All FAQs (Helpie FAQ)

Choose Appropriate Process Parameters: The key to avoiding cracking lies in selecting suitable bending radii and angles. Generally, the bending radius should be at least twice the thickness of the flat bar to avoid excessive stress concentration. Additionally, the angle should gradually increase to prevent the flat bar from experiencing excessive tensile forces instantaneously, which could lead to cracking.

Control Temperature Properly: The temperature of the aluminum flat bars during the bending process also affects the likelihood of cracking. Proper temperature control can reduce material hardness and minimize the risk of cracking. Depending on the situation, preheating before bending or locally heating the bending area using heating equipment can help alleviate stress concentration and reduce the risk of cracking.

Use Suitable Tooling: Proper tooling can alleviate stress concentration on the aluminum flat bars and provide adequate support. Using cushioning materials such as rubber pads or U-shaped grooves can reduce stress concentration and lower the risk of cracking.

Pre-processing of Materials: Before processing, aluminum flat bars can undergo appropriate annealing treatment or T6 heat treatment to increase their hardness and strength. This can enhance the tensile strength of the flat bars and reduce the risk of cracking.

• Point 1: Hardness of the Aluminum Flat Bars: Aluminum flat bars with high hardness are prone to cracking. It is crucial to select aluminum flat bars with high cost-effectiveness, focusing on the aluminum alloy and its state. The hardness of alloys from series 6 and 7 is higher than that of series 1, 3, and 5. It’s preferable to anneal them to the O state before bending. Quality of the aluminum flat bars also matters.
• Point 2: Thickness of the Aluminum Flat Bars: Overly thick aluminum flat bars are not conducive to bending. Thinner aluminum flat bars are preferred whenever possible.
• Point 3: Spacing of the Bending Radius (R): A larger bending radius (R) increases the pass rate, so it’s advisable to adjust the bending radius to be larger whenever possible.
• Point 4: Alignment of the Aluminum Flat Bars’ Grain Direction: The bending direction should be perpendicular to the grain direction of the aluminum flat bars, not parallel. For aluminum flat bar components with metal drawing requirements, it is preferable to perform the drawing after bending, if feasible in the manufacturing process, to reduce the risk of cracking during bending.

Before inquiring about an aluminum bending machine, it’s essential to gather pertinent information to ensure we recommend an informed decision aligning with your specific bending requirements.
Aluminum Alloys: Note the specific aluminum alloys you’ll be bending (e.g., 6061-T6). The hardness state of aluminum is important.
Drawings: Drawings of aluminum extrusions and bending process drawings.

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About PBA-CNC Aluminum Benders: Aluminum profile bending machines (also called aluminum benders) are used to form aluminum profiles.
An aluminum bender is the forming of aluminum profiles in one axis by a multi-roll bending machine. If the semi-finished product is not moved during the bending process, the distance between the rollers, their diameter, and the depth of immersion determine the bending radius. To produce particularly large bends, the material is pulled through the roller bending machine and moved alternately. The distance between the rollers is gradually adjusted. In most cases, roll bending is the most flexible and cost-efficient bending method. A profile is guided between three adjustable bending rolls and gradually bent in the desired radius.
Roll bending is the ideal bending method for profiles with complex designs and different radii. BIT’s PBA CNC profile bending machine has become specialized in 3D aluminum profile bending machines.