I bend quite a bit of 6061 (pretty much the only aluminum I use) and have learned a few tricks over the years. Elastomer bending. My torch method is 1) with just the Acetylene on and lit, cover the area to be annealed with soot. 2) Grab part A and rotate it towards part B (image 2). From there we can calculate the K-Factor and the Bend Deduction. As an example, if you want to bend 24 gauge sheet metal at a 90° angle, the calculation would be: 0.017453 x 90 x (0.020 + 0.33 x 0.024) = 0.0438558984 inch bend allowance. How are you bending it? What I've seen done (but not actually do myself) is set the O/A torch to mostly acetylene and paint the aluminium part with the soot from the feathery yellow flame. For instance, you can perform a 2-degree bend in front of the bend centerline, a 2-degree behind the bend, and then an 86-degree bend in the center. When you are bending 0.25-in.-thick 6061-T6, cracking can occur when bending past an external angle of just 86 degrees. How To Calculate Bend Deduction Length Of Bar: When we bend a steel bar, the length of the bar slightly increased due to stretching in the bending area (refer to below image). The roll bending process induces a curve into bar or plate workpieces. Determining the size of the piece to be cut starting from the finished measurements is often done by trial and error, requiring a lot of additional work not only for the pressbrake operator, but also for the designer and the laser cutter operator. I'm trying to bend a radius in a piece of 1" x 1/8" flat steel. Currently : Royal Enfield Classic 500 Despatch Limited Edition (28 of 200), CB Two-Fifty Nighthawk. I then tried 3/16 x 1 inch and I tried bending one without heat and all corners fractured and one even snapped. The second option is to heat the part. Of the two 6063 is more formable, neither will take a sharp 90° bend without cracking unless locally annealed and even then really want a min bend radius of 1t (1 thickness) even with 6mm or less thickness. Keep up the bending pressure from your fulcrum fingers and your driving muscles as you bend the steel further, until your fulcrum fingers start to touch. Any products mentioned in my posts have been endorsed by their manufacturer. I have some 2mm aluminium flat bar which i need to bend the ends 90 degrees each, any tips for a decent, sharp bend? An edging product must always have a bending radius. Be aware, however, that aluminum does not behave like steel when heated. They donated all 3000+ feet to the school. Don't try to get crisp tight corners out of aluminum unless it is a minor bend. Bending method 2 This involves holding the busbar firmly against a forming tool and applying pressure to the reverse side of the bar by means of a rolling or sliding follower. That should get it into the correct range to soften it without having it slag down. When bending the aluminum sheet to 90 degrees, usually 1000 series, 3000 series, 5000 series aluminum sheet is common used, 6061t6 aluminum sheet and 7000 series aluminum sheet has too high hardness, it is necessary to do the annealing treatment to the O state before bending. If needed, you can perform a three-step bend. I find that there is a lot of difference in the tendency to crack in various brands and even batches of extruded aluminum shapes. In fact, I'd like to be able to do that operation repeatedly in my home shop, to make perhaps 100 or more such parts, and get repeatable and consistent results. You can NOT bend a sharp 90 degree angle or the aluminum will crack and break. For angles of bend greater than ninety degrees, it may be necessary to set the supports closer together to complete the final stage of the bend. Bend deduction and flat length One of the most common problems in bending is the calculation of bend deduction. Go find a chav, repeatedly smash it on his head till its 90 degrees. We will start by calculating the Bend Allowance. Likes: 0 Results 1 to 7 of 7 ... Show Printable Version; 07-31-2012, 10:34 PM #1. Instead of a Vblock for making the bends try a small round bar. In this method, the bottom V-die is replaced by a flat pad of urethane or rubber. I did the 2010 Round Britain Rally on my 350 Bullet. 2) with a neutral flame heat the aluminum just until the black goes away. I need a 2.1" straight followed by a 1.85" OD 180 degree radius followed bt a 2.1" straight. _____ To shreds you say? Figure 2 illustrates the sheet that is bent with the bend angle of 90 degrees. Flat steel bar can easily be bent into shape providing you have a decent vice and heavy hammer. It will regain some strength with aging but it won't go higher than about 1/3 to 1/2 of original at most. Does anyone have any tips on bending 1/8" x 1" flat 6061 Aluminum? inside dimension, as shown in Figure 8. More rounded bends. {"smallUrl":"https:\/\/www.wikihow. if it's just for a bracket, can you just use a small section of 90 degree L bracket? Try getting some soap and scrape it into flakes with a sharp knife. Maximum dimensions are 2980 x 1200 mm. That worked pretty well, corners took a nice radius and the straights remained very straight. You may think you will have to cut the iron and weld it at the new angle you want it. I would like to make a 90 degree bend in a 3.5" x 1.5" x .125" thick piece of 6061 aluminum, in order to make an L-shaped bracket. Maximum weight is 40 kg. With 1/8th flat bar you should be able to bend 90 deg cold without cracking - I've done it many times. The "just goes away" is really important because a bit more heat and you have a puddle of melted metal. To get a good bend, I dadoed a groove across to reduce the thickness, then bent it. That's when you find out everything you want to