Bending 6061 at 1T radius? You won't get success unless that material has been annealed to dead-soft, and maybe not then. Think of it this way, the radius on the inside of the bend is 1/4", on the outside is 1/2", so around the inside of the circle there will be (2 X pi X r, or) 1.5708" of material while around the outside there needs to be 3.1416" of material. Presuming you are trying to make a 90° bend, the ID has 0.3927" and the OD has 0.7854" of material - You have exceeded the limits of Poisson's ratio, and the limits of plastic deformation of aluminum.
If your corner needs to be that tight, weld the 2 plates together at your angle. |