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Thickness and bending radius of aluminum profile bending

The thickness and bending radius of aluminum profiles are crucial considerations when bending aluminum. These factors can significantly influence the success of the bending process and the quality of the final product.

  • Thickness: The too-thick aluminum plate is not easy to bend. Everyone knows they should use the thinnest possible sheet of aluminum.
  • Bending Angle Radius: The larger the R angle, the higher the success rate, so try to increase the bending R angle as much as possible.

Thickness

  • Material Thickness: The thickness of the aluminum profile is a critical factor. Thicker materials require more force to bend and are less formable. Thinner materials are generally more easily bent.
  • Minimum Thickness: There is a minimum thickness that can be successfully bent without causing defects. Below this threshold, cracking or other forms of material failure may occur.
  • Material Type: Different aluminum alloys and tempers may have varying thickness limits for successful bending. Softer alloys and tempers are typically more formable.

The table below shows the permitted bend radii for 90o bending.

Bending Radius

  • Minimum Bend Radius: The minimum bend radius is the smallest radius that the aluminum can be bent without causing cracking or excessive deformation. This value depends on the alloy, temper, and thickness of the material.
  • Bend Radius Guidelines: It’s crucial to adhere to bend radius guidelines provided by the aluminum supplier or industry standards. Using a smaller bend radius than recommended can lead to cracking or deformation.
  • Die Selection: The die or tooling used for bending should have a radius that is equal to or larger than the minimum bend radius required for the specific aluminum profile. Using a die with a smaller radius may result in material failure.

A factor to consider is that during the process of bending aluminum, the metal hardens and strengthens by reason of the working effect. Apart from alloy selection, thickness and bend radius are also critical factors that must be considered.

Read More: Minimum Recommended Bend Radius Chart of Aluminum and Steel Profiles

Percentage of aluminum profile bending elongation

A third factor to be considered is that the formability of a specific alloy can be found in the percentage of elongation and the difference between yield strength and ultimate tensile strength.

This rule states that the higher the elongation value (the wider the range between yield and tensile strength), the better the forming ability of the alloy.

From the aforementioned descriptions of alloys and the data shown in table 1, it is quite obvious that the best series for forming, and thus for bending process, are series 3xxx, 5xxx, and in some cases 6xxx. Series 2xxx and 7xxx are not to be considered and thus should be avoided due to being extremely strong. They are difficult to form in any way.

Summary

In summary, the thickness of the aluminum profile and the minimum bend radius are interrelated factors that need to be carefully considered during the bending process. Using the appropriate thickness for your application and ensuring the chosen bend radius is within the recommended guidelines are essential steps to achieve successful bending without causing cracking or other defects in the aluminum profile.