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.