Need help bending 1/4" aluminum

[LD1]

The problem with welding AL is it loses most of it's strength and will easily bend or break.

Not true

 

[ajmaxham]

Doesn't need to be super strong. T6, based on what I've read, will be more than strong enough. I completely understand that the thicker the material the larger the radius needs to be. I'm just having a heck of a time finding a machine to do what I'm after. I don't really want a huge press brake (have seen the harbor freight tool suggestion). I seen other types of bending machines for decorative steel that put a nice radius on flat stock but I haven't seen anything that can handle something 3" wide or slightly wider. One of the things I want to do with this piece of aluminum is to make my own roof rake that cuts the snow rather than something that actually "rakes" the snow off. Any of you that have dealt with all of the snow we've gotten and have had issues with snow on your roof probably know what I'm talking about. I think that I should be able to make something that's better than what's available commercially. The bender that I've seen that I think could do a good job is a spiral type bender - just need something to accommodate something wider than 1 1/4"

Google metal bender on ebay there is one that will bend up to 4'' wide.



4" Hand Operated Steel Bending Brake & Sheet Metal Form Bender with Pressing Die

Used for metal forming on mild steel up to 4" wide

I think it would bend 1/4'' aluminum OK but mine failed when bending 5/16'' x 4'' mild steel. I now have a 20 ton shop press and use a press brake.


This industrial sheet metal form bender is hand operated and used for metal forming on mild steel up to 4" wide x 5/16" thick. The form bender is a useful tool for press bending ornamental iron, mild steel, aluminum and other metals

Bending Capacity: 2.5 tons
Maximum pressing movement: 2 1/2"
Can create 90 degree bends by simply turning a hand lever until the desired angle is accomplished
Mild steel material capacities (width x thickness):
3/4" x 11/16"
2" x 7/16"
4" x 5/16"
Minimum Radius: 1/4"
Pressing Scale
Pressing die and work stop assembly included
Heavy duty solid steel construction
Overall dimensions: 17 3/8" x 10 1/8" x 5 1/2"

 

[CNC Dan]

The problem with welding AL is it loses most of it's strength and will easily bend or break.

True. But 6061 can be heat treated bach to T6 condition, so you can aneal it, bend it, and heat treat it.

There is a chart on line somewhere that gives the time/temp. curves to do it. Could be done in a kitchen oven if it would fit.

 

[DaveOmak]

I have bent aluminum.... Do NOT bend 90 degrees.... It will tear... You have to do multiple small bends of 30 to 45 degrees... 3 each 30 degree bends will not tear... on 1/4" material I suggest 30 degree bends... about 1/2-3/4" apart if that will do you.... Anneal if it does not compromise your project....

 

[LD1]

I have bent aluminum.... Do NOT bend 90 degrees.... It will tear...

You cannot make a blanket statement like that.

I think we have established that it all depends on the alloy and temper of aluminum.

Some will bend, some wont

 

[CNC Dan]

You cannot make a blanket statement like that.

I think we have established that it all depends on the alloy and temper of aluminum.

Some will bend, some wont

That's right. Just look at the top of a soda can. The edge is roled over 180°.

 

[LD1]

I think the alloy we used when I worked at the can plant was 3104. And 0.0108 thick. You could fold it in half very tightly like folding and creasing paper and it wouldn't fracture. On the other extreme, some 6061 we had for various projects, you'd be lucky to get 30,degrees before it snapped.

Cold rolled bar stock is very similar. It won't bend without heat or it will fracture.

 

[bindian]

I have bent aluminum.... Do NOT bend 90 degrees.... It will tear... You have to do multiple small bends of 30 to 45 degrees... 3 each 30 degree bends will not tear... on 1/4" material I suggest 30 degree bends... about 1/2-3/4" apart if that will do you.... Anneal if it does not compromise your project....

We used this method when we had helicopter pop out skid panel repairs that were longer than our slip roller. We bent composite bond aluminum at 1/8th inch intervals, then bonded it to the skid panel. It is very tedius bending repetative bends a few degrees every 1/8th inch for over 11 inches. But you could do it this way with 1/4 inch thick. Maybe every 1/4 inch, but the radius would be huge.
hugs, Brandi

 

[bigdeano]

You can bend 6061T6 90 deg or more if you use the proper radius for the thickness. I've done it. Google bend radius for 6061t6.

 

[bindian]

You can bend 6061T6 90 deg or more if you use the proper radius for the thickness. I've done it. Google bend radius for 6061t6.

With .250 thickness? How big was your radius?
hugs, Brandi