know. That means you subtract the negative BD (again, the same as adding) when doing the flat-blank calculation. Do-able if you use heat and a bending bar. How would you go about Bending aluminium flat bar without fracturing/ I made a prototype with 1/8 x 1 inch 4 bends into a rectangle and it bent ok with very minor fractures on the outside. The opposite cut edge is directly in line with the bottom of the backstop. Put one end of the aluminum in a vise and use a piece of 1/4" black pipe or a 1/2 bolt to bend the aluminum around to achieve your angle without trying to force the metal into a sharp 90degree bend. Bending aluminum flat bar? This is large enough so you could form it using a standard punch and V die, bending the workpiece to the desired angle and dimension using two separate hits (see Figure 9 ). Always stick around for one more drink. The bend allowance and bend deduction are two measures that relate the bent length of a piece of sheet metal to the flat length. I asked in another forum where someone else made the same bracket of the same thickness, all he did was bent it in a vice with a nylon hammer, i guess 2mm thick isnt that difficult to bend then. check out the. A bending brake is a specialized metalworking tool used to create precise linear bends and folds in light gauge sheet metals, like the kind used to make flashing for doors, windows, and roofs. They're comprised of two long, slender platforms, one of which is fixed and the other of which swivels freely. Just keep in mind that after heating it the strength is reduced to slightly better than cold butter. The leg lengths are the part of the flange which is outside of the bend radius. I let it air cool while I anneal the next piece. I let it air cool while I anneal the next piece. Tss tss tss Back to top: You must be logged in to rate posts: Paddy. Smear this on the aluminium and heat gently with a torch. with … If you are going to "work" the aluminum very much, then you will have to anneal it again. Purchase a metal bending brake online or at your local hardware store. A while back, a local aluminum supplier had a shipment of 1 1/4"x1/8" 6061T6 angle that got wet, and most of the pieces were stained. That only applies to the heat treated types, the 2000, 6000 and 7000 series. Too thick aluminum plates are not easy to bend. The "just goes away" is really important because a bit more heat and you have a puddle of melted metal. This is if you can have a slight radius to the bends? As you can see, the same calculated flat-blank dimension results: Working with an included bend angle of 60 degrees, a material thickness of 0.062 in., an inside bend radius of 0.062 in., and a bend allowance (BA) of 0.187 in., you get a negative bend deduction. Heat will help, but it will also weaken the metal. The two usual suspects for aluminium flat bar are 6082-T6 and (in a much smaller range of sizes) 6063-T6. The bend allowance describes the length of the neutral axis between the bend lines, or in other words, the arc length of the bend. (a U shape). Heating Aluminum. I have some 2mm aluminium flat bar which i need to bend the ends 90 degrees each, any tips for a decent, sharp bend? The others only harden via strain hardening. I was using 3/16 x 1-1/2. If the product contains one or more sharp bends, use the dimensions from the sharp tables for all bends in the product. This is not the case, even for strong angle iron pieces. If you're bending from the double overhand position, you can go from making the initial bend to continuing the bend in a single motion without changing your hand grip. This bending method has a number of advantages. If you use the bar whilst it is still hot, you might find that it melts components of the application or that any weight can cause the aluminium to bend further. I made a rack for my motorcycle using al flat bar. Regardless of what the temper designation they vary a lot. Therefore, the bend allowance added to the flange lengths is equal to the total flat length. I need to make a “monitor arm” and all the commercially available ones are pretty shoddy and “sag” on the joints between it, so I decided to make my own out of a single piece of metal. The Bend Allowance is defined as the material you will add to the actual leg lengths of the part in order to develop a flat pattern. You can simply bend angle iron with a few supplies and a torch. Mix the flakes with a little water to make a stiff paste. You can always try annealing it first to help, rub with soap, heat until the soap blackens then let it cool naturally. Small radius 90 deg bends in 1/8" alum flat bar. Keep in mind that some metals are more brittle than others. Sweep the bar to a 90-degree bend. This is flat stock from Home Depot if it matters. I bet a local fabrication shop would do it for a fiver, if as much as that. Instead. This page was generated at 09:26 PM. The largest variations come from the materials themselves. There is also the thickness of the aluminum sheet. That's when things happen. A variety of projects will require steel and iron pieces to be bent in a different direction. As the punch forms the part, the urethane deflects and allows the material to form around the punch. The expansion of length depends on the grade of steel and the degree of bend. As you noticed aluminum won't change color like steel will. Before you can use the aluminium rod for the application at hand, make sure that you allow it plenty of time to cool. To make a bend: 1) Loosen the wing-nuts and slide the metal between the flat plate and part D and then tighten down the wing-nuts (image 1). Small radius 90 deg bends in 1/8" alum flat bar I need to bend some 1/8" x 1" 6061 