Aluminum extrusion bending problem
Aluminum extrusion bending problem
(OP)
We are having difficulties creating a consistent radii on our new mandrel bender. the material and 6063 T4 and the parts have about a 110mm radius and about 40mm wide x 15mm tall. it has 4 bends all 90 degrees. The part has a +- tolerance of 1mm on both the radii, length and width. We are having a hard time getting a consistent radii and it will vary from 107 to 110 in a single part. This is making it very difficult to make consistent parts. As for every mm the radius changes it effects the leg length equally.They are not staying consistent as which bend is small or large either. One time bend 1 will be perfect all other small. Next time bend 3 will be good and all others small. The angles all seem to be good within .3 degree.
Thanks in advance.
Thanks in advance.





RE: Aluminum extrusion bending problem
Do you think it might help if you provided a sketch or a drawing of the overall component?
In addition if it's a new mandrel bender have you considered contacting the supplier of the machine?
“Do not worry about your problems with mathematics, I assure you mine are far greater.” Albert Einstein
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
I just read your original post and realized I'm way off base - you are mandrel bending, not rolling. Some of my wasted breath may be useful but not much.
Are you air-bending? Are you stretch bending? You could try heating the material as you bend it.
Tell us more about your shape and equipment for better answers and less BS.
RE: Aluminum extrusion bending problem
je suis charlie
RE: Aluminum extrusion bending problem
One possibility would be to redesign the part around what is attainable with your bending process. There are others.
Cheers
Greg Locock
New here? Try reading these, they might help FAQ731-376: Eng-Tips.com Forum Policies http://eng-tips.com/market.cfm?
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
If you slow the bender down a little it might help also.
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P.E. Metallurgy, Plymouth Tube
RE: Aluminum extrusion bending problem
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P.E. Metallurgy, Plymouth Tube
RE: Aluminum extrusion bending problem
je suis charlie
RE: Aluminum extrusion bending problem
Maybe grouping the blanks by estimated age would minimize the amount of fiddling you have to do with the tooling.
Also, I'm wondering if the bender could be adapted to heat the area to be bent just before bending, how much of a temperature change would be needed, and if it would work at all....
Mike Halloran
Pembroke Pines, FL, USA
RE: Aluminum extrusion bending problem
Cheers
Greg Locock
New here? Try reading these, they might help FAQ731-376: Eng-Tips.com Forum Policies http://eng-tips.com/market.cfm?
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
RE: Aluminum extrusion bending problem
I suspect the neutral axis is shifting due to variations in the material properties and that the bender is not controlling the bend at the surface where the radius is to be controlled.
RE: Aluminum extrusion bending problem
bending them like the 2 on the right not the one on the left. at 4 90s to make a rectangle