Can aluminum angle be bent to a radius ?
 

I have a project where I need to bend aluminum angle to two radiuses. The angle I am thinking of using is 2.5 x 2.5 x 3/16 thick 6061 T6 . Basically making a U out of an 8 ' stick .

Plan to make relief cuts where I want to bend . The radius bends are about 14-16 inches long the rest stays straight . Is this crazy or can it work ?

know nothing about this but i imagine youll need something to form it against/around

in fer learnin'!

https://www.cumberlandmetals.com/aluminum/minimum-bend-radii/

sure seems like it. 3t minimum radius

I have never done this, but if I had to I would make a mandrel of the correct radius and try to determine how close together I would have to make the V shaped reliefs on the face of the angle which will remain in a plane. Cut the V reliefs and make it conform to the mandrel.
Good luck.
Les

Rick, you working on your truck camper?

You can shape aluminum with the right set of rollers and hand cranked machine but you have to anneal the alloy as required so it doesn't crack. There's no need to make relief cuts. Fair warning... Metal work can become a very deep rabbit hole.

http://forums.pelicanparts.com/uploa...1693510307.jpg

You can do it on a shrinker/stretcher

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I have one with replaceable jaws....

If you're intending to start with a piece of 90° aluminum angle, you may need to make relief cuts in one leg, or both, depending on how the bends will be made, if you don't have the proper tools for bending metals.

Also, 6061-T6 aluminum is not really suitable for bending at any more than a slight angle. It'll crack on the outside of the bend radius if bent 90°. Alloy 5051-H32 is more suitable for forming.

Yeah Paul I am . This is the last piece of the puzzle for the overhead sleeping area . Basically replacing 55 year old rotted wood structure with aluminum .

Yeah I am thinking maybe 5051/5052 might be a better choice . I will transfer my cardboard template onto a piece of plywood. Then build it up to make my bending form . This is a one time deal so home build it is .

Make it from two pieces and tig weld it.

I hate working with aluminum and stainless so avoid it as much as possible. But I would try heating it with a torch and bending without relief cuts. Itll be a delicate balance but i think it can be done. Just do a little spot at a time and work your way around

I have watched some YT videos using kerf cuts as one method of bending and heat as the other . I think using angle with each leg being 2.5 inches is too much material to bend with just heat .

I wish I had tig available but I don't . This project skeleton framework will be held together with rivets/screws/adhesive .

Bend Square tubing then cut it diagonal. A job shop should be able to bend square tubing no problem. I have a square die for my bender but it’s only 1 inch. 3/16 is pretty thick you’re not going to touch it with a shrinker stretcher or el cheap tools. You could probably bend by filling tube with sand use heat and bend it around something, anneal it then bend don’t use steady heat.

I've had success bending aluminium by heating it first. Practice on some scrap bits so it doesn't matter when you get it wrong. Get it very hot with a Mapp gas torch and have fun.

Bill I do have a Mapp torch along with oxy/acetylene. Good to know you have had success . I have to get the material in my hands . I may find that 1/8th thickness is strong enough . The 1/8 thickness would be easier to bend ............. I think 😋 .

Well, maybe. Maybe not.

Great idea on the relief cuts, that will solve a significant issue, waviness on the web. See below.

In a past career I sold about $30 million a year of fabricated aluminum extrusion. All 6000 series: 6061, 6063, and 6005.

You know what conventional wisdom would say? It won’t work. (And, I think that there is a large smidge of wisdom here.)

But, how do people bend aluminum all the time and pull it off?

You got me. But they do.

In a perfect world, 6063 T4 (different alloy, different heat treat) is the material of choice. It has far lower mechanical strength. And we did bend some of this. Also, we bent up some of the 6061/6005 prior to any heat treat for some pretty cool bike frames. But, I wasn’t involved in ANY of that.

So the answer is to either purchase some material with less strength or modify readily available material into such. (Using heat to reduce the mechanical strength). Also, in your case, it really may simply bend without any reduction of mechanical properties. A good roller as shown above may be perfect. Not sure.

Then, there is the bending. The web being bent on the thin plane, should be fine. But, the web that gets stretched or compressed will be the challenge. If it is just stretch, it won’t be so hard as long as the radius is not too tight. If compressed, it can get wavey. A die set that captures and tightly holds the web will help. (Yay! Relief cuts!)

I haven’t worked in the industry for over two decades, so my recollections are not the best. Also, I am not a metallurgist or engineer so my description isn’t very precise. But you should get the idea.

For the places I worked, bending extrusion was something that the factory really stayed away from as much as possible. It was a very finicky process. So, it may or may not work. I do think with a jig/roller set up and some heat, you should be able to pull this off. And, you may be able to make it happen just from the relief cuts!

Also, I am happy to chat if you think I can lend insight.

Have fun and good luck!

Part of the equation may be to fill it with sand. This can resist creasing.

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Not sure how you fill angle material with sand ? This is a one time project for me . This will be a backyard/DIY solution . For what I know right now I will build a bending jig out of wood . I will kerf cut the aluminum where I want to bend it . I will also heat the aluminum .

If it works I am set . If it doesn't work my plan B will be to rivet in the straight sections and make radius pieces out of flat sheet stock . May not be as strong as one piece but the two radius corners are only supporting a mattress .

The weight of myself and my wife along with the mattress will be more centered . And that framework will be 2 1/2 " square aluminum sitting on top of the angle material on the perimeter . I am fairly confident I can pull this off .

A bending company should be able to do it no problem. We use Bendco in Houston and I’ve never heard them say they can’t roll something. All they ask is do you want it rolled the hard or easy direction.

Square tube would be much easier though.

If you’re a good aluminum welder you could fabricate the two corners and weld to the straights.