FONNOV ALUMINIUM provides aluminium bending services in our aluminium fabrication factory. We can custom bend aluminium bars, aluminium extrusions, aluminium tubes, and pipes and aluminium structural shapes to meet your specifications.
Engineers design a variety of aluminium parts according to product needs. These designs usually cannot be achieved simply by aluminium extrusion and require further processing, and bending aluminium extrusion is one of the processes. LED lamps, armrests, furniture, automation, and frame products require bending technology for their products. Aluminium tubing bending is is the most requested service among our customers. The following is an example of a 90-degree bent aluminium tube OD38 * 2.5MM.
The Problems of Bending Aluminium Extrusion
It is easy to bend aluminium panels, but it is not easy to bend aluminium extrusion. During the bending process of aluminium profiles, you may encounter some problems, such as:
The aluminium profiles are out of shape after bending.The aluminium profiles maybe break or damage after bending.
Therefore, to get an effective aluminium extrusion bending, engineers need to consider some factors when designing the bent aluminium extrusion.
What Factors Need to Be Considered When Designing the Bent Aluminium Extrusion?
The internal and external structure, size, and curvature of the profile.
The complexity of aluminium extrusion structure and the bending work is more difficult. Sometimes this structure is impractical for bending. If the aluminium profile is designed to bend after extrusion, the extrusion should be designed for bendability first. Well-designed extrusions can create seamless connections in the structure. If the extrusion design is not bendable, some changes to the section may make it easier to bend to the required radius.
Bending will compress the inside, while the outside will stretch. The hollow profile brings another problem: in the absence of support, the metal tends to bend inward under pressure. This can be overcome by filling the hollow interior to some extent with something that can resist buckling or increasing the wall thickness, increasing the internal radius can overcome this situation.
Surface requirements after bending
Generally, there are surface treatment requirements for curved aluminium. Anodizing and powder spraying are the most common surface treatment methods. Sometimes, the curved surface will bring micro cracks. To avoid this, surface treatment should be performed after bending. If certain faces of the extruded section are visible and important in appearance, the designer should ensure that these faces can be formed without traces. If smooth curved surfaces are critical, then the extrusion design should be seriously considered.
Extrusion material of profile product
Different applications require the use of different aluminum alloys for extrusion. Different aluminum alloys have different characteristics in terms of strength, hardness, and bendability. Some aluminum alloys are easier to bend, such as 3003, 6063, and 6061. Most aluminium extrusion bending involves 6063 and 6061 alloys because these aluminum alloys have good strength and formability. Heat treatment makes the alloy more difficult to bend, so it is usually best to do it after forming the final shape.
These factors are best considered in the product design stage, and the most suitable bending method can be selected according to these factors in the later aluminium processing.
How to Bend Aluminium Extrusion?
So what are the main methods to bend? How do these methods achieve the bending? There’re mainly four bending methods to create curvature.
Rotary Draw Bending
Place the extruded material on the bending machine and fix it in place. The bending abrasive tool is rotated to bend the extrusion. This is the most common way we produce round tube handrails.
Push RAM is used to bend the aluminum material, forcing the extruded material to form the required curvature.
Three Rolling Bending
Place the extruded material on it and bend the extruded material by moving it. This method is suitable for profiles with symmetrical structures, such as aluminium tubes, aluminium channel, and aluminium tee.
The two ends of the profile are fixed in place, the machine moves to make the two ends of the profile squeeze, and the profile is stretched out to the same curvature as the mold. This method is suitable for workpiece with a large radius.