An incredible amount of finesse and skill goes into the process of profile bending. The profile bending process is characterized by stretching and compression, which may cause the complex cross-section to deform and important functions to be lost.
The most suitable technique depends on several factors. These include the cross-section of the profile (the wall thickness and the various functions), the desired radius, the bending direction (over the strong x-x axis or the weak y-y axis), the alloy and the hardness state of the material.
There are several methods of profile bending, choosing a right profile bending method will can prevent a lot of needless headaches.
Read More: How to bending aluminum without cracking it
Profile bending machines use a technique called cold rolling, to produce quality curved sections in a cost-effective way.
Large sweeping curves, and varying radius curves, such as ellipses, tight bends, rings, and coils, can be achieved for a wide range of sections and material types. In many cases, roll bending is the most flexible and cost-efficient bending method. Roll bending of profile bending process is an ideal technique for (large) profiles and for different radii and complex cross-sections. Roll bending greatly improves the properties and structure of the metal profile.
Stretch bending originated within the aviation industry, it is now also widely used for architectural, machinery, and automotive applications. It is a very precise bending method whereby the material surface remains in perfect condition and the cross-section is minimally deformed.
With stretch bending the profile is firmly clamped at both ends. The machine applies tension to the profile and then pulls it around a bending tool. The material does not come into contact with the machine so the surface of the material remains in perfect condition. cross-sectional distortion is kept to a minimum due to the constant tension on the profile with stretch bending machine. In contrast to roll bending, the material does not come into contact with the machine so the surface of the material remains in perfect condition.
When rolling a (thin walled) profile in a small radius, there is an increased risk of tearing and straining. To prevent this, means of mandrel are used to bend the profile bending. How that mandrel fits can be critical, when a profile bending machine receives material, the operator usually will measure the ID and OD to ensure they are within the mill’s tolerance range, then choose or order a mandrel to suit.
The mandrel bending process is accurate, fast and delivers consistent quality. It is extremely suitable for medium and large series.
Profile bwnding need ensure the section deformation is kept to a minimum and that the functionalities are retained, even in the bend, and at the same time pay attention attention to the process and use of special tools guarantee maximum surface protection. So like many others in metal manufacturing, considering curved member distortion from the get-go—with open communication among the designer, profile bending fabricator—can prevent a lot of needless headaches.