT + .059” No t Rec o m m en ded

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”. CORNER - Ch a m f er

D (m i ni m u m ) = 2.5XT + .059”, D = .059 Rec o m m en ded

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D (m i ni m u m ) < 2.5XT + .059” No t Rec o m m en ded

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Sheet Metal Design Guidelines C o r ner F o x c o nn . do c _ r ev . 0 1 Co r n er a n d p a i n t ( f i n i s h ) Des i g n Gu i del i n e: The S har p Cor ner wi l l l ead to p ai nti ng p r obl em s i f the c or ner su r f ac es wi l l be p ai nted. CORNER

P ai nt the su r f ac es wi th Rou nd Cor ner Rec o m m en ded

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P ai nt the su r f ac es wi th S har p Cor ner No t Rec o m m en ded

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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. BENDI NG

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

Bend ang l e i s an ac u te ang l e No t Rec o m m en ded

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).

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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

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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. CURL

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

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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 Des i g Fr om the c u Fr om the c u

o Ho n Gu ac u r r l. ac u r r l.

le 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: 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 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

Cu r l 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) that a c u r l shou l d be f r om a bend i s: As an i nter nal bend (D2a): ni ne ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the c u r l. As an ex ter nal bend (D2b): si x ti m es the m ater i al thi c k ness p l u s the i nsi de r adi u s of the c u r l. Fea t u r e P o s i t i o n

D1a (m i ni m u m ) = T + R When L i s l ess than .39“ then D1b (m i ni m u m ) = 2T + R When L i s .39” to 1.96” then D1b(m i ni m u m ) = 6T+ R When L i s ov er 1.96” then D1b(m i ni m u m ) = 10T D2a (m i ni m u m ) = 9T + R D2b (m i ni m u m ) = 6T + R Rec o m m en ded

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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