Bending a U shaped

[MBG]

I got a flat piece of aluminum about 3/8 thick and I want to "bend" and u shape in it. Two 90 degree bends that make a "U".

Could this be possible? If so how do you do it?

[mxtras]

You can not bend it unless it is T-1 or T-0 temper. Even then, if it is older than about a year, it is likely aged to a higher temper which will fracture when bent. Under normal storage conditions, a T0 material will migrate past a T-1 condition in about one year.

If it IS T-1 or T-0, then bend it as usual with an interior radius of maybe 1.5-2X the thickness - you will be fine.

I should continue by saying that this is relative to most of the popular alloys, including 6061, 6063, 5013 and 2000 series. Most of your thicker sections are structural, therefore are likely 6061-t5 which can not be bent. You can cut it and weld it but you will not get it bent. The structural stuff is ALL at least T5 - it has to be special ordered from the mill to get a T-0 or T-1 for bending applications. 6063 is extruded and has similar constraints.

Scott

[One of Many]

Originally Posted by MBG I got a flat piece of aluminum about 3/8 thick and I want to "bend" and u shape in it. Two 90 degree bends that make a "U". Could this be possible? If so how do you do it?

More information is needed to define POSSIBLE?

Material alloy?
Length of bend line?
Inside Bend Radius expected?
Basic dimensions of each leg, +/- what?

Take 3/8" 6061-T6 for example. This will require roughly 22 tons/ft of bend length on a press brake using a 2.75" lower V-die. Using a wider lower die, say like 3" will lower the tonnage to around 20 tons/ft, but will increase the bend radius.

Deep bends take special tooling. Does your U configuration have room to bend it on a press?

A press brake is the most realistic way 3/8" could be bent, but........As you can see. The variables in "Possible" can be influenced by many other factors.

DC

[ViperTX]

Draw it up and ask some of the local sheet metal shops for a price. Consider whether you want to cut it and then either weld or screw it together.

[MBG]

I want to do it with t6. So it can't be done? I would have to mill the slot out instead?

[motomitch1]

How long is it?

[MBG]

it is about 3 inches long 2 inches are on the same plane and 1 inch is lowered about .375"

[One of Many]

Originally Posted by MBG I want to do it with t6. So it can't be done? I would have to mill the slot out instead?

No one knows if it can be done, without knowing exactly what it is you are using with physical dimensions that may or may not complicate it. Whether you have the proper equipment or if it can be done safely and with good results is still to be determined by the required information to guide you in the proper direction.

What alloy of T6? What is the bend length?

T6 is technically a Heat treat process , but not all alloys in this condition will take a bend without cracking.

Milling slots out would make it bend easier, if it will bend at all. As long as you weld it(assuming it is weldable) or it will unbend or break even easier.

Most of the 6000 and 5000 series should bend without cracking. 7000 and some 2000 series alloys either won't bend without cracking or can after time.

This also applies to welding. 6000 series, 7075, from what I hear can be welded with care, but 2024 should not, without a controlled post anneal to prevent crystalizing the material in the weld region as it ages.

DC

[mxtras]

"No one knows if it can be done" - One of Many

The aluminum you are talking about (3/8" thick) is likely 6061 and not 6063.

Anything greater than T-1 condition 6061 or 6063 series (the most popular alloys) will not bend without fracturing. You can anneal it and then it will bend.

I would look at other methods to make this part other than bending, or change the material spec.

Scott

[One of Many]

Originally Posted by mxtras "No one knows if it can be done" - One of Many The aluminum you are talking about (3/8" thick) is likely 6061 and not 6063. Anything greater than T-1 condition 6061 or 6063 series (the most popular alloys) will not bend without fracturing. You can anneal it and then it will bend. I would look at other methods to make this part other than bending, or change the material spec. Scott

3/8" 6061 T6 will bend fine on a press brake. It is done all the time. Many of the other alloys do not have the ductility to bend without fracture at a T6 condition and could snap with great force and fly at far greater speeds than one can react to.....

IMHO, it is not a safe gamble to guess. Yikes!

Load calculator

Select the material type and thickness. The lower V-die should be 8 times the material thickness, but can be altered to keep the max die load within limits, machine capacity and radius realistic.

When the elongation gets lower than 10-15%, trouble is looming when attempting to bend any heavy plate. While thinner materials in the same condition don't pose as much of a threat, they still will not bend without cracking, although I have seen some thin stuff bent with very generous radiuses for non-structural applications, but that material was treated to a W condition and kept in freezers to stablize it in that condition until formed. Once at room temp it would return to a condition just short of its original T6, T7 condition in a day or so.

Tensile Strength

DC

[gbell212]

this material can be stressed relieved to lower the temper thus making it bendable, this will work as long as the finished part doesn't need to be structurally sound. this can be done with any cutting torch using a rosebud tip. Or you can order the material in a T1 condition and Age harden it after its bent to T6 condition.