How to Bend Aluminum Sheet Metal

Aluminum bending is significant in industrial applications due to its lightweight and durable characteristics. Aluminum bending and cutting are widely used in metal manufacturing. It offers good corrosion resistance, excellent formability, and good weldability. and, It is heat treatable, making it an ideal choice for projects that requires high strength. The aluminum sheet metal is easy to break after bending, or it will crack after anodizing bending. This article will tell you how to bend aluminum sheet Metal correctly.

 

What is the advantage of Aluminum bending?

• Lightweight:  It is an ideal choice for reducing the overall weight of a piece by avoiding unnecessary thickness.
• High strength aluminum alloys tend to be less ductile, making them more challenging to bend or form without cracking.
• Aluminum is naturally corrosion resistant, balance of strength, and formability, making it an ideal choice for parts exposed to harsh environmental conditions.
• It has a high elongation percentage and good cold workability, It means it can be formed without cracking.

 

Best Aluminum for Bending

What helps to determine the right alloy for metal bending? And what alloys are the best aluminum for bending?

The best aluminum for sheet metal bending is the 5052-H32 alloy, it has below feathers:

• Formability: Bending aluminum sheets with higher strength will be more difficult due to the tradeoff between strength and elongation—ductility.
• Thickness and Bend radius: Aluminium alloys will harden and strengthen during bending process. Therefore, thickness and bend radius are factors you need to consider.
• The percentage of elongation: Investigating the rate of elongation and the difference between yield strength and ultimate tensile strength will also help you make the right decision.

 

How to bend aluminum sheet metal without cracking

• Thickness: Use the thinnest possible sheet of aluminum.
• Aluminum Grades and Impact on Bending:  For aluminum, the harder the grade, the greater the amount of spring back you will need to deal with; Usually, T1, T3, and T5 are used. T6 and T7 series are too hard and need to be annealed to 0 tempers before bending.
• Bending angle R: Try to increase the bending R angle. The larger the R angle, the higher the success rate.
• Avoid sharp bends: Use gentle curves. Sharp bends can apply excessive stress to aluminum, causing it to crack crack.