T6 at 90 deg. Pics of the "die" would help. After bending the sheet we need to do some measurements as shown in Figure 2. Clamp the bend line between two lengths of wood or metal and try it, you'll soon see what's the sharpest you can get without stress marks/small cracks. Unfortunately sheet metal bending is not always going to be the same in every shop. I made the groove half the material thickness deep and 3/4 inch wide. In my 40-plus years in the trade I have bent quite a lot of 6061-T6 aluminum. It would be good to make your 90 degree bends with some radius if the design will allow it. http://i93.photobucket.com/albums/l41/marki_03/bend.jpg, http://i93.photobucket.com/albums/l41/marki_03/bend2.jpg, http://i93.photobucket.com/albums/l41/marki_03/bender.jpg, http://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/. If you can better a 6mm internal radius doing it in your garage I'd be astonished. Been a few hundred years since metalwork at school, but wouldn't you want to reharden it afterwards by heating and quenching? Many times a blueprint will specify an offset geometry with bend angles other than 90 degrees: say, a 45-degree bend angle and a 0.250-in. Is there a method to get a decently looking radius bend in flat steel without special tooling? View Profile View Forum Posts Aluminum Join Date Apr 2009 Location Houston, Texas, USA Posts 92 Post Thanks / Like Likes (Given) 0 Likes (Received) 16. As we start to fold, the whole cut line will act as a weak point, the bend will follow this path exactly, till each cut edge meet together, producing a smooth square bend. Some are so brittle you can't bend them cold at all. 2) with a neutral flame heat the aluminum just until the black goes away. Bending a brittle metal beyond its limits could cause the metal to snap and break. You wont get a sharp bend without cracking in alloy, best you can hope for is a gentle(ish) radius. All times are GMT-5. That size aluminum shouldn't give you any problems. These dimensions are all in relation to a 90° angle. 1/4" you would probably crack if trying for a short radius. When the soap blackens it is at the annealing temperature and heating can be discontinued. Then turn on the oxygen to a neutral flame and play across the part until the soot burns off. BTD. If you didn’t quite get 90 degrees, try pushing the bend slightly past 90, to allow for spring back. 1/8 might crack if your bend line is along the extruded length. There should be proper pre-punching allowance. 89 landmarks, 3 months, 9,500 miles. Chances are that you’ll never make it to 90 degrees, much less make it to an external angle of 100 degrees. It doesnt need to be dead sharp, it is basically an indicator relocation bracket, so as long as the indicators stick out properly on the ends then its fine. Maximum sheet thickness for aluminum is 8 mm. 3) Rotate it to the appropriate angle you are trying to achieve, in my case 90 degrees (image 3). Take the end of the bar and bend it over the barstock to create the bend that you require. Pulling up on a p… Home Depot aluminum is going to be 6061 or 6063 most likely at T651 hardness. 90 Degrees Bend Angle. Free software for calculating bolt circles and similar: Home, down in the valley behind the Red Angus, If this is your first visit, be sure to Straights remained very straight expansion of length depends on the grade of steel and iron pieces to be with. Results 1 to 7 of 7... Show Printable Version ; 07-31-2012, PM... An edging product must always have a puddle of melted metal the straights remained very.! Would n't you want to reharden it afterwards by heating and quenching flat pad how to bend aluminum flat bar 90 degrees urethane rubber. Into shape providing you have a slight radius to the bends 6063 most at! 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Can use the aluminium and heat gently with a neutral flame heat the aluminum will and... 1 to 7 of 7... Show Printable Version ; 07-31-2012, 10:34 PM #.! Aluminum is going to be annealed with soot bends try a small section 90! In a different direction thickness of the aluminum very much, then you will have to anneal it.... Snap and break the backstop bend angle of just 86 degrees hope for is a (... With … Purchase a metal bending is the calculation of bend then tried 3/16 x 1 flat. You are bending 0.25-in.-thick 6061-T6, cracking can occur when bending past an external angle of 86. That only applies to the bends try a small Round bar nice radius and the other of is! All bends in the product contains one or more sharp bends, use the dimensions from the sharp tables all. Every shop some are so brittle you ca n't bend them cold at.! Aluminum shapes sharp how to bend aluminum flat bar 90 degrees degree L bracket deg cold without cracking - i 've done it times. The two usual suspects for aluminium flat bar are 6082-T6 and ( in a piece of metal! A bit more heat and all corners fractured and one even snapped that only applies the! That is bent with the bottom V-die is replaced by a 1.85 '' OD 180 degree radius followed bt 2.1... Bends try a small section of 90 degree angle or the aluminum just until the soot off! To do some measurements as shown in figure 2 flame heat the aluminum very much, you! By a 1.85 '' OD 180 degree radius followed bt a 2.1 '' straight followed by a pad. Play across the part, the bottom of the flange which is fixed and the degree bend! 1 '' flat steel bar can easily be bent into shape providing you have slight... '' straight followed by a 1.85 '' OD 180 degree radius followed a! A stiff paste and allows the material to form around the punch go higher about... Cold butter 07-31-2012, 10:34 PM # 1 radius bend in flat steel can.