Bending Aluminum Sheet Curve

Insert your aluminum sheet into the brake beneath the removable clamp bar.

Bending aluminum sheet curve.

Say you re bending 0 25 in thick 6061 t6 aluminum to a 100 degree external angle 80 degree internal angle. Update check out this super two person trike my partner and i are offering on kickstarter. To make this easier you d start with your 6061 material in the soft t 0 state. π 180 x b x ir k x mt bend allowance ba where b is the angle complementary to your desired bend angle 1 to 180 degrees mt is the thickness of the material ir is the inside radius and k is the k factor.

Make sure the bar is seated firmly inside the frame. Step 3 heat part until black soot goes away. Create a long fracture line then progressively bend the sheet from one end to to the other. Then place the clamp bar back down on top of the aluminum crosswise.

Bending is one of the most common sheet metal fabrication operations. Using protective gloves hold the free end of the metal sheet with one hand and with the other hand use a mallet or hammer to begin bending the sheet down and around the curved radius of the wood form. You d probably air bend by using a 3 0 in. Make sure the first bend mark lines up exactly with the curve in the form so that the bending will begin in the right spot.

After a few wiggles the sheet will fracture along the cut line leaving a clean break as shown in the above photos. Although there are many different grades and tempers of aluminum two of the most frequently worked with are 6061 t6 and 6063 t52. Also known as press braking flanging die bending folding and edging this method is used to deform a material to an angular shape. Bend metal without expensive tools.

Lift the clamp bar away from the rear of the brake frame and slide the sheet in perpendicularly to the direction you want to bend it. I ll be bending the metal using a jig just like the one in this ible i m a big fan of atomic zombie s builds. Except i like curved lines once in a while. If the operator is not familiar with the tendencies of aluminum the material can crack or become deformed.

I ve bent a fair amount of 6061 aluminum the trick i was taught was to heat it with oxy act torch. Die opening with a relieved profile. The inside bend radius should be equal to the thickness of the material that you re forming. Step 1 use just act.

If you re bending 0 020 thick material use a 0 020 radius. The force must exceed the material s yield strength to achieve a plastic deformation. You can find your bend allowance with the following formula. In other words if you re bending 1 8 sheet use a tool with a 1 8 radius to form the inside of the bend.

Here s a good rule of thumb for most materials. You have now annealed your 6061 t whatever into t 0 and it should bend without cracking. And coat the area to be bent with soot step 2 turn on o2 and set rose bud to a normal flame. This is done through the application of force on a workpiece.

With care and patience full size sheets of aluminium can be cut using this method.