Need help bending 1/4" aluminum

connor77 · Feb 15, 2015

Can anyone that has aluminum bending experience recommend a brake (or something else) that will allow me to bend (mostly 90 degree angles) into aluminum as thick as 1/4" and as wide as 6". I am having a really tough time finding a brake or other device that will accommodate something this thick. I would like to be able to bend more than just sheet metal gauge thicknesses. This is hobby related for what it's worth. I am not inclined to spend thousands on a huge and powerful brake that won't get much use. It's not a huge difference but if the gauge of the aluminum has to be a little thinner like 3/16" I'd be OK with this I guess.

Any help appreciated.

Thanks!

Kyle_in_Tex · Feb 15, 2015

1st, you will need to buy 6061 in the T0(T zero) condition. You can slightly heat 6061 T6 material with an O/A torch adjusted to a yellow flame to take it back to T0.

You will probably have to heat it at the seam you want to bend. Carefully though, too much and it will melt.

There is no substitute for a press brake for bending wide pieces that I know of. If you can clamp some pieces against a metal straight edge, you might can use a mallet to bend it or build a device that grips it across the seam edge with a long handle to have leverage. How wide do you need to bend?

Another thing, don't use this metal for any type of situation where a person's life hangs in the balance. Messing with heat treats throws the engineering numbers out the window.

bcp · Feb 15, 2015

Not knowing the final shape of your project pieces, could you cut 6 inch sections out of a piece of AL angle?

Bruce

muddstopper · Feb 15, 2015

If you have a shop press, you can try making something like this, https://www.youtube.com/watch?v=pKv_pD_oREk

CNC Dan · Feb 15, 2015

You will need to aneal the part before bending. This will soften it so it will bend with less force, and without cracking. For .250" thick, you may need to aneal after bending half way.

To make the bend, a press break would be best. You will need a die ( female part) that is much wider than usual. I'll guess about 2" wide.

Good luck, and be sure to let us know how it goes.

ns_in_tex · Feb 15, 2015

Don't know anything about bending aluminum, but we have bent a lot of 1/4"x6" steel with a cheap (less than 400.00) 30 ton (bottle jack) press, with a 20 ton jack.
By spreading out the die some, we have bent 4"x5/8" steel to maybe a 45 degree.
After using a hand jack for a while, we finally went to a air over hydraulic jack.
Made our own dies out of material on hand.

connor77 · Feb 15, 2015

Thanks for the help guys. I am just trying to make a "U" shape out of 3" wide 3/16" thick aluminum. The "U" shape can be pretty hard - almost 90 degrees. The length of the piece I'm trying to bend is approx 40". The uprights will be 8" high with the bottom of the "U" being 24". I need to learn more about anealing and know that if I bend too far or against the grain I run the risk of breaking the piece.
If anyone can suggest a bottle jack press model with seller information I would appreciate it.
I've also seen people who have made their own press using angle steel. Have not looked at the videos yet so apologies if this is what has been sent.

Bladehauler · Feb 15, 2015

this and a press from harbor freight might get you where you need to be.

20 TON Press Brake Heavy Duty DIY Builder Kit

pat32rf · Feb 15, 2015

Took some pieces of 1/4" x14" wide to a machine shop. They put it in their press and it promptly snapped on the bend line. They then welded it up and I've been using them as a top lip on my loading ramps for ten years now.... They did warn me that this might happen...

PILOON · Feb 15, 2015

In aviation I worked with all kinds of aluminum and from what I recall even soft alu will want a serious radius not to snap.
It is like 3 X the metal thickness and that for dead soft and on a press brake.
I would consider angle stock and rivets.
1/8" soft would bend nicely over a 3/16" radius bar but it would want a hefty brake to handle it.

Have you considered cutting strips and welding? That would give you nice sharp angles which can always be dressed by fileing or with a disk sander if appearances are important.