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Need to radius an aluminum extrusion

Need to radius an aluminum extrusion

Need to radius an aluminum extrusion

(OP)
I need to radius an aluminum extrusion between the ranges of a 20' and a 10' radius.  I know this is large, but the shape I need to bend to that is a fairly large almost rectangular shape.  The extrusion is 2" x 5-1/2" and it needs to be bent the hard way.  If anyone can point me to a source to help me calculate this it would be most appreciated.  Thanks in advance.

Davey

RE: Need to radius an aluminum extrusion

What do you need to calculate?

RE: Need to radius an aluminum extrusion

(OP)
I am hoping to treat the extrusion shape as a simple rectangle for a calculation.  I would then basically be bending a rectangular tube around a radius.  If I could calculate minimun wall thickness needed so that my rectangle won't collapse I might know if my extrusion could stand a chance as well.

My dimensions for the rectangle are: 2" x 5-7/8".  My minumum radius would be 10' (or 20' dia.) and that would be to the inside surface.  The extrusion is being bent the "hard way" as well - one 2" surface will be stretched along the outside of the part.  This is a 6063 T5 Aluminum extrusion with a wall thickness of .08".

Davey

RE: Need to radius an aluminum extrusion

The mechanical wonks can advise you more specifically but but I suspect that the side walls will buckle in column failure.  The slendrness ratio is about 75:1.

RE: Need to radius an aluminum extrusion

We bend steel thin-walled tubing often at our shop.  We fill the tube with a compound called "cero-bend" that supports the wall from collapsing.  We bend 1/2" square tube with 0.035" wall to a 4" inside radius.  We worked this out empirically, so I can't give you a formula.  Scaling my stuff up to your size, you may have a chance;  your radius is pretty gentle.  Cero-bend is some kind of bismuth compound that melts at about 150-200°C.  We heat up a ladle with a blow torch and pour it in.  Maybe you want to make sure you're not affecting the heat treatment of your 6063-T5 tube if you decide to do this.

Steven Fahey, CET
"Simplicate, and add more lightness" - Bill Stout

RE: Need to radius an aluminum extrusion

An old method of controlling buckling is to fill the tube with dry sand.  Still works and is fairly cheap if you are only running a few of these.
It appears that the elongation is about 2.3%, (Dmax/Dmin)so check allowable.

Griffy

RE: Need to radius an aluminum extrusion

Griffengm,

Sand might work for our tubes, too.  Do you have to pack sand in much?  We have to be careful that the cero-bend doesn't get voids in it when we fill the tubes.

Steven Fahey, CET
"Simplicate, and add more lightness" - Bill Stout